Line/Current Collector Details TRIZ Cases

Using separate strap and head strips cuts material waste, enables full edge finishing, and supports a flush laser-welded termination band.

A spiral-wound belt clamps cables, wires, or ropes between layers to keep kits sorted and speed retrieval during assembly.

Sheared and deformed strand ends form bonded wire tips in a crimp terminal, cutting electrical resistance without solder or added process steps.

A segmented insertion hole lets terminal legs pass without folding and keeps the insert member stable during wave soldering.

A non-contact terminal portion blocks welding heat from the insulating layer, preserving insulation and withstand voltage in compact semiconductor modules.

Opposed pin bends shift RX and TX vias apart on the PCB, cutting crosstalk and impedance discontinuities in dense high-speed links.

Separating each contact into two parallel spring pieces lowers connector impedance without tightening pitch or sacrificing contact elasticity.

Carbon fiber and titanium inserts cut hydraulic tool head weight while preserving the strength needed for crimping, cutting, and pressing.

A surface-mounted laser weld joins pin-shaped contacts to PCB conductive paths, avoiding flux and drilled holes while reducing thermal stress.

A protruding shield element blocks solder wicking onto the cable, protecting vehicle glazing connectors from handling stress and breakage.

Transverse clamping after each feed keeps carrier-strip contacts aligned, improving crimping precision while limiting material stress.

A pneumatic piston holder closes crimping tool legs automatically, cutting hand and wrist strain while supporting high-output wire work.

Dielectric-guided 0°-to-90° center-conductor routing cuts insertion and return loss in compact PCB-to-cable connectors up to 65 GHz.

Built-in protection elements inside the connector housing prevent ESD, EOS, and EMI while freeing PCB mounting space in compact electronics.

A thickened front end wall stabilizes RJ45 wire alignment during crimping, enabling simultaneous shearing and reducing manual trimming.

Direct wire insertion and laser welding replace plating in high-aspect-ratio holes, simplifying interlayer connections and improving reliability.

Preformed solder is pressed into connector pin cavities to avoid repeated melting, reduce voids, and speed high-density wire assembly.

A gold-coated pigtail spring connector joins IMD feedthrough wires to PCBs without soldering, easing assembly while preserving connection reliability.

Tensioning the exposed shielding foil before radial blade cutting enables uniform removal from shielded cables without scraps or cable damage.

Cross-linked conductive elastomer fillers in through holes prevent conductive-layer cracking and peeling under repeated electrical test loading.

A cone-guided compression path and camera-monitored robotics automate high-voltage cable lug crimping to improve speed and reduce defects.

Straight insertion from opposite sides creates stable angled electrical contacts, simplifying housing element production and reducing defects.

An interposer with an integrated transition and waveguide couples millimeter-wave IC outputs to standard PCB layouts while shrinking package size.

Different cap materials match board thermal expansion during reflow, reducing mezzanine connector misalignment and preserving accurate connections.

External heating melts low-melting joining material to splice mineral-insulated cables quickly while preserving hermetic sealing and strength.

Integrated boss-and-recess features self-align busbars, preventing relative motion while improving contact quality and assembly precision.

Variable insulation radii between connector contacts reduce creeping currents and signal distortion while keeping sensor connections compact and replaceable.

Heat-resistant seal members let a camera-module connector survive reflow soldering while maintaining waterproofing and reducing relay-connector space.

Varying insulation distances and insulating carrier features cut creeping currents, protect analog sensor signals, and prevent wrong sensor pairing.

A die-and-punch press forms a recess-projection interlock that securely fixes minute metal wires or plates with high strength.

An edge-opening bearing lug lets the pivot pin be inserted with fewer parts and steps while keeping the hand pliers joint secure and stable.

Magnetically fixed interchangeable crimping modules let one plier handle multiple wire sizes while preserving crimping precision and portability.

A combined ball and needle bearing layout absorbs axial and radial forces to improve crimping precision, repeatability, and compactness.

Direct insertion and soldering of shield and conductor portions cuts extra parts, shortens the link, and reduces transmission loss.

Two PCB assemblies with pin carriers replace bulky pin headers to align OBD connector pins, cut stress, and simplify assembly.

A delayed crimping signal opens an air valve after crimping, giving time to remove the wire before the next contact feeds.

Snap-fit wire manager and load bar keep twisted pairs aligned and twisted, cutting crosstalk while simplifying field termination.

Movable wire guides close the gap between guide sections, simplifying wire alignment and reducing orienting mechanism complexity.

A friction-welded contact part and sealing plug keep coolant inside a tubular power line, enabling lighter cables and higher charging current.

An integrated holder secures a sleeve on a clamped cable, simplifying assembly and keeping the component fixed during processing.

A two-piece strap and head assembly cuts material waste and enables edge finishing before laser welding for a flush, strong termination band.

Ten planar crimp surfaces distribute radial force evenly to secure composite cores while limiting surface damage and ovalization.

A compensating device and force storage means hold crimping connections securely during transport, then enable proper crimping across varying diameters.

An opening in the meander exposes the welding tab for laser access while the spring-like connector shape resists assembly stress with minimal deformation.

Pre-shaping one wire with a reentrance improves positioning and current uniformity when welding dissimilar wire cross-sections.

Complementary alignment and height-determination elements lock a cable rack at preset heights for accurate, reliable cable feeding.

A bifurcated handle and gear ring mechanism adapts to terminal sizes while reducing crimping stroke, effort, and tool complexity.

A trapped stop part and pivot bolt simplify pliers assembly, improve disassembly resistance, and support automated production.

Vertical insertion of pawl, spring, and pulling bar protrusions into lever plates simplifies pliers assembly and supports partial automation.