SATA Connector Assembly Using Flexible Flat Cable
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Solution Overview
Problem
Existing SATA connector assemblies require special cable management equipment and processes, which are time-consuming and costly, with high production costs and low yield.
Innovation Solution
An electrical connector assembly using a flexible flat cable (FFC) with an insulating housing and a PCB, where the FFC is securely fastened by the housing and PCB, eliminating the need for cable management equipment and processes, and featuring a cover for inspection and adhesive injection to secure the connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional cable management equipment and processes are used to solder cable to conductors, then electrical connections can be established, but the manufacturing process becomes time-consuming and costly with low yield
Solution Approach 1:
The patent extracts the cable management function from the traditional soldering process by introducing a separate FFC component with pre-attached conductors. This allows the FFC to be independently prepared and then simply connected to the PCB, eliminating the need for complex cable management equipment and processes during assembly.
Solution Approach 2:
The conductors are pre-attached to the FFC in advance through soldering or other connection methods before the final assembly. This preliminary action transfers the complex soldering work to a separate preparation stage, allowing the main assembly process to focus on simple connection operations that improve productivity.
2Reliability
If traditional cable management equipment and processes are used, then electrical connections can be established, but production cost increases significantly
Solution Approach 1:
By extracting the cable management function into a separate FFC component, the patent eliminates the need for expensive specialized equipment and processes. The simplified connection method reduces manufacturing costs while maintaining connection reliability through the secure fastening mechanism.
Solution Approach 2:
The FFC serves as a disposable or replaceable component that simplifies the overall manufacturing process. By using a standardized FFC with pre-attached conductors, the system replaces expensive and complex cable management equipment with a simple, cost-effective connection solution.
3Ease of manufacture
If the FFC is not securely fastened, then assembly is simple, but the electrical connection becomes insecure when the FFC is pulled
Solution Approach 1:
The patent merges the fastening function with the connection structure by integrating the fastening mechanism into the housing and PCB assembly. The housing and PCB work together to clamp the FFC, combining structural support with secure fastening in a single integrated solution that maintains both simplicity and reliability.
Solution Approach 2:
The housing acts as an intermediary component that mediates between the FFC and the PCB. It provides the clamping force and structural support needed to securely hold the FFC in place, while the adhesive provides additional bonding. This intermediary structure enables secure fastening without complicating the assembly process.
4Reliability
If adhesive is injected to fasten the FFC and PCB, then connection security is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The housing serves as an intermediary structure that simplifies the adhesive application process. By providing a dedicated injecting hole and clamping structure, the housing guides the adhesive to the correct location and ensures proper distribution, reducing the complexity of the overall process while improving connection security.
Solution Approach 2:
The housing structure itself facilitates the adhesive application and fastening process through its built-in injecting hole and clamping mechanism. The structure is designed to guide the adhesive and ensure proper bonding without requiring additional complex equipment or processes, allowing the system to fasten itself with minimal external intervention.
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
Facilitates manufacturing, reduces production costs, ensures secure electrical connections, and simplifies the assembly process by firmly holding conductors in place and protecting the soldering area.
Implementation Method 1
an injecting hole is formed on the cover so that a person may inspect whether the bending portion of the FFC is fastened or not by seeing through the hole. Moreover, adhesive may be injected into the injecting hole to fasten the FFC and the PCB
Implementation Method 2
the power terminals each having a soldering portion soldered in each of the first soldering holes; a plurality of data terminals fastened in the grooves of the insulating housing respectively, the data terminals each having a mating portion inserted into each of the data terminal holes, and the data terminals each having a soldering portion soldered in each of the second soldering holes
Data Source
AI summary
A SATA connector assembly is provided with an insulating housing, a plurality of data and power terminals, a PCB and an FFC, wherein the data and power terminals inserted in the insulating housing, the PCB secured to the insulating housing, the FFC soldered on the PCB, the data and power terminals are electrically interconnected the FFC by the PCB. The provision of the unitary construction feature of FFC can save the production cost due to its eliminating cable management equipment and the step of cable managing processes.