Flexible Ribbon Cable Nesting in Electric Toothbrush Sliding Assembly
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Solution Overview
Problem
Existing interconnect methods for user interface and internal assemblies in electric toothbrushes are not suitable for sliding assembly construction, lacking reliability and manufacturability.
Innovation Solution
A flexible ribbon cable is used to interconnect the user interface and internal assemblies, folding into a curved shape during assembly to nest inside the tubular housing without interfering with operation, utilizing a strain relief member for stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing interconnect methods (pogo pins, Zebra elastomeric connectors) are used to connect user interface assembly and internal assembly, then electrical and data connection is achieved, but the assembly process becomes complex and unreliable for sliding construction
Solution Approach 1:
The patent uses a flat flexible cable (thin film) instead of rigid connectors like pogo pins or Zebra elastomeric connectors. This flexible cable can bend and fold to accommodate the sliding assembly construction, providing reliable electrical and data connection between the user interface assembly and internal assembly without requiring complex top-down assembly processes.
Solution Approach 2:
The flexible cable is designed to dynamically change its configuration during assembly - extending outward when the internal assembly is being inserted, then folding into a curved shape as the assembly completes. This dynamic behavior allows the cable to adapt to the sliding construction process while maintaining connection reliability.
2Ease of operation
If the flexible ribbon cable has sufficient length to extend out of the housing for connection, then operability during assembly is improved, but the cable may interfere with internal assembly operation when inserted
Solution Approach 1:
The cable is functionally segmented into different portions: a first end portion connected to the user interface assembly, a flexible middle portion with predetermined length that allows extension during assembly, and a second end portion that connects to the internal assembly. This segmentation allows each portion to serve its specific function while avoiding interference.
Solution Approach 2:
The flexible cable is designed to fold into a curved shape during insertion and nesting within the tubular housing. This curved configuration allows the cable to occupy space efficiently without creating sharp angles or rigid structures that would interfere with the operation of the internal assembly components.
Data Source
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AI summary
A power device having a tubular housing (112) and a wired communication assembly for coupling a user interface assembly (118) and an internal assembly (114). The wired communication assembly includes a flexible ribbon cable (116) having a first end portion (138) configured to be coupled to the user interface assembly (118), a second end portion (142) configured to be coupled to the internal assembly (114), and a flexible middle portion (140). During insertion of the internal assembly (114) into the housing (112), the flexible ribbon cable (116) folds into a curved shape such that the flexible ribbon cable (116) nests inside the tubular housing (112) after the internal assembly (114) is completely inserted and the flexible ribbon cable (116) does not interfere with operation of the internal assembly (114).