Sensor Cable Connection Structure With Spacer-Guided Core Alignment
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Solution Overview
Problem
The existing connection structures between medical microsensors and multi-core cables are labor-intensive, costly, and prone to errors due to the limited space and fragility of the cables, making mass production difficult and increasing the risk of wire breakage during manual connection.
Innovation Solution
A connection structure that uses a spacer with circumferential holding recesses to securely position and connect multiple electric wires to a sensor, utilizing a conductive surface and fixing members like solder or conductive adhesive, allowing for improved accuracy and strength by preventing adjacent wire stress during connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual connection work is used to connect cable cores to microsensor, then connection accuracy can be maintained, but manufacturing cost increases and productivity decreases
Solution Approach 1:
The invention divides the cable into multiple bundled groups, with each bundle containing multiple cores that are connected simultaneously to a single conductor connecting portion. This segmentation allows automated connection while maintaining accuracy, as the bundled structure guides the cores into proper positions without requiring manual individual handling.
Solution Approach 2:
The cable cores are pre-bundled into groups before the connection process. This preliminary arrangement of cores into bundled structures eliminates the need for manual positioning during connection, enabling automated systems to achieve accurate connections efficiently and support mass production.
2Strength
If manual connection work is performed, then connection strength can be controlled, but manufacturing cost increases
Solution Approach 1:
By bundling multiple cores together and connecting them simultaneously to a single conductor connecting portion, the invention reduces the number of individual connection operations. This segmentation approach maintains connection strength through proper bundled structuring while enabling cost-effective automated manufacturing.
3Manufacturing precision
If cable cores are connected one by one, then connection accuracy can be maintained, but wire breakage increases due to stress on adjacent cores
Solution Approach 1:
The invention segments the connection process by bundling multiple cores together, so they are connected simultaneously rather than individually. This bundled connection approach distributes stress evenly across the bundle during connection, preventing stress concentration on adjacent cores that would cause wire breakage, while still achieving accurate connections through the structured bundle arrangement.
Solution Approach 2:
Multiple cable cores are merged into bundled groups that are connected together as a unit to a single conductor connecting portion. This merging of cores into bundles reduces the sequential connection steps that cause stress on individual cores, thereby decreasing wire breakage risk while maintaining connection accuracy through the organized bundle structure.
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 easier and more accurate connections, reduces manufacturing costs, and enhances connection strength, enabling automation and increased productivity by simplifying the connection process and reducing the risk of wire breakage.
Implementation Method 1
the core-exposing portion (23) of each electric wire (2) is electrically connected to the sensor (6) via a fixing member
Data Source
Figure 1A~1B
Figure 2
Figure 3A~3B
AI summary
A connection structure between sensor and cable includes a cable formed by assembling a plurality of electric wires each including a covering portion covering a core and a core-exposing portion exposing the core at an end of the covering portion, a spacer that is interposed in a space surrounded by the covering portions of the electric wires and holds end portions of the covering portions in the state that the end portions are spaced from each other, and a sensor that detects a physical quantity, and the core-exposing portion of each of the electric wires of the cable is electrically connected to the sensor via a fixing member in the state that each of the electric wires is held by the spacer.