Flexible PCB Wire Harness Layout for Compact Multi-Row Connectors
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Solution Overview
Problem
Existing wire harnesses face challenges in achieving both multi-polarization of connectors and suppressing the size enlargement of the connector.
Innovation Solution
A wire harness design incorporating a connector with a plurality of terminals, a housing, and flexible printed wiring boards with through-holes for terminal insertion, allowing for compact arrangement and easy adaptation to specification changes, while using a force-multiplying mechanism for efficient connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple terminals are arranged in multiple rows to achieve multi-polarization, then the connector size increases, but compact size is required
Solution Approach 1:
The patent transitions from a single-plane terminal arrangement to a multi-layer three-dimensional configuration. Terminals are arranged in multiple rows across at least two different planes, allowing multi-polarization to be achieved by utilizing the vertical dimension (depth) rather than only the horizontal plane. This dimensional transition enables multiple polarizations while maintaining a compact connector footprint.
2Adaptability or versatility
If terminals are arranged in multiple rows for multi-polarization, then the connector becomes more complex, but simplicity is desired
Solution Approach 1:
The connector is segmented into multiple independent terminal groups arranged in different rows and planes. Each terminal group can be independently configured with rod-shaped or tubular insertion portions, allowing modular design and assembly. This segmentation enables multi-polarization functionality while maintaining structural simplicity through standardized modular units.
3Adaptability or versatility
If flexible printed wiring boards are used for connection, then adaptability to specification changes is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent utilizes the flexibility parameter of flexible printed wiring boards to enable specification changes. The FPCs can be bent and routed to accommodate different terminal configurations and connection requirements. This parameter change (from rigid to flexible) provides adaptability while the through-hole design maintains manufacturing precision by providing fixed insertion points for terminals.
Data Source
AI summary
A wire harness includes a connector, a first flexible printed wiring board, and a second flexible printed wiring board, and in this configuration, the connector includes a plurality of terminals and housings, each of the terminals has a rod-shaped or tubular insertion portion, the housings retain the terminals arranged in a plurality of rows with the insertion portion protruding, the terminals includes a first terminal group and a second terminal group, the first flexible printed wiring board is provided with a through-hole into which the insertion portion of the first terminal group is inserted and a printed circuit connected to the insertion portion of the first terminal group, and the second flexible printed wiring board is provided with a through-hole into which the insertion portion of the second terminal group is inserted and a printed circuit connected to the insertion portion of the second terminal group.