Connector Plug Insert Guiding for Accurate IDC Wire Termination
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Solution Overview
Problem
Existing electrical connector solutions fail to provide reliable contact between insulation displacement contacts (IDC) and cables or wires, and suffer from insufficient positional accuracy.
Innovation Solution
A plug insert with a guiding assembly and wire manager module that positions IDCs accurately within cable receptacles, ensuring reliable contact and assembly by guiding the wire manager module from a pre-assembly to an assembly position, where IDCs extend into the receptacles to cut insulation and establish electrical contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulation displacement contacts (IDC) are used to terminate data lines, then electrical contact is established, but reliable contact between IDC and cable/wire is not achieved
Solution Approach 1:
The guiding assembly pre-positions the wire manager module and IDC components before the actual contact-making process. The guiding slots and guiding posts establish predetermined alignment paths that ensure the IDC contacts are positioned accurately relative to the cable receptacles before the crimping or termination action occurs, thereby achieving both reliable contact and manufacturing precision
Solution Approach 2:
The guiding assembly acts as an intermediary mechanism between the wire manager module and the plug insert body. It mediates their relative positioning through guiding slots and posts, ensuring that the IDC contacts align precisely with the cable receptacles, thus resolving the contradiction between contact reliability and position accuracy
2Ease of operation
If wire manager module is movable during assembly, then assembly flexibility is improved, but positional accuracy of components deteriorates
Solution Approach 1:
The wire manager module is designed to be movable during the assembly process through the guiding assembly, allowing flexible insertion and positioning operations. However, once assembled, the guiding slots and posts constrain the module to maintain precise positional relationships, thus achieving both assembly flexibility and component position accuracy
Data Source
AI summary
A plug insert comprises a plug insert body including at least one contact member accessible from outside the plug insert, at least one insulation displacement contact electrically connected to the contact member, and a guiding assembly. At least one wire manager module includes at least one cable receptacle for receiving and holding a cable or wire. The guiding assembly guides the wire manager module relative to the plug insert body from a pre-assembly position, to an assembly position in which the insulation displacement contact extends into the cable receptacle.