Switch-Containing Cable Bending Conduction Control

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Solution Overview

Problem

Existing switch-containing cables face issues with unintended conduction due to bending, leading to false operations, and complex configurations that hinder usability, especially in portable devices like earphones.

Innovation Solution

A switch-containing cable design featuring a belt-like conductor film with a movable first conductor film and an insulating spacer, allowing for a gap that prevents conduction during bending while facilitating conduction when pressed by fingers, along with lead wire insertion holes and swelled parts for localized switching.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If two conductive members are vertically and oppositely disposed with conductive rubber between them to enable switching by external pressurization, then switching operation becomes easy and location-independent, but the cable becomes liable to false operation when bended due to unintended conduction

Engineering Contradiction:

Improveswitching operationVSAvoidfalse operation

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent uses a flexible insulating film instead of conductive rubber to separate the conductive members. This thin film maintains the switching function while preventing unintended conduction during bending, as it provides reliable electrical insulation even when the cable is deformed.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent employs a composite structure combining conductive members with an insulating film and insulating resin. This composite material approach ensures both the switching capability (through conductive members) and prevention of false operation (through insulating materials) are achieved simultaneously.

Inventive Principle:

Principle #40Composite materials

2Reliability

If positive and negative electrodes are oppositely disposed on inner surfaces of one base material to prevent unintended conduction during bending, then reliability improves, but the configuration becomes complex requiring corrugated or rectangular shapes and insulating slits

Engineering Contradiction:

Improveunintended conduction preventionVSAvoidelectrode structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent divides the cable structure into distinct segments: conductive members, insulating film, and insulating resin. This segmentation allows each component to perform its specific function without requiring complex shapes or configurations, simplifying the overall electrode structure while maintaining reliability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The insulating film acts as an intermediary between the positive and negative electrodes, providing electrical insulation without requiring the electrodes to have complex corrugated or rectangular shapes. This mediator approach simplifies the electrode configuration while preventing unintended conduction.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of operation

If conductive rubber is used between conductive members to enable switching, then the cable can be easily made conductive by pressurization, but the resistance value decreases during bending causing unintended operation

Engineering Contradiction:

Improveconduction activationVSAvoidresistance value stability

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The patent replaces the conductive rubber (which degrades in performance during bending) with a more stable insulating film and resin combination. This substitution ensures consistent electrical properties and resistance values even when the cable is bent, eliminating the reliability issues associated with conductive rubber.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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 design ensures reliable non-conduction during bending, preventing false operations and enhancing usability by allowing easy recognition of switching through finger pressure, while enabling signal transfer and localized switching.

Implementation Method 1

an insulating spacer arranged between this second conductor film and the first conductor film to maintain a gap therebetween

Methodology Applied

Scientific EffectElectrical insulation: Dielectric

Implementation Method 2

the first conductor film constituting the belt-like conductor film is movably overlaid on the insulating spacer

Methodology Applied

Scientific EffectMechanical displacement: Displacement

Data Source

PatentUS10211009B2Switch-containing cable

Publication Date: 2019.02.19 FOSTER ELECTRIC CO LTD

AI summary

A switch-containing cable when bended does not conduct electricity, but conducts electricity when pressurized with fingers. The cable has belt-like first and second oppositely disposed conductor films including respective first and second belt-like base materials on inner surfaces of which respective first and conductors are disposed; an insulating spacer arranged to maintain a gap therebetween; and a belt-like sheath configured with the first and second conductor films sandwiching the spacer and containing a belt-like conductor film functioning as a switch member in a hollow cavity. The first conductor film constituting the belt-like conductor film is movably overlaid on the insulating spacer, and the hollow cavity of the sheath includes a gap allowing for lengthwise relative displacement of at least the first belt-like base material caused by bending the sheath with respect to the belt-like conductor film housed in the hollow cavity, thereby preventing the cable from conducting electricity when bended.