Patent Description:
Flexible flat cables used in rotary connector devices are known (see, for example, <CIT>).

<CIT> discloses a flat cable assembly according to the preamble of claim <NUM>.

However, in a flat cable described in <CIT>, a notch is provided in a conductor exposure section provided in an end portion to overlap two flat cables, and this increases the manufacturing cost.

An object of the technology disclosed in the present application is to reduce the manufacturing cost of a flat cable assembly for a rotary connector device.

The invention provides flat cable assembly for a rotary connector device according to claim <NUM>.

In a first aspect the flat cable assembly comprises a first lead block, a first flat cable, and a second flat cable. The first lead block includes a first lead block body and a first conductor that includes a first exposure surface exposed from the first lead block body and is attached to the first lead block body. The first flat cable includes a first cable end portion connected to the first exposure surface so as to extend from the first exposure surface in a first direction. The second flat cable includes a second cable end portion connected to the first exposure surface so as to extend from the first exposure surface in a second direction, which is different from the first direction.

In the flat cable assembly for a rotary connector device according to the first aspect, the second cable end portion extends from the first exposure surface in the second direction, which is different from the first direction in which the first cable end portion extends, and this can increase the degree of freedom in disposing the first flat cable and the second flat cable. Accordingly, the manufacturing cost of the flat cable assembly for a rotary connector device can be reduced.

A flat cable assembly for a rotary connector device according to a second aspect is the flat cable assembly for a rotary connector device according to the first aspect, wherein the second direction is substantially opposite to the first direction.

The flat cable assembly for a rotary connector device according to the second aspect can further increase the degree of freedom in disposing the first flat cable and the second flat cable.

A flat cable assembly for a rotary connector device according to a third aspect is the flat cable assembly for a rotary connector device according to the first or second aspect, wherein the second direction is substantially parallel to the first direction.

The flat cable assembly for a rotary connector device according to the third aspect can further increase the degree of freedom in disposing the first flat cable and the second flat cable.

In the flat cable assembly for a rotary connector device according to claim <NUM> and a fourth aspect the second cable end portion is disposed on the first exposure surface so as not to overlap with the first cable end portion.

In the flat cable assembly for a rotary connector device according to the fourth aspect, interference between the first cable end portion and the second cable end portion can be suppressed, and the degree of freedom in disposing the first flat cable and the second flat cable can be further increased.

A flat cable assembly for a rotary connector device according to a fifth aspect is the flat cable assembly for a rotary connector device according to the fourth aspect, wherein the first cable end portion includes a first conductive end. The second cable end portion includes a second conductive end. The second conductive end is disposed on the first exposure surface so as not to overlap with the first conductive end.

The flat cable assembly for a rotary connector device according to the fifth aspect can further increase the degree of freedom in disposing the first flat cable and the second flat cable while suppressing interference between the first cable end portion and the second cable end portion.

A flat cable assembly for a rotary connector device according to a sixth aspect is the flat cable assembly for a rotary connector device according to any one of the first to fifth aspects, wherein the first conductor includes a first protruding portion protruding from the first lead block body in a first protruding direction, which is different from at least one of the first direction and the second direction.

In the flat cable assembly for a rotary connector device according to the sixth aspect, other connectors can be connected to the flat cable assembly using the first protruding portion.

A flat cable assembly for a rotary connector device according to a seventh aspect is the flat cable assembly for a rotary connector device according to any one of the first to sixth aspects, wherein the second cable end portion extends from the first exposure surface in the second direction and is bent so as to extend further in the first direction.

In the flat cable assembly for a rotary connector device according to the seventh aspect, the first flat cable and the second flat cable can be formed compactly in the vicinity of the first lead block.

A flat cable assembly for a rotary connector device according to an eighth aspect is the flat cable assembly for a rotary connector device according to any one of the first to seventh aspects and further comprises a second lead block. The second lead block includes a second lead block body and a second conductor that includes a second exposure surface exposed from the second lead block body and is attached to the second lead block body. The first flat cable includes a third cable end portion connected to the second exposure surface so as to extend from the second exposure surface in a third direction. The second flat cable includes a fourth cable end portion connected to the second exposure surface so as to extend from the second exposure surface in a fourth direction, which is different from the third direction.

In the flat cable assembly for a rotary connector device according to the eighth aspect, the fourth cable end portion extends from the second exposure surface in the fourth direction, which is different from the third direction in which the third cable end portion extends, and thus the degree of freedom in disposing the first flat cable and the second flat cable can be increased. Accordingly, the manufacturing cost of the flat cable assembly for a rotary connector device can be reduced.

A flat cable assembly for a rotary connector device according to a ninth aspect is the flat cable assembly for a rotary connector device according to the eighth aspect, wherein the fourth direction is substantially opposite to the third direction.

The flat cable assembly for a rotary connector device according to the ninth aspect can further increase the degree of freedom in disposing the first flat cable and the second flat cable.

A flat cable assembly for a rotary connector device according to a tenth aspect is the flat cable assembly for a rotary connector device according to the eighth or ninth aspect, wherein the fourth direction is substantially parallel to the third direction.

The flat cable assembly for a rotary connector device according to the tenth aspect can further increase the degree of freedom in disposing the first flat cable and the second flat cable.

A flat cable assembly for a rotary connector device according to an eleventh aspect is the flat cable assembly for a rotary connector device according to any one of the eighth to tenth aspects, wherein the fourth cable end portion is disposed on the second exposure surface so as not to overlap with the third cable end portion.

The flat cable assembly for a rotary connector device according to the eleventh aspect can further increase the degree of freedom in disposing the first flat cable and the second flat cable while suppressing interference between the third cable end portion and the fourth cable end portion.

A flat cable assembly for a rotary connector device according to a twelfth aspect is the flat cable assembly for a rotary connector device according to the eleventh aspect, wherein the third cable end portion includes a third conductive end. The fourth cable end portion includes a fourth conductive end. The fourth conductive end is disposed on the second exposure surface so as not to overlap with the third conductive end.

The flat cable assembly for a rotary connector device according to the twelfth aspect can further increase the degree of freedom in disposing the first flat cable and the second flat cable while suppressing interference between the third cable end portion and the fourth cable end portion.

A flat cable assembly for a rotary connector device according to a thirteenth aspect is the flat cable assembly for a rotary connector device according to any one of the eighth to twelfth aspects, wherein the fourth cable end portion extends from the second exposure surface in the fourth direction and is bent so as to extend further in the third direction.

In the flat cable assembly for a rotary connector device according to the thirteenth aspect, the first flat cable and the second flat cable can be formed compactly in the vicinity of the second lead block.

A flat cable assembly for a rotary connector device according to a fourteenth aspect is the flat cable assembly for a rotary connector device according to any one of the eighth to thirteenth aspects, wherein the second conductor includes a second protruding portion protruding from the second lead block body in a second protruding direction, which is different from at least one of the third direction and the fourth direction.

In the flat cable assembly for a rotary connector device according to the fourteenth aspect, other connectors can be connected to the flat cable assembly using the second protruding portion.

A flat cable assembly for a rotary connector device according to a fifteenth aspect is the flat cable assembly for a rotary connector device according to any one of the eighth to fourteenth aspects, wherein the first flat cable extends from the first cable end portion to the third cable end portion. The second flat cable extends from the second cable end portion to the fourth cable end portion.

In the flat cable assembly for a rotary connector device according to the fifteenth aspect, the first lead block and the second lead block can be disposed at two ends of the first flat cable and at two ends of the second flat cable.

A rotary connector according to a sixteenth aspect comprises a stator, a rotator provided rotatably about a rotation axis with respect to the stator, and the flat cable assembly for a rotary connector device according to any one of the eighth to fifteenth aspects, the flat cable assembly being disposed at least partially within a cable housing space defined by the stator and the rotator. The first lead block is attached to the rotator. The second lead block is attached to the stator.

The rotary connector according to the sixteenth aspect can reduce the manufacturing cost of the flat cable assembly for a rotary connector device. Accordingly, the manufacturing cost of a rotary connector device can be reduced as well.

A flat cable assembly for a rotary connector device according to a seventeenth aspect is the flat cable assembly for a rotary connector device according to any one of the first to fifteenth aspects, wherein the length of the first flat cable is different from the length of the second flat cable.

The technology disclosed in the present application can reduce the manufacturing cost of a flat cable assembly for a rotary connector device.

In the drawings, the same reference signs denote corresponding or identical components.

As illustrated in <FIG>, a rotary connector device <NUM> comprises a stator <NUM> and a rotator <NUM>. The rotator <NUM> is provided rotatably about a rotation axis A1 with respect to the stator <NUM>. In the present embodiment, for example, the stator <NUM> is configured to be fixed to a vehicle body, and the rotator <NUM> is configured to be fixed to a steering wheel.

The rotary connector device <NUM> includes a first connector <NUM>, a second connector <NUM>, and a third connector <NUM>. The first connector <NUM> and the second connector <NUM> are attached to the rotator <NUM>. The first connector <NUM> and the second connector <NUM> are configured to be electrically connected to, for example, a steering side electric connector. The first connector <NUM> and the second connector <NUM> are electrically connected via the steering side electric connector to an electric circuit such as a switch of a steering wheel and an airbag device. The third connector <NUM> is attached to the stator <NUM>. The third connector <NUM> is configured to be electrically connected to, for example, a vehicle body side electric connector. The third connector <NUM> is connected via a vehicle body side electric connector to electrical devices (for example, a control device and a battery) provided on the vehicle body.

As illustrated in <FIG>, the stator <NUM> and the rotator <NUM> define a cable housing space S1, which is provided so as to surround the rotation axis A1, between the stator <NUM> and the rotator <NUM>. The rotary connector device <NUM> comprises a flat cable assembly <NUM> for a rotary connector device. The flat cable assembly <NUM> for a rotary connector device may also be referred to as a flat cable assembly <NUM>. The flat cable assembly <NUM> is disposed at least partially within the cable housing space S1 defined by the stator and the rotator. For example, the cable housing space S1 is annular and extends in a circumferential direction D1 with respect to the rotation axis A1.

The flat cable assembly <NUM> is electrically connected to the first connector <NUM> and the third connector <NUM> (see <FIG>). The flat cable assembly <NUM> is flexible and has a flat shape. The flat cable assembly <NUM> may also be referred to as a flexible flat cable.

As illustrated in <FIG>, the flat cable assembly <NUM> comprises a first lead block <NUM>, a first flat cable <NUM>, and a second flat cable <NUM>. The first lead block <NUM> includes a first lead block body 61A and a first conductor 61B. The first conductor 61B has a first exposure surface 61C being exposed from the first lead block body 61A and is attached to the first lead block body 61A.

In the present embodiment, the first conductor 61B is disposed within the first lead block body 61A. The first lead block body 61A is formed of a non-metal material. For example, the first lead block body 61A is formed of a resin material having insulating properties. On the other hand, the first conductor 61B is formed of a metal material. The first conductor 61B is embedded in the first lead block body 61A by insertion molding. However, the structure of the first lead block <NUM> is not limited to the present embodiment.

The first flat cable <NUM> is flexible and has a flat cross-sectional shape. The second flat cable <NUM> is flexible and has a flat cross-sectional shape. The first flat cable <NUM> includes a first cable end portion 62A. The first cable end portion 62A is connected to the first exposure surface 61C so as to extend from the first exposure surface 61C in a first direction D21. The second flat cable <NUM> includes a second cable end portion 63A. The second cable end portion 63A is connected to the first exposure surface 61C so as to extend from the first exposure surface 61C in a second direction D22 different from the first direction D21.

In the present embodiment, the first cable end portion 62A includes a first conductive end 62B. The second cable end portion 63A includes a second conductive end 63B. The first conductive end 62B and the second conductive end 63B are connected to the first exposure surface 61C. For example, the first conductive end 62B and the second conductive end 63B are connected to the first exposure surface 61C by a joining structure such as solder or crimping.

In the present embodiment, the second direction D22 is substantially opposite to the first direction D21. The second direction D22 is substantially parallel to the first direction D21. More specifically, the second direction D22 is opposite the first direction D21. The second direction D22 is parallel to the first direction D21. However, the relationship between the first direction D21 and the second direction D22 is not limited to the present embodiment.

The second cable end portion 63A is disposed on the first exposure surface 61C so as not to overlap with the first cable end portion 62A. The second conductive end 63B is disposed on the first exposure surface 61C so as not to overlap with the first conductive end 62B. The second conductive end 63B is disposed apart from the first conductive end 62B.

The first conductor 61B includes a first protruding portion 61D. The first protruding portion 61D protrudes from the first lead block body 61A in a first protruding direction D23, which is different from at least one of the first direction D21 and the second direction D22. In the present embodiment, the first protruding direction D23 is different from the first direction D21 and the second direction D22. However, the relationship between the first direction D21, the second direction D22, and the first protruding direction D23 is not limited to the present embodiment. The first protruding direction D23 may be the same as at least one of the first direction D21 and the second direction D22.

As illustrated in <FIG>, the flat cable assembly <NUM> further comprises a second lead block <NUM>. The second lead block <NUM> includes a second lead block body 64A and a second conductor 64B. The second conductor 64B has a second exposure surface 64C being exposed from the second lead block body 64A and is attached to the second lead block body 64A.

In the present embodiment, the second conductor 64B is disposed in the second lead block body 64A. The second lead block body 64A is formed of a non-metal material. For example, the second lead block body 64A is formed of a resin material having insulating properties. On the other hand, the second conductor 64B is formed of a metal material. The second conductor 64B is embedded in the second lead block body 64A by insertion molding. However, the structure of the second lead block <NUM> is not limited to the present embodiment.

The first flat cable <NUM> includes a third cable end portion 62C. The third cable end portion 62C is connected to the second exposure surface 64C so as to extend from the second exposure surface 64C in a third direction D31. The second flat cable <NUM> includes a fourth cable end portion 63C. The fourth cable end portion 63C is connected to the second exposure surface 64C so as to extend from the second exposure surface 64C in a fourth direction D32, which is different from the third direction D31.

In the present embodiment, the third cable end portion 62C includes a third conductive end 62D. The fourth cable end portion 63C includes a fourth conductive end 63D. The third conductive end 62D and the fourth conductive end 63D are connected to the second exposure surface 64C. For example, the third conductive end 62D and the fourth conductive end 63D are connected to the second exposure surface 64C by a joining structure such as solder or crimping.

In the present embodiment, the fourth direction D32 is substantially opposite to the third direction D31. The fourth direction D32 is substantially parallel to the third direction D31. More specifically, the fourth direction D32 is opposite the third direction D31. The fourth direction D32 is parallel to the third direction D31. However, the relationship between the third direction D31 and the fourth direction D32 is not limited to the present embodiment.

The fourth cable end portion 63C is disposed on the second exposure surface 64C so as not to overlap with the third cable end portion 62C. The fourth conductive end 63D is disposed on the second exposure surface 64C so as not to overlap with the third conductive end 62D. The fourth conductive end 63D is disposed apart from the third conductive end 62D.

The second conductor 64B includes a second protruding portion 64D. The second protruding portion 64D protrudes from the second lead block body 64A in a second protruding direction D33, which is different from at least one of the third direction D31 and the fourth direction D32. In the present embodiment, the second protruding direction D33 is different from the third direction D31 and the fourth direction D32. However, the relationship between the third direction D31, the fourth direction D32, and the second protruding direction D33 is not limited to the present embodiment. The second protruding direction D33 may be the same as at least one of the third direction D31 and the fourth direction D32.

As illustrated in <FIG> and <FIG>, the first flat cable <NUM> includes a first lead wire 62E and a first covering portion 62F having insulating properties and covering the first lead wire 62E. The first lead wire 62E includes the first conductive end 62B and the third conductive end 62D.

The second flat cable <NUM> includes a second lead wire 63E and a second covering portion 63F having insulating properties and covering the second lead wire 63E. The second lead wire 63E includes the second conductive end 63B and the fourth conductive end 63D.

As illustrated in <FIG>, the first flat cable <NUM> extends from the first cable end portion 62A to the third cable end portion 62C. The second flat cable <NUM> extends from the second cable end portion 63A to the fourth cable end portion 63C. The first flat cable <NUM> extends in a strip shape from the first cable end portion 62A to the third cable end portion 62C. The second flat cable <NUM> extends in a strip shape from the second cable end portion 63A to the fourth cable end portion 63C. In other words, the first cable end portion 62A and the third cable end portion 62C constitute two ends of the first flat cable <NUM>. The second cable end portion 63A and the fourth cable end portion 63C constitute two ends of the second flat cable <NUM>.

The second cable end portion 63A of the second flat cable <NUM> extends from the first exposure surface 61C in the second direction D22 and is bent so as to extend further in the first direction D21. Similarly, the fourth cable end portion 63C of the second flat cable <NUM> extends from the second exposure surface 64C in the fourth direction D32 and is bent so as to extend further in the third direction D31. Thus, in a state in which the first lead block <NUM>, the second lead block <NUM>, the first flat cable <NUM>, and the second flat cable <NUM> are assembled, the second flat cable <NUM> overlaps with the first flat cable <NUM>. Furthermore, in a state in which the flat cable assembly <NUM> is assembled, the second protruding direction D33 is opposite the first protruding direction D23. The length of the first flat cable <NUM> is different from the length of the second flat cable <NUM>. In the present embodiment, the length of the first flat cable <NUM> is longer than the length of the second flat cable <NUM>.

As illustrated in <FIG>, in a state in which the flat cable assembly <NUM> is assembled to the stator <NUM> and the rotator <NUM>, the first lead block <NUM> is attached to the rotator <NUM>, and the second lead block <NUM> is attached to the stator <NUM>. The flat cable assembly <NUM> is wound in the circumferential direction along a wall of the stator <NUM> and a wall of the rotator <NUM> in the cable housing space S1.

As illustrated in <FIG>, the rotary connector device <NUM> comprises a flat cable assembly <NUM> for a rotary connector device. The flat cable assembly <NUM> comprises a first lead block <NUM>, a second lead block <NUM>, a first flat cable <NUM>, and a second flat cable <NUM>. The first lead block <NUM>, the second lead block <NUM>, the first flat cable <NUM>, and the second flat cable <NUM> of the flat cable assembly <NUM> has substantially the same structure as the first lead block <NUM>, the second lead block <NUM>, the first flat cable <NUM>, and the second flat cable <NUM> of the flat cable assembly <NUM>. Thus, a description of the first lead block <NUM>, the second lead block <NUM>, the first flat cable <NUM>, and the second flat cable <NUM> can be substituted for a description of the first lead block <NUM>, the second lead block <NUM>, the first flat cable <NUM>, and the second flat cable <NUM> by replacing "<NUM>", "<NUM>", "<NUM>", "<NUM>", "<NUM>", "<NUM>", "D21", "D22", "D23", "D31", "D32", and "D33" with "<NUM>", "<NUM>", "<NUM>", "<NUM>", "D41", "D42", "D43", "D51", "D52", and "D53", respectively.

As illustrated in <FIG>, a second cable end portion 73A of the second flat cable <NUM> extends in a second direction D42 from the first lead block <NUM>, and then is bent in a first direction D41. Similarly, a fourth cable end portion 73C of the second flat cable <NUM> extends from the second lead block <NUM> in a fourth direction D52, and then is bent in a third direction D51. Thus, in a state in which the first lead block <NUM>, the second lead block <NUM>, the first flat cable <NUM>, and the second flat cable <NUM> are assembled, the second flat cable <NUM> overlaps with the first flat cable <NUM>. Furthermore, in a state in which the flat cable assembly <NUM> is assembled, a second protruding direction D53 is opposite a first protruding direction D43. The length of the first flat cable <NUM> is different from the length of the second flat cable <NUM>. In the present embodiment, the length of the first flat cable <NUM> is longer than the length of the second flat cable <NUM>.

The characteristics of the flat cable assembly <NUM> are as follows.

The rotary connector device <NUM> can reduce the manufacturing cost of the flat cable assembly <NUM> for a rotary connector device. Accordingly, the manufacturing cost of the rotary connector device <NUM> can be reduced as well.

Note that the flat cable assembly <NUM>, as with the flat cable assembly <NUM>, can exhibit the effects of (<NUM>) to (<NUM>) described above.

Furthermore, although in the embodiment described above, the first flat cable <NUM> is a flat cable separate from the second flat cable <NUM>, the first flat cable <NUM> and the second flat cable <NUM> may be an integral flat cable. For example, by connecting the third cable end portion 62C and the fourth cable end portion 63C, the first flat cable <NUM> and the second flat cable <NUM> may be configured as an integral flat cable. In such a case, for example, the integral flat cable includes an intermediate portion corresponding to the third cable end portion 62C and the fourth cable end portion 63C, the intermediate portion being connected to the second lead block <NUM>. The same configuration can be applied to the first flat cable <NUM> with respect to the second flat cable <NUM>.

It should be noted that, in the present application, "comprise" and its derivatives are non-limiting terms describing the presence of a component and do not exclude the presence of other components not described. This also applies to "have", "include" and their derivatives.

In the present application, a number such as "first" or "second" is merely a term for identifying a configuration, and does not have any other meaning (e.g., a particular order, or the like). For example, the presence of a "first element" does not imply that a "second element" exists, and the presence of a "second element" does not imply that a "first element" exists.

Expressions such as "parallel", "orthogonal", and "identical" in the present disclosure should not be interpreted strictly and include respectively the meanings of "substantially parallel", "substantially orthogonal", and "substantially identical". Further, representations of other arrangements are not to be strictly interpreted.

Furthermore, the expression "at least one of A and B" in the present disclosure encompasses, for example, all of (<NUM>) only A, (<NUM>) only B, and (<NUM>) both A and B. The expression "at least one of A, B, and C" encompasses, for example, all of (<NUM>) only A, (<NUM>) only B, (<NUM>) only C, (<NUM>) A and B, (<NUM>) B and C, (<NUM>) A and C, and (<NUM>) all of A, B, and C. In the present disclosure, the expression "at least one of A and B" is not interpreted as "at least one of A and at least one of B".

Claim 1:
A flat cable assembly for a rotary connector device, comprising:
a first lead block (<NUM>,<NUM>) including a first lead block body (61A, 71A) and a first conductor (61B, 71B) including a first exposure surface (61C, 71C) exposed from the first lead block body, the first conductor being attached to the first lead block body;
a first flat cable (<NUM>,<NUM>) including a first cable end portion (62A, 72A) connected to the first exposure surface (61C, 71C) so as to extend from the first exposure surface in a first direction (D21, D41); and
a second flat cable (<NUM>, <NUM>) including a second cable end portion (63A,73A) connected to the first exposure surface so as to extend from the first exposure surface in a second direction (D22, D42) that is different from the first direction,
characterized in that the second cable end portion (63A,73A) is disposed on the first exposure surface (61C, 71C) so as not to overlap with the first cable end portion (62A, 72A).