Flat Shield Cable Grounding via Folded Conductor Windows
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Solution Overview
Problem
Existing shield flat cables face issues with incomplete hole formation during manufacturing, leading to positional errors and contact failures between ground lines and the shield layer, resulting in insufficient grounding and noise interference, particularly at small conductor pitches.
Innovation Solution
The method involves folding and exposing ground lines outside the insulating film at specific windows, allowing for accurate electrical connection to the shield layer, ensuring reliable grounding by forming windows wider than the conductor pitch to prevent resin dregs obstruction and positional deviations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If holes are formed through the insulating film before lamination with a die, then the shield layer can be connected to ground conductors, but positional errors occur due to misalignment of running flat conductors and insulating film, causing contact failures
Solution Approach 1:
The insulating film is laminated onto the flat conductors first, establishing a stable baseline. Then holes are formed at predetermined positions relative to the already-fixed insulating film structure, ensuring accurate alignment without subsequent positional errors during further lamination processes
Solution Approach 2:
The insulating film is designed with differentiated regions: a first insulating film covering signal conductors and a second insulating film (or window portion) at ground conductor positions that allows hole formation. This local structural variation enables precise hole positioning at critical grounding points while maintaining overall insulation integrity
2Manufacturing precision
If holes are formed with a laser after lamination of insulating films, then positional accuracy can be improved, but resin dregs remain inside holes causing incomplete formation and contact failure, especially at small conductor pitches
Solution Approach 1:
The insulating film is laminated onto the flat conductors first, establishing a stable baseline. Then holes are formed at predetermined positions relative to the already-fixed insulating film structure, ensuring accurate alignment without subsequent positional errors during further lamination processes
Solution Approach 2:
The insulating film is designed with differentiated regions: a first insulating film covering signal conductors and a second insulating film (or window portion) at ground conductor positions that allows hole formation. This local structural variation enables precise hole positioning at critical grounding points while maintaining overall insulation integrity
Data Source
AI summary
A manufacturing method of a flat shield cable has a step of arranging a plurality of flat conductors including a ground line parallel with each other in one plane at a pitch P, a step of forming a flat cable by laminating a first insulating film on the flat conductors from both sides of an arrangement plane of the flat conductors, a step of laminating a shield layer on outside surfaces of the flat cable, and a step of electrically connecting the ground line to the shield layer. The manufacturing method further has a step of cutting the ground line at a portion other than in the conductor exposure portions and folding cutting portions of the ground line to outside the first insulating film before laminating the shield layer, and a step of electrically connecting only the folded ground line among the flat conductors to the shield layer.