Flat FPC Cable Structure for Thin, Flexible Data Interconnects
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Solution Overview
Problem
Existing FPC cables and data cables face challenges in achieving high reliability, flexibility, and miniaturization while maintaining lightweight and ultra-thin designs, particularly in the context of increasing demands for high-density and miniaturized electronic products.
Innovation Solution
The FPC cable consists of a sheet-like metal foil conductor coated with an insulating layer and a skin, forming a flat, integral strip shape with exposed bonding pads, and can include electronic components, integrated with connectors for data transmission, utilizing materials like copper or constantan alloy foils and PI films for enhanced flexibility and reduced thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional FPC cable structures are used, then reliability is maintained, but flexibility and thinness are compromised
Solution Approach 1:
The patent uses a thin film insulating layer (6-7mm length, 0.2-0.4mm width) that provides both insulation and structural integrity while maintaining extreme thinness. The skin layer coating the conductor further protects while keeping the overall structure ultra-thin and flexible, resolving the contradiction between reliability and thinness.
Solution Approach 2:
The patent employs composite material structure with conductor (copper foil, constantan alloy foil, or gold foil), insulating layer (PI film), and skin coating. This multi-material composite approach ensures electrical reliability, mechanical strength, and flexibility simultaneously, overcoming the limitation of single-material designs.
2Ease of manufacture
If conductor and insulating layer are separately assembled, then manufacturing is easier, but integration and reliability are reduced
Solution Approach 1:
The patent merges the conductor and insulating layer into a one-piece integral piece through fixed connection, eliminating separate assembly steps. This integration improves reliability by ensuring consistent electrical and mechanical performance while the standardized structure actually simplifies manufacturing processes.
3Volume of moving object
If cable volume is reduced for miniaturization, then product density increases, but flexibility and movement capability are compromised
Solution Approach 1:
The patent transitions from traditional round cable geometry to a flat long strip shape (length 6-7mm, width 0.2-0.4mm, length-to-width ratio >4). This dimensional change enables ultra-thin profile for miniaturization while the flat structure provides superior flexibility and ability to conform to three-dimensional spaces, simultaneously achieving volume reduction and enhanced flexibility.
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
This configuration enables flexible, ultra-thin, and lightweight FPC cables suitable for high-density electronic products, reducing volume and weight, allowing for random arrangement and movement, and integrating components effectively in three-dimensional spaces.
Implementation Method 1
a front side and a back side of the conductor are respectively coated with the insulating layer
Implementation Method 2
the conductor is fixed to the corresponding insulating layer through a viscose glue
Data Source
AI summary
Provided are an FPC cable and a data cable. The FPC cable includes a conductor, an insulating layer and a skin, where the conductor is made of a sheet-like metal foil, and a front side and a back side of the conductor are covered with the insulating layer and are fixedly connected to form a one-piece integral body; and the one-piece integral body is coated with the skin, so that the FPC cable integrally has a flat long strip shape.