Multi-layer Ribbon Cable for Coil Spring Signal Transmission
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Solution Overview
Problem
Existing ribbon cables require increased space and additional connectors when transmitting a larger number of signals, as the width of the cable must expand or multiple cables are needed, which is inefficient in coil spring applications.
Innovation Solution
Conductors are arranged in multiple layers stacked vertically, with insulating layers and window-shaped openings to allow for increased signal transmission without significant space expansion, enabling easy electrical contact and integration of multiple conductors into a single connector.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a wider ribbon cable is used to transmit more signals, then the number of signals that can be transmitted increases, but the installation space required increases significantly
Solution Approach 1:
The patent transitions from a two-dimensional arrangement of conductors (side-by-side in a single layer) to a three-dimensional arrangement by stacking multiple conductor layers vertically. This dimensional change allows more conductors to be packed into the same footprint area, increasing signal capacity without proportionally increasing the installation space.
Solution Approach 2:
The patent implements nested structures by placing multiple conductor layers within each other in the vertical direction. Each conductor layer is nested within the housing structure, with insulating layers providing separation. This nesting approach maximizes the use of available space by utilizing the vertical dimension within the housing.
2Quantity of substance
If multiple separate ribbon cables are used to transmit more signals, then the signal transmission capacity increases, but the device complexity and number of connectors increase
Solution Approach 1:
The patent combines multiple conductor layers into a single integrated ribbon cable assembly. All conductor layers are housed together within one housing structure and connected to a single connector, merging what would otherwise require multiple separate cables and connectors. This reduces device complexity while maintaining high signal transmission capacity.
Solution Approach 2:
The single connector design serves multiple functions by establishing electrical connections with all conductor layers simultaneously. The connector is designed to accommodate conductors from multiple layers, making it a universal connection interface that replaces what would otherwise require multiple separate connectors.
3Quantity of substance
If conductors are arranged in multiple layers, then the number of conductors increases without significant space increase, but the difficulty of electrical contact and manufacturing increases
Solution Approach 1:
The patent incorporates window-shaped openings in the insulating layers during the manufacturing process, before the cable is installed. These openings are pre-positioned to align with the conductors, facilitating easier electrical contact during installation. The preliminary creation of these access points reduces the difficulty of subsequent manufacturing and assembly operations.
Solution Approach 2:
The insulating layers with window-shaped openings serve as intermediaries that both electrically isolate the conductors and provide controlled access points for electrical contact. The windows act as mediators between the need for insulation and the need for connectivity, allowing conductors to be contacted through the openings while maintaining electrical isolation in other areas.
Data Source
Figure 1a~1b
Figure 2
AI summary
The invention relates to a flat ribbon cable (10) for a coil spring with several conductors (11, 12) arranged parallel to each other and electrically insulated from each other, wherein the conductors (11, 12) are arranged in at least two superimposed and insulated conductor layers (15, 16).