Multi-core Cable Distal End Miniaturization via Angled Mold Faces

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Solution Overview

Problem

Existing multi-core cables face challenges in miniaturizing the distal end due to increased width dimensions as the number of electronic wires increases, making it difficult to achieve a compact design.

Innovation Solution

A multi-core cable design featuring a mold part made of resin that fixes electronic wires in at least two rows, with angled end faces to allow for a more compact arrangement, where the first row of insulated wires protrudes at an inclined angle and the second row of coaxial wires protrudes perpendicularly, reducing the width and length dimensions of the distal end.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If the number of electronic wires is increased, then the functionality and communication capacity are improved, but the width dimension in the direction of parallel arrangement increases, making it difficult to miniaturize the distal end

Engineering Contradiction:

Improvenumber of electronic wiresVSAvoidwidth dimension of distal end

Core Design Contradiction:

Quantity of substanceVSArea of stationary object

Solution Approach 1:

The patent applies dimensionality change by transitioning from a single-row arrangement to a multi-row arrangement of electronic wires within the mold part. This allows the wires to be organized in multiple rows (first row, second row, etc.) protruding from different end faces, effectively distributing the wires in two-dimensional space rather than confining them to a single linear dimension, thereby reducing the width requirement while accommodating more wires

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The patent segments the electronic wires into multiple groups arranged in different rows, with each row protruding from a specific end face of the mold part. This segmentation allows independent positioning and connection of wire groups to different surfaces of the substrate, optimizing space utilization and reducing the overall width dimension of the distal end

Inventive Principle:

Principle #1Segmentation

2Device complexity

If the electronic wires are arranged in parallel in a single row, then the connection structure is simple, but the width dimension increases and miniaturization becomes difficult

Engineering Contradiction:

Improvearrangement structure of electronic wiresVSAvoidwidth dimension of distal end

Core Design Contradiction:

Device complexityVSArea of stationary object

Solution Approach 1:

The patent resolves this contradiction by introducing a multi-row arrangement where electronic wires are distributed across multiple rows that protrude from different end faces of the mold part. This two-dimensional arrangement strategy reduces the width dimension while the mold part maintains structural simplicity through standardized positioning and connection mechanisms

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Area of stationary object

If the distal end of the multi-core cable is miniaturized, then the overall cable size is reduced, but the connection strength and positioning precision with the substrate may be compromised

Engineering Contradiction:

Improvewidth dimension of distal endVSAvoidconnection strength between cable and substrate

Core Design Contradiction:

Area of stationary objectVSStrength

Solution Approach 1:

The patent achieves miniaturization while maintaining connection strength by utilizing multi-row arrangements that protrude from different end faces. This allows wires to be connected to different surfaces of the substrate (first surface, second surface, opposite surface), distributing the connection load across multiple attachment points and enhancing overall connection strength despite reduced overall size

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

4Area of stationary object

If the electronic wires are arranged in multiple rows with angled end faces, then the width dimension is reduced for miniaturization, but the manufacturing complexity of the mold part increases

Engineering Contradiction:

Improvewidth dimension of distal endVSAvoidmold part manufacturing

Core Design Contradiction:

Area of stationary objectVSEase of manufacture

Solution Approach 1:

The patent employs asymmetric design in the mold part by providing end faces with different angles relative to the central axis line. The first end face has a first angle while the second end face has a second angle, creating an asymmetric structure that optimizes wire arrangement and reduces width dimension. This asymmetric design is integrated into the mold part manufacturing process, allowing for precise positioning while maintaining manufacturability through standardized molding techniques

Inventive Principle:

Principle #4Asymmetry

Data Source

PatentUS10038257B2Multi-core cable and multi-core cable with substrate

Publication Date: 2018.07.31 SUMITOMO ELECTRIC INDUSTRIES LTD

AI summary

A plurality of electronic wires are fixed by a mold part in a state arranged in at least two rows. The mold part has a first end face from which the electronic wires of a first row in the plurality of electronic wires protrude and a second end face from which the electronic wires of a second row in the plurality of electronic wires protrude. An angle of the first end face with respect to a direction of a central axis line of a multi-core cable differs from an angle of the second end face with respect to the direction of the central axis line. The electronic wires of the first row in the first end face protrude along a direction away from the electronic wires of the second row protruding from the second end face.