Bare Blade Insulation Displacement Connector for Flexible PCB Wiring
Solution Overview
Problem
Conventional insulation displacement connectors (IDCs) occupy valuable space on circuit boards and limit wire connection options due to their shape and configuration, particularly in applications where smaller components and more flexible wire orientations are needed.
Innovation Solution
A space-efficient IDC design featuring bare, single-wire contact elements with opposed blades and a cap structure that allows for minimal board space usage and flexible wire orientation, enabling connections at various angles and orientations using a cap that secures the wire between the blades for piercing and contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If conventional IDC housing members are used, then wire connections are secured and protected, but valuable board space is wasted and placement flexibility is limited
Solution Approach 1:
The patent removes the traditional housing member from the IDC design, extracting only the essential contact element functionality. The bare contact element with opposed blades performs the wire piercing and electrical connection without requiring a protective housing, thereby minimizing board space occupation while maintaining connection security through the blade structure itself
Solution Approach 2:
The contact element is segmented into opposed blades that can independently pierce and contact the wire core. This segmentation allows the contact element to function without a housing while the blades provide both the piercing action and the securing mechanism through their opposing structure
2Adaptability or versatility
If conventional IDC shapes and configurations are used, then structural stability is maintained, but wire connection orientation flexibility is limited
Solution Approach 1:
The patent introduces a cap member that can be positioned at various angles relative to the contact element, allowing the wire connection orientation to be dynamically adjusted. The cap provides structural stability while enabling flexible orientation of the wire insertion direction, accommodating different routing requirements without compromising connector integrity
3Area of stationary object
If multiple wire connections are made on a single contact pad, then space efficiency is improved, but wire orientation options are increased
Solution Approach 1:
The contact element with opposed blades and associated cap is designed to accommodate multiple wires in different orientations on a single contact pad. The universal design allows the same basic structure to handle various wire configurations, making the connector adaptable to multiple connection scenarios while maintaining space efficiency
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 solution allows for multiple wire connections at different orientations on a single contact pad, optimizing space usage and enhancing flexibility in PCB layouts without the need for additional housing, thus accommodating smaller components and increasing connection density.
Implementation Method 1
one or more contact elements incorporating a set of blades or jaws that cut through the insulation around the wire and make electrical contact with the conductive core
Data Source
AI summary
An electrical insulation displacement connector includes a bare single-wire contact element having a first end defined by opposed blades that define a receipt aperture for an insulated wire, and a second end configured for direct electrical contact at a contact position on a printed circuit board. Retaining structure is defined on the blades. A cap is configured for fitting over the exposed bare blades. The cap includes side walls and end walls with a slot defined in each of he end walls that align with the blade aperture. The side walls are engaged by the retaining structure upon pressing the cap onto the blades. The slots in the end walls of the cap have a width and height such that upon fully pressing the cap onto the blades, the slots engage and longitudinally align the insulated wire into the blade aperture so that the blades pierce and make electrical contact with a core in the insulated wire.