Flat Cable Substrate Segmented Limb Design

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Solution Overview

Problem

Pre-folded flex printed circuit boards in electronic devices face material damage and unreliable positioning during assembly due to high mechanical loading and flexibility, leading to potential functional failures and increased material requirements.

Innovation Solution

A substrate for electric flat cables with an inner and outer limb structure connected by a web, providing rigidity in one direction and flexibility in another, allowing for controlled alignment and reduced material stress, which can accommodate electric terminals and conductors to form a flexible yet stable cable.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If pre-folded flex printed circuit boards are used to increase flexibility and control position, then flexibility and position control are improved, but material damage and functional failure occur due to high mechanical loading

Engineering Contradiction:

Improveposition controlVSAvoidfunctional failure

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The substrate is divided into multiple limbs (inner limb, outer limbs) connected by a web, creating a segmented structure that distributes mechanical loads across multiple elements rather than concentrating stress at fold points, thereby preventing material damage while maintaining flexibility

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The substrate transitions from a two-dimensional flat structure to a three-dimensional multi-limb configuration where limbs can move relative to each other in the vertical dimension while maintaining planar connections, enabling position control without excessive mechanical stress

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Adaptability or versatility

If pre-folded flex printed circuit boards are used to enable component movement and alignment, then assembly flexibility is improved, but unreliable positioning occurs during and after assembly

Engineering Contradiction:

Improveassembly flexibilityVSAvoidpositioning precision

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The substrate employs a dynamic structure where limbs can move relative to each other through the connecting web, allowing the cable to adapt to different assembly configurations while maintaining controlled positioning through the geometric constraints of the limb-web-limb architecture

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

Multiple limbs are merged into a single integrated substrate structure sharing common connecting webs, allowing coordinated movement of multiple connection points while maintaining relative positional relationships through the shared structural framework

Inventive Principle:

Principle #5Merging (Combining)

3Volume of moving object

If flex printed circuit boards are folded to achieve compact form, then space efficiency is improved, but increased material requirement occurs to achieve sufficient longitudinal extent

Engineering Contradiction:

Improvespace efficiencyVSAvoidmaterial requirement

Core Design Contradiction:

Volume of moving objectVSQuantity of substance

Solution Approach 1:

The multi-limb structure allows the substrate to nest or stack in a compact configuration when not in use, with limbs arranged to minimize occupied volume while maintaining full longitudinal extent when deployed, effectively achieving space efficiency without material waste

Inventive Principle:

Principle #7Nested doll (Nesting)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The substrate enables reliable positioning and reduced material stress, preventing damage and ensuring stable electrical connections during assembly, while allowing for flexible alignment and reduced material usage.

Implementation Method 1

The substrate may be at least largely rigid in respect of a deformation within the plane of extent

Methodology Applied

Scientific EffectRigidity:

Implementation Method 2

the substrate may be at least largely flexible in respect of a relative alignment of the limbs in a second direction, which is perpendicular to the plane of extent of the substrate

Methodology Applied

Scientific EffectFlexibility:

Implementation Method 3

a connecting web, which extends so as to adjoin and connect the first portions of the inner and the at least one outer limb

Methodology Applied

Scientific EffectMechanical connection: Mechanical Fastener

Data Source

PatentUS10122142B2Flat cable, substrate thereof, and method of manufacturing an electric assembly

Publication Date: 2018.11.06 E SOLUTIONS

AI summary

A substrate for an electric flat cable is disclosed that includes an inner limb, having a first and a second portion spaced apart from each other along a longitudinal extent of the inner limb, at least one outer limb, having a first and a second portion spaced apart from each other along a longitudinal extent of the outer limb, and a connecting web, which extends so as to adjoin the first portions of the inner and the at least one outer limb. The inner limb extends at least substantially parallel to the outer limb, in a first direction. The second portion of the outer limb surrounds the second portion of the inner limb, at least partially, such that at least a cart of the second portion of the outer limb is disposed in the first direction in respect of the second portion of the inner limb.