Folded Flat Cable Connector Assembly
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Solution Overview
Problem
The challenge in connector assemblies is that two connectors with identical arrays of elements cannot be connected properly due to their mirror image nature, requiring 'left hand' and 'right hand' connectors, which complicates manufacturing and inventory management, as assemblers want to use only one type of connector.
Innovation Solution
The solution involves folding substantially flat cables with a bend angle greater than 150° around two fold lines across their width, allowing two connectors with the same handedness to be connected, enabling identical arrays to align correctly, thus eliminating the need for mirror-image connectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If two connectors with identical arrays of elements are used, then manufacturing and inventory management are simplified, but the connectors cannot be connected properly due to mirror image nature
Solution Approach 1:
The cable is folded back on itself in a U-shape configuration, changing the spatial arrangement from a straight line to a three-dimensional folded structure. This dimensional change allows the cable to connect two identical connectors by routing the signal path through the fold, enabling both connectors to have the same terminal orientation while still achieving proper electrical connections.
2Ease of operation
If mirror image connectors are used, then proper connection is achieved, but device complexity and inventory requirements increase
Solution Approach 1:
The folded cable configuration enables a single connector design to serve multiple functions - it can connect to identical connectors on both ends, eliminating the need for separate left-hand and right-hand connector variants. This universal connector design simplifies inventory management while maintaining proper electrical connections.
Data Source
AI summary
A connector assembly includes first and second connectors. Each connector includes a plurality of terminals A1 through An, n is an integer ≥2, sequentially arranged in a row. The connector assembly also includes a flat cable that includes a plurality of electrical conductors electrically connecting the terminals of the first and second connectors. For each i from 1 to n, terminal Ai of the first connector is electrically connected, via a different electrical conductor of the cable, to the terminal Ai of the second connector. The cable includes a bend greater than about 150° around at least two fold lines that extend across the entire width of the cable. Each of the first and second connectors is configured to mate with the same mating connector, such that when each of the first and second connectors mates with the same mating connector in a same plan view, the An terminals are both either on a left or a right side of the A1 terminals.