Flexible Flat Cable Nonwoven Fabric Shielding Layer
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Solution Overview
Problem
Conventional flexible flat cables with shield layers lack sufficient flexibility, leading to high restoring forces and the need for fixing members to maintain bent shapes, which complicates installation and increases costs in downsized electronic equipment.
Innovation Solution
A flexible flat cable design featuring a nonwoven fabric layer with embossed recessed portions on its surface, sandwiched between insulation and shield layers, optimizing the arrangement of fiber yarns and void content to reduce restoring forces and enhance flexibility while matching characteristic impedance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional flexible flat cable with shield layer is used, then shielding property and characteristic impedance matching are improved, but flexibility deteriorates and restoring force increases
Solution Approach 1:
The nonwoven fabric layer is provided only on one surface of the insulation layer rather than both surfaces, creating asymmetric local quality that reduces overall stiffness while maintaining shielding effectiveness on the critical side
Solution Approach 2:
The cable combines multiple materials with different properties: conductors for signal transmission, insulation layer for electrical isolation, nonwoven fabric for flexible structural support, and shield layer for electromagnetic interference protection, creating a composite structure that balances conflicting requirements
2Reliability
If a conventional flexible flat cable with shield layer is used, then shielding property and characteristic impedance matching are improved, but device complexity increases due to need for fixing members
Solution Approach 1:
The nonwoven fabric layer provides inherent flexibility control and shape retention properties, allowing the cable to maintain bent shapes through its own structural characteristics without requiring external fixing members or additional components
Solution Approach 2:
By controlling the basis weight, void content, and embossed shape parameters of the nonwoven fabric layer, the cable achieves optimal balance between flexibility and shape retention, eliminating the need for additional fixing mechanisms
3Reliability
If a conventional flexible flat cable with shield layer is used, then shielding property and characteristic impedance matching are improved, but manufacturing cost increases
Solution Approach 1:
The invention extracts and eliminates the unnecessary component of fixing members (such as acetate tapes) from the cable assembly, reducing material costs, assembly complexity, and manufacturing time while maintaining the essential shielding functionality
Solution Approach 2:
By optimizing the nonwoven fabric parameters (basis weight of 40-90 g/m2, void content of 170-280 cm3/m2), the cable achieves the desired flexibility and shape retention at lower material and manufacturing costs compared to conventional designs requiring additional fixing components
Data Source
AI summary
A flexible flat cable includes a plurality of conductors arranged in parallel at predetermined intervals, an insulation layer provided on both surfaces of the conductors, a nonwoven fabric layer provided on an outer surface of the insulation layer, and a shield layer provided on an outer surface of the nonwoven fabric layer. The nonwoven fabric layer includes a nonwoven fabric having a plurality of recessed portions formed on a surface thereof, the recessed portion being enclosed by a pair of opposite long sides and a pair of opposite short sides.