Neck Strap Fixing Structure Using Flexible Circuit Board
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Solution Overview
Problem
Conventional methods for encapsulating core wires in headphone neck straps result in increased volume, insufficient cable management space, and require time-consuming welding, leading to high rework probabilities.
Innovation Solution
A fixing structure for a neck strap using a housing with a through groove for a flexible circuit board, which reduces volume and eliminates the need for welding by using a plug-in coupling method, incorporating a positioning element, supporting element, and protecting layer made from materials like nylon and rubber.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If core wires are encapsulated with insulating material, then electrical insulation is ensured, but the volume of the wire material increases
Solution Approach 1:
The patent merges the insulating material with the housing structure by forming the housing from insulating material and integrating the through groove directly into it. This eliminates the need for separate insulating material around core wires, reducing overall volume while maintaining electrical insulation functionality.
Solution Approach 2:
The patent extracts the insulating function from separate encapsulating material and transfers it to the housing structure itself. The housing is designed with insulating properties and includes the through groove as an integral part, removing the need for additional insulating layers around core wires.
2Reliability
If core wires are coupled through welding method, then electrical connection is achieved, but work hours increase and rework probability increases
Solution Approach 1:
The patent replaces the welding process (thermal/mechanical system) with a plug-in coupling method where flexible circuit boards are inserted through the through groove and secured mechanically. This substitution eliminates the time-consuming welding process while maintaining reliable electrical connection, directly addressing the productivity issue.
3Reliability
If multiple sets of core wires are embedded in rubber layer, then electrical insulation is provided, but cable management space becomes insufficient
Solution Approach 1:
The patent transitions from embedding wires within a bulky rubber layer to using a flat housing structure with a through groove. This dimensional change allows wires to pass through the groove in a more space-efficient manner, improving cable management while maintaining insulation through the insulating housing material.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution significantly reduces the overall volume of the neck strap, conserves work hours, and decreases rework probabilities by utilizing flexible circuit boards and eliminating the need for welding, while allowing for flexible design and installation without affecting the electronic product's appearance or cable management.
Implementation Method 1
the supporting element is bent and then released, the supporting element has an elastic recovery so as to restore the original shape
Implementation Method 2
The positioning element is made of a nylon material
Data Source
AI summary
A neck strap including at least one flexible circuit board, at least two fixing structures, a positioning element, a protecting layer, and a supporting element is provided. The at least two fixing structures are disposed on two opposite ends of the at least one flexible circuit board and has a housing. The positioning element is disposed in the housing and a through groove is formed between the housing and the positioning element. The protecting layer is at least partially sleeved around the positioning element, the at least one flexible circuit board, and the at least two fixing structures. The supporting element is disposed through the positioning element.