Flexible PCB Cable Assembly for High-Speed Dense Interconnects
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Solution Overview
Problem
Conventional PCB solutions fail to meet high-speed data transmission requirements and direct attach cables occupy excessive space, making them unsuitable for high-density and large quantity interconnections.
Innovation Solution
A chip-to-module cable assembly using a flexible PCB with a three-layer structure, comprising flexible material parts on upper and lower layers and a rigid connection portion in the middle, with rigid material portions for support and hollow portions for reduced material usage, allowing for high-speed signal transmission and flexible assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a conventional PCB solution is used to connect the switching chip to the I/O connector, then the interconnection is compact and integrates well, but it cannot satisfy the signal transmission requirement at high speeds higher than the specified speed threshold
Solution Approach 1:
The interconnection path is segmented into two parts: a flexible PCB cable with hollow cross-section for high-speed signal transmission, and a rigid PCB for structural support and low-speed connections. This segmentation allows each part to be optimized for its specific function, resolving the contradiction between speed and reliability.
Solution Approach 2:
The flexible PCB cable uses a composite structure with hollow cross-section, combining flexible material parts and rigid material portions. This composite design enables the cable to achieve both high-speed signal transmission capability and mechanical flexibility, overcoming the limitations of conventional solid PCB structures.
2Loss of energy
If a cable is directly connected between the switching chip and the I/O connector to achieve low loss, then the signal transmission quality improves, but the cable occupies large space and is difficult to assemble
Solution Approach 1:
The patent uses a flexible PCB cable with a thin-walled hollow cross-section design. This flexible shell structure maintains the low signal loss characteristics of cable connections while significantly reducing the space occupancy compared to traditional rigid cables, and improving assembly flexibility.
Solution Approach 2:
The flexible PCB cable employs a hollow cross-section structure that can be filled with foam or air, creating a porous-like internal structure. This design reduces the overall volume of the cable while maintaining its mechanical strength and electrical performance, resolving the contradiction between signal loss and space occupancy.
3Volume of moving object
If a flexible PCB cable with hollow cross-section is used, then space is saved and assembly is facilitated, but the structure becomes more complex
Solution Approach 1:
The patent transitions from a conventional two-dimensional PCB layout to a three-dimensional flexible cable structure with hollow cross-section. This dimensional change allows the interconnection to pass through complex spatial paths, saving space and facilitating assembly while the modular joint design keeps the overall system complexity manageable.
Solution Approach 2:
The hollow cross-section of the flexible PCB cable can be filled with other components or nested within other structures, creating a nested configuration. This nesting approach reduces the overall volume required and simplifies the integration with other system components, offsetting the increased structural complexity.
Data Source
AI summary
This application relates to a chip-to-module cable assembly, includes a first joint, a second joint and a first flexible PCB cable, the flexible PCB cable, including flexible material parts located on upper and lower layers and a connection portion located on a middle layer, wherein the connection portion comprises two rigid material portions respectively located at end portions of the flexible material parts on the upper and lower layers and a hollow portion between the two rigid material portions, the flexible material parts each comprises at least one conducting wire, one end of each of the at least one conducting wire is connected to a first interface terminal of the first joint, and another end of the conducting wire is connected to a second interface terminal of a second joint.