Segmental Calendering for Flexible Flat Cable Spacing and Connection
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Solution Overview
Problem
Existing flexible flat cable technologies face challenges in achieving variable conductor spacings and reliable connections, leading to increased risks of short-circuits and inefficient product miniaturization due to fixed spacing-control rods and rounded cross-sections, which limit structural design flexibility and product commonality.
Innovation Solution
A segmental calendering device that alternates between flat and round regions on the cables, using a framework with sliding guide mechanisms and a conductor-space controlling pole with pin wheel groups to adjust cable spacings and ensure reliable connections, allowing for variable cable specifications and reduced short-circuit risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If fixed spacing-control rods are used to maintain cable spacing, then cable arrangement stability is improved, but product miniaturization is hindered and resource waste increases
Solution Approach 1:
The patent divides the cable structure into segments with different cross-sectional shapes (flat segments for connection, round segments for spacing). This segmentation allows different functional requirements to be met in different parts of the cable, enabling miniaturization at connection points while maintaining stability through round segments elsewhere.
Solution Approach 2:
The patent applies different cross-sectional shapes to different locations of the cable. Flat cross-sections are used locally at connection points to improve welding quality and reduce plug-in component volume, while round cross-sections are used in other areas to maintain cable spacing and arrangement stability. This local differentiation resolves the contradiction between miniaturization and stability.
2Reliability
If cable cross-sections are made flat to improve connection reliability, then welding quality and connection reliability are improved, but cable spacing increases leading to larger overall dimensions
Solution Approach 1:
The cable is segmented into flat portions for connections and round portions for spacing. The flat segments provide reliable welding and connections, while the round segments maintain compact spacing. This segmentation allows the cable to achieve both good connection reliability and compact overall dimensions.
Solution Approach 2:
Flat cross-sections are applied locally only where connections are needed, while round cross-sections are used in non-connection areas. This localized application of different geometries ensures connection reliability where required without unnecessarily increasing overall cable spacing and dimensions.
3Adaptability or versatility
If variable cable specifications are required, then adaptability is improved, but device complexity increases due to multiple spacing-control rods
Solution Approach 1:
The patent employs adjustable and movable components in the spacing-control mechanism, allowing the device to adapt to different cable specifications dynamically. Instead of requiring multiple fixed spacing-control rods for different specifications, the mechanism can be adjusted to accommodate variable requirements, reducing overall device complexity while maintaining adaptability.
Data Source
AI summary
A segmental calendering device includes a framework, a pair of left-rolling sliding guide mechanism, a pair of right-rolling sliding guide mechanisms, an upper-calendering roller and a supporting mechanism of the upper-calendering roller, a lower-calendering roller as well as a pressing mechanism. The upper-calendering roller is rotatably supported within the supporting mechanism of the upper-calendering roller and disposed above a position between a left wallboard and a right wallboard of the framework, and the supporting mechanism of the upper-calendering roller slides along the pair of left-rolling sliding guide mechanisms and the pair of right-rolling sliding guide mechanisms. The lower-calendering roller is disposed below the upper-calendering roller correspondingly and rotatably supported between the left wallboard and the right wallboard. The pressing mechanism is for applying a pressure on the supporting mechanism of the upper-calendering roller and for adjusting the pressure.