1. Field of the Invention
The present invention relates to a multiconductor cable incorporating a plurality of insulated wires, coaxial conductors, or the like and a method of producing the multiconductor cable, particularly to a multiconductor cable in which a plurality of wires and conductors are tied together in a bundle at the intermediate portion and are arranged in a flat array at both ends, where the cable is provided with connectors or similar components, and a method of producing the multiconductor cable.
2. Description of the Background Art
As information communications devices, such as notebook-size computers, cellular mobile phones, and video cameras, have been widely used in recent years, they are required to reduce their size and weight. Consequently, connection between the main body of a device and a liquid crystal display and wiring in a device are made using extremely fine insulated wires and shielded wires including coaxial conductors. In addition, a multiconductor cable in which the foregoing wires and conductors are bound together is also used be cause it facilitates the wiring. A multiconductor cable is electrically connected through a connector having the shape of a card-edge connector in which a multitude of contacts are arranged in a row (such a connector is used for the connection of a printed circuit, for example).
To solve this problem, the wiring through a turning portion, such as a hinged portion for an opening-and-closing operation, is made using a multiconductor cable 1b provided with connectors as shown in
In the multiconductor cable 1b composed of a plurality of wires 2 having the same length, wires placed in the middle position of a flat array are slackened and wires placed at the outside positions are pulled. As a result, the wires placed at the outside positions tend to break. To overcome this problem, the published Japanese patent applications Tokukoushou 61-230208 and Tokukai 2000-294045 have disclosed a multiconductor cable having a specific structure (see
However, no disclosure has been made about the length of a wire placed at an outer position. No clarification is made for the case that undergoes twisting. In practical application, when a multiconductor cable provided with connectors has a length of E and a width of D and the length E is at least six times the width D, it is confirmed that the intermediate portions of the wires constituting the multiconductor cable and having the shape shown in
However, if the length E is small to the extent that the ratio E/D is less than six, a problem is caused due to the difference in length between the minimum length of the wire placed at the center of the bundle and the maximum length of the wire placed at the outermost position of the bundle. More specifically, at the time of bundling a plurality of wires arranged in a flat array, even when the length of wires to be placed at the outer side and to undergo tension is simply increased, a wire having an excess length tends to buckle or break. In addition, for the use in a turning portion, if no consideration is given to the twisting, a break of wire cannot be prevented, that is, the problem cannot be totally solved.
An object of the present invention is to offer a multiconductor cable that is reduced in the possibility of break even for use at a place where the cable undergoes twisting and a method capable of producing the multiconductor cable easily at a low cost.
To attain the foregoing object, the present invention offers a multiconductor cable that incorporates a plurality of wires that:
(a) are arranged in a flat array with a specific pitch at both ends of them;
(b) have an intermediate portion at which they are bundled together; and
(c) have lengths different from one another, the lengths varying successively from the minimum length, Ls, to the maximum length, Lm. The multiconductor cable satisfies the following formulae:
D/E>⅙, and (Lm−Ls)>{(D2+E2)1/2−E},
where D is the width of the cable at both ends, E is the distance between the ends of the cable, Lm is the maximum length, and Ls is the minimum length.
The multiconductor cable may satisfy the following formulae:
θ<45 degrees, and (Lm−Ls)<3×{2D(21/2−1)}≈2.5D,
where θ is the angle produced by a wire's portion from one of the ends to the intermediate portion and the same wire's portion in the intermediate portion, Lm is the maximum length, Ls is the minimum length, and D is the width of the cable at both ends. In the multiconductor cable, the wire placed at the center of the array of the wires may have the minimum length. In the multiconductor cable, the wire placed at one of the outermost positions of the array of the wires may have the minimum length. The multiconductor cable may be intended to use at a place where it undergoes twisting with a twisting angle of 80 to 190 degrees.
According to one aspect of the present invention, the present invention offers a method of producing at least one multiconductor cable that incorporates a plurality of wires that:
(a) are arranged in a flat array with a specific pitch at both ends of them; and
(b) are bundled together at an intermediate portion. The method includes the following steps:
(c) the preparing of an arranging tool provided with at least one wire-holding-groove-forming portion having a plurality of wire-holding grooves with different lengths from a minimum length of Lsa to a maximum length of Lma, the lengths being varied successively. In the arranging tool, the at least one wire-holding-groove-forming portion is provided with at both end portions a transforming-portion-arranging section for arranging a transforming portion of the wires. In the above description, the transforming portion is a portion located between each of the ends and the intermediate portion;
(d) the arranging of a plurality of wires using the arranging tool;
(e) the attaching of an adhesive tape or a member having a similar function to the transforming portions of the wires so that the arranged state can be maintained;
(f) the removing of the wires from the arranging tool with maintaining the arranged state;
(g) the forming of a terminal structure for electrical connection at both ends; and
(h) the bundling of the intermediate portions of the wires together.
In the arranging tool, the at least one wire-holding-groove-forming portion may satisfy the following formulae:
Da/Ea>⅙, and (Lma−Lsa)>{(Da2+Ea2)1/2−Ea},
where Da is the arranging width of the transforming-portion-arranging section, and Ea is the effective length of the at least one wire-holding-groove-forming portion. The method may use the arranging tool in which the at least one wire-holding-groove-forming portion is at least two wire-holding-groove-forming portions connected in tandem. In this description, the or each wire-holding-groove-forming portion is provided for forming one multiconductor cable.
Advantages of the present invention will become apparent from the following detailed description, which illustrates the best mode contemplated to carry out the invention. The invention can also be carried out by different embodiments, and its several details can be modified in various respects, all without departing from the invention. Accordingly, the accompanying drawing and the following description are illustrative in nature, not restrictive.
The present invention is illustrated to show examples, not to show limitations, in the figures of the accompanying drawing. In the drawing, the same reference numeral and sign refer to a similar element. In the drawing:
Multiconductor cables 11a and 11b are formed by arranging both ends of a plurality of wires 12 in a flat array with a specified pitch and then connecting an electrical connector 13 to each of the ends. It is desirable that the multiconductor cables 11a and 11b provided with connectors incorporate wires 12 that are single-conductor wires having an overall diameter as relatively small as 1.0 mm or less, for example, and a good flexibility. The single-conductor wire may be an insulated wire, a coaxial conductor, or a shielded wire, for example. The lengths of the individual wires 12 are different from one another successively from the minimum length, Ls, to the maximum length, Lm. The width of the cable at the end is denoted as D, and the distance between the rear ends of the electrical connectors 13 connected to the ends of the cable, i.e., the distance between the ends of the cable is denoted as E.
Before the intermediate portions of the wires constituting the cable are bundled, the multiconductor cables 11a and 11b are formed such that wires 12 other than the wire having the minimum length Ls have an excess length forming a slack. At the intermediate portion 12b, the excess length of the wire increases with increasing distance of the wire from the wire 12 having the minimum length Ls. Therefore, when the wires are arranged in a flat array, the array has a shape that bulges laterally to a large extent.
In the multiconductor cable 11a shown in
The intermediate portions 12b may be bundled by using a bundling member 14, such as an adhesive tape. When shielded wires are used, the wires may be bundled by using a grounding member 15 so that a specific portion can be grounded as required. The shape of the bundled portion has no specific limitations providing that the wires 12 are tied together in a bundle. The bundle may take any shape. A single bundling member 14 may be used to bundle wires at one place with a specific length. A plurality of bundling members may also be used to bundle wires at a plurality of places. Furthermore, the bundled wires 12 may either be tied together tightly or be loosely bound such that their movement is not restricted by one another.
In the multiconductor cable 11b shown in
When the wires constituting the multiconductor cable 11b are bundled at the intermediate portion, the cable is formed such that transforming portions 12a decrease the spacing between wires as the position moves both from the electrical connector 13 to the intermediate portion 12b and from one of the outermost positions of the wire array to the other outermost position and, as a result, form a right-angled triangle. The length of one of the transforming portions 12a having been transformed into a triangle is denoted as E1, and that of the other as E2. The length of the bundled intermediate portion 12b is denoted as E3. Consequently, the equation “E=E1+E2+E3” is established. The method of bundling the wires 12 is the same as that of the first embodiment.
Next, the present invention is explained in detail below by referring to
As described earlier, it has been confirmed that in a multiconductor cable, when the distance E is at least six times the width D, the application of twisting due to a turning of 180 degrees or less does not cause a break. Consequently, the present invention deals with a multiconductor cable that has the distance E less than six times the width D and therefore is considered to be prone to break.
In the first embodiment, as shown in
In other words, when the maximum length Lm is longer than the minimum length Ls by “Lm1+Lm2−E1−E2,” the intermediate portions 12b can be bundled without elongating the wire placed at the outermost position of the array (because no tension is applied, the wire does not elongate). Here, to simplify the explanation, a case where the formula “E1=E2=½EE” is established is taken up for discussion (in this case, “Lm1+Lm2” becomes the minimum).
In this case, the equation “Lm−Ls=(E2+D2)1/2−E” can be obtained. In other words, when the difference between the maximum length Lm and the minimum length Ls, i.e., “Lm−Ls,” is predetermined in excess of “(E2+D2)1/2−E,” the wire that is placed at the outermost position of the array and that has the maximum length Lm can be bundled along the wire that is placed at the center of the array and that has the minimum length Ls without undergoing tension.
In the second embodiment, as shown in
In other words, when the maximum length Lm is longer than the minimum length Ls by “Lm1+Lm2−E1−E2,” the intermediate portions 12b can be bundled without elongating the wire placed at the other outermost position of the array (because no tension is applied, the wire does not elongate). Here, to simplify the explanation, a case where the formula “E1=E2=½E” is established is taken up for discussion (in this case, “Lm1+Lm2” becomes the minimum).
In this case, the equation “Lm−Ls=(E2+4D2)1/2−E” can be obtained. In other words, when the difference between the maximum length Lm and the minimum length Ls, i.e., “Lm−Ls,” is predetermined in excess of “(E2+4D2)1/2−E,” the wire that is placed at the other outermost position of the array and that has the maximum length Lm can be bundled along the wire that is placed at the opposite outermost position of the array and that has the minimum length Ls without undergoing tension.
In addition, according to practical experience, it is desirable that the wire that is placed at the outermost position of the array and that has the maximum length Lm be formed to have an angle, θ, of less than 45 degrees, where the angle θ is an angle produced by a wire placed from the end to the bundled intermediate portion and the center axis of the bundled intermediate portion (see
As described above, of the various embodiments, the embodiment that can minimize the value of “Lm−Ls,” which is the difference between the maximum length Lm and the minimum length Ls, is the first embodiment under the condition that the two lengths of the bent and slanted portions at both transforming portions 12a are set to be equal (Lm1=Lm2, or E1=E2). In this case, “Lm−Ls” becomes “(E2+D2)1/2−E.” Therefore, the multiconductor cable is required to satisfy the following formulae:
D/E>⅙, and (Lm−Ls)>{(D2+E2)1/2E},
where D is the width at both ends of the cable, E is the distance between the ends of the cable, Lm is the maximum length, and Ls is the minimum length. In this case, when the angle, θ, produced by a wire placed from the end to the intermediate portion 12b and the center axis of the intermediate portion 12b is predetermined to be less than 45 degrees, the relation “Lm−Ls>0.41D” can be realized.
When a multiconductor cable having the above-described structure is used for the wiring through a turning portion such as the connection between a main board and a liquid crystal display of a cellular mobile phone, a notebook-size computer, a video camera, and the like, it is used at a place where it undergoes twisting with a twisting angle of 90 to 180 degrees (80 to 190 degrees when a margin is considered). In addition, because a plurality of wires are bundled together and the bundled portion as a whole is thick to a certain extent, when the wires are bent, the central position may deviate. Consequently, it is difficult to maintain the value of “Lm−Ls” at the calculated value. Therefore, it is necessary to predetermine the value of “Lm−Ls,” which is the difference between the maximum length Lm and the minimum length Ls, with a certain margin.
However, when the value of “Lm−Ls” is increased more than necessary, the excess length at the bundled intermediate portion increases excessively and may produces a slack. When this happens, the total appearance becomes unsightly and bending, buckling, and breaking tend to occur. As explained by referring to
θ<45 degrees, and (Lm−Ls)<3×{2D(21/2−1)}≈2.5D,
where θ is the angle produced by a wire′ portion from one of the ends to the intermediate portion and the same wire′ portion in the intermediate portion, Lm is the maximum length, and Ls is the minimum length.
In the wire-holding grooves 22, a transforming-portion-arranging section 22a is formed at both sides such that the section has grooves parallel with one another with a pitch according to the wire-arranging pitch at the ends of the multiconductor cable to be produced. An intermediate-portion-arranging section 22b is formed in the following way. The shortest linear groove at the center has a minimum length of Lsa. The outermost grooves have a maximum length of Lma. The grooves increase their length successively as their position moves from the center to the outside, so that they are bent with an angular shape or a curved shape. A plurality of wires are placed on the arranging face 21 of the arranging tool 20a, and they are squeezed into the wire-holding grooves 22 by using a spatula or a similar tool so that they can be arranged.
Subsequently, an adhesive tape or a similar member is attached onto at least the transforming-portion-arranging sections 22a at both sides, so that the wires held in the wire-holding grooves 22 are fixed so as to maintain the arranged state. The adhesive tape may be made of polyethylene or other plastic on which adhesive is applied. Then, both ends of the wires are neatly aligned along an edge 21a of the arranging tool 20a by cutting or another method. The wires maintained in the arranged state are removed from the arranging tool 20a. An electrical connector or another terminating member is connected to both ends of the wires, as shown in
In addition, the transforming-portion-arranging section 22a of the arranging tool 20a has an arranging width, Da, which is nearly the same as the cable width D shown in
Da/Ea>⅙, and (Lma−Lsa)>{(Da2+Ea2)1/2−Ea},
where Da is the arranging width at the transforming-portion-arranging section, and Ea is the effective length of the wire-holding-groove-forming portion.
When the above-described arranging tool is used to produce a multiconductor cable provided with connectors, a plurality of wires placed between the ends can be easily arranged by automatically setting the individually different lengths successively from the minimum length to the maximum length. As a result, the cable can be produced with uniform quality and at a low cost without relying on the skill of the workers.
According to the present invention, even though a multiconductor cable has a small total length, the intermediate portions of the wires constituting the cable can be bundled together effectively. Therefore, the present invention enables the achievement of a miniaturized multiconductor cable.
The present invention is described above in connection with what is presently considered to be the most practical and preferred embodiments. However, the invention is not limited to the disclosed embodiments, but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.
The entire disclosure of Japanese patent application 2004-046375 filed on Feb. 23, 2004 including the specification, claims, drawing, and summary is incorporated herein by reference in its entirety.
Number | Date | Country | Kind |
---|---|---|---|
2004-046375 | Feb 2004 | JP | national |
Number | Date | Country | |
---|---|---|---|
Parent | 11058415 | Feb 2005 | US |
Child | 11498133 | Aug 2006 | US |