Flat Cable Connector Assembly for Automated Type-C Welding
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Solution Overview
Problem
Existing wire harnesses for Type C connectors require complex welding processes due to the need to weld multiple circular conductors individually, leading to inefficiencies and high manufacturing costs, and the conductors are difficult to manage and identify due to their disorderly bundling.
Innovation Solution
A connector assembly with a flat cable and injection-molded insulator that integrates core wires and terminals with a circuit board, allowing for easy welding and automatic production, featuring a row of core wires with varying cross-sections and sizes, and a shield layer for signal stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple circular conductors are used for Type C connector wire harness, then electrical connection functionality is achieved, but welding process complexity increases and production efficiency decreases
Solution Approach 1:
The patent merges multiple separate circular conductors into a single integrated flat cable structure with multiple core wires. This consolidation eliminates the need for individual welding operations on each conductor, transforming a complex multi-step welding process into a simplified single-step process, thereby significantly improving production efficiency and reducing welding process complexity
Solution Approach 2:
The flat cable is segmented into multiple independently insulated core wires within a unified structure. Each core wire maintains its electrical independence while being organized in a structured manner, allowing for easier identification and connection compared to disorderly bundled circular conductors, thus reducing welding process complexity without compromising functionality
2Ease of operation
If multiple circular conductors are bound together disorderly, then wire harness assembly is formed, but volume increases and identification difficulty increases
Solution Approach 1:
Multiple core wires are merged into a single flat cable assembly with a unified outer insulation layer, consolidating what would otherwise be separate voluminous circular conductors. This integrated structure reduces the overall volume while maintaining all necessary electrical connections, and the structured arrangement enables easy identification of each core wire's position and function
3Ease of manufacture
If conventional circular conductor preparation is performed (peeling, bending, cutting layers), then welding readiness is achieved, but processing time increases and manufacturing costs increase
Solution Approach 1:
The flat cable is pre-prepared during manufacturing with core wires that are already exposed and ready for welding, eliminating the need for time-consuming post-delivery preparation steps such as peeling outer insulation, bending and cutting braided layers, and removing aluminum foil. This preliminary preparation significantly reduces conductor preparation time and simplifies the welding process, making it more ease of manufacture
Solution Approach 2:
The patent extracts and eliminates unnecessary intermediate layers (such as complex braided layers and aluminum foil layers) that would require additional preparation steps. By designing the conductor structure without these extraneous layers, the core wire is directly accessible for welding, thereby reducing both preparation time and manufacturing complexity
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 solution enables efficient, automatic production with reduced manufacturing costs and improved handling, while ensuring signal stability through the use of a shield layer.
Implementation Method 1
The insulator is injection-molded onto the circuit board, the rear end of the plurality of terminals and the front end of the row of core wires through an embedded injection molding process, such that the insulator, the circuit board, the plurality of terminals and the row of core wires form an integral part.
Data Source
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AI summary
The present invention discloses a connector assembly and a flat cable. The connector assembly includes: a circuit board; a connector including a housing and a plurality of terminals disposed in the housing; a flat cable including a row of core wires and an inner insulation layer wrapping the row of core wires; and an insulator. Rear end of the terminals protrudes from the housing and is electrically connected to the circuit board, front end of the row of core wires is exposed from the inner insulation layer and is welded to the circuit board. The insulator is injection-molded onto the circuit board, the rear ends of the terminals and the front ends of the core wires through an embedded injection molding process, such that the insulator, the circuit board, the terminals and the core wires form an integral part. In the present invention, the flat cable has the advantage of small volume, easy handling and convenient welding, and enables automatic production, thereby improving the production efficiency and reducing the manufacturing costs. Furthermore, in some embodiments of the present invention, the flat cable further has a shield layer, which can ensure the stability of signal transmission of the connector assembly.