Capped Insulation Displacement Connector for Vibration Resistance
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Solution Overview
Problem
Existing insulation displacement connectors (IDCs) are complex and not well-suited for stressful environments due to the need for movable parts and are prone to wire dislodgment under shock and vibrations, particularly in surface mounting technology (SMT) applications.
Innovation Solution
A capped insulation displacement connector assembly with fixed contact elements and a cap that serves as a tool for inserting wires, providing a secure channel with retaining structures to prevent wire dislodgment, and a locking mechanism to prevent cap removal, suitable for use with printed circuit boards (PCBs).
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If IDCs use movable parts for SMT mounting, then adaptability to surface mounting technology is improved, but device complexity increases and reliability deteriorates under shock and vibrations
Solution Approach 1:
Instead of making the contact elements movable relative to the housing, the patent inverts the approach by making the housing movable relative to the fixed contact elements. The housing slides along the contact elements during insertion, achieving SMT mounting capability while keeping the contacts stationary and simple.
Solution Approach 2:
The connector is divided into separate components: a stationary contact element and a movable housing. This segmentation allows the housing to perform the movement function while the contact element remains simple and fixed, resolving the contradiction between adaptability and complexity.
2Ease of operation
If IDCs use movable parts for connection, then ease of operation is improved, but reliability deteriorates in high-vibration environments
Solution Approach 1:
The patent reverses the traditional movable contact design by making the housing movable instead. The housing slides along fixed contact elements during wire insertion, maintaining ease of operation while eliminating the reliability issues associated with movable contacts in vibrating environments.
Solution Approach 2:
The housing is pre-configured with guiding features that align and constrain the movement path along the fixed contact elements. This preliminary arrangement ensures smooth operation during insertion while maintaining stable, fixed contact points that resist vibration and shock.
3Adaptability or versatility
If IDCs are designed for SMT applications, then adaptability to modern manufacturing is improved, but device complexity increases
Solution Approach 1:
Rather than making contact elements slide within a fixed housing, the patent inverts the design so the housing slides along fixed contact elements. This inversion achieves SMT application suitability through the movable housing while keeping the contact elements simple and stationary.
Solution Approach 2:
The movable housing serves multiple functions: it guides wire insertion, provides the sliding motion for SMT mounting, and houses the insulation displacement mechanism. This multi-functionality achieves adaptability to SMT applications without requiring separate complex mechanisms for each function.
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 enhances the reliability of IDCs by securely fixing wires in high-vibration environments and simplifies the connection process, ensuring stable electrical contacts and easy integration with pick-and-place manufacturing processes.
Implementation Method 1
blades or jaws that cut through the insulation around the wire and make electrical contact with the conductive core
Implementation Method 2
engaging locking structure operably configured between the cap and body that engages in the fitted configuration of the cap on the body to prevent inadvertent removal of the cap from the body
Implementation Method 3
retaining structure that prevents wire dislodgment
Data Source
AI summary
An electrical insulation displacement connector (IDC) assembly includes a body having at least one channel with an open top side for receipt of an insulated conductive core wire. A contact element is fixed in the body with a first insulation displacement end defined by opposed blades oriented across the channel, and a second end extending from a bottom surface of the body for electrical contact with a PCB. The IDC assembly includes a cap having a size and configuration to engage over the body, with the cap including a recess with an open bottom that is aligned with the body channel in a fitted configuration of the cap on the body. The wires may be initially received in the cap recesses wherein upon pressing engagement of the cap onto the body, the insulated conductive core wire is pressed into the body channel between the contact element.