Elastic Tab Insulation Displacement Connector for Fine Wires
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Solution Overview
Problem
Current insulation displacement connection systems are limited in their ability to connect fine 'capillary' wires due to the rigidity of terminal tabs and the need to avoid cutting the wire, which restricts their use and leads to issues with welding, such as wire fragility and temperature control.
Innovation Solution
A terminal with elastic inner tabs and a central pin that abrades the enamel insulation without cutting the wire, allowing for a secure and reliable electrical connection by using the tabs' elasticity to maintain contact and the central pin's shape to support the wire, enabling connection without the need for welding or crimping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If rigid tabs are used in insulation displacement connectors, then the connector can securely grip the wire, but the wire may be cut due to excessive force on fine capillary wires
Solution Approach 1:
The patent changes the mechanical parameter of the tabs from rigid to elastic, allowing them to deform and apply controlled pressure. This enables the tabs to grip the wire securely while accommodating fine capillary wires without exerting excessive force that would cause cutting. The elastic property allows the tabs to adapt their pressure based on wire diameter.
Solution Approach 2:
The tabs are designed to be elastic rather than rigid, allowing them to dynamically adjust their position and applied force during insertion and operation. This dynamic behavior enables the tabs to flex around the wire, maintain secure contact, and prevent wire cutting by distributing pressure evenly.
2Reliability
If welding is used to connect fine capillary wires, then reliable electrical connection can be achieved, but the wire becomes more fragile due to annealing
Solution Approach 1:
The patent replaces the thermal welding process with a mechanical insulation displacement connection system. Instead of heating and melting the wire to create a connection, elastic tabs mechanically pierce the insulation and establish electrical contact with the wire. This substitution eliminates the annealing effect that weakens the wire while maintaining reliable electrical connection.
3Stability of the object's composition
If the terminal tabs are made rigid to maintain position during insertion, then insertion stability is improved, but the system cannot accommodate wires of varying diameters
Solution Approach 1:
The tabs are designed with elastic properties, changing their mechanical parameter from rigid to flexible. This allows them to maintain structural stability during insertion while adapting to different wire diameters. The elastic tabs can deform to accommodate varying wire sizes and then maintain stable contact pressure.
Solution Approach 2:
The elastic tabs provide dynamic adaptability during insertion, allowing the system to accommodate wires of varying diameters. The tabs flex during insertion to match the wire size, then maintain stable positioning through their elastic recovery, providing both insertion stability and versatility.
4Strength
If the wire is wound on itself to prevent breakage during welding, then wire strength is maintained, but the connection complexity increases
Solution Approach 1:
The patent replaces the welding process (which requires wire winding to prevent breakage) with a mechanical insulation displacement connection using elastic tabs. This substitution eliminates the need for wire winding entirely, as the elastic tabs directly connect to the wire without requiring it to be bent or wound, thereby reducing connection complexity while maintaining wire strength.
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
This solution allows for a reliable, vibration-resistant, and thermally stable electrical connection for fine wires, overcoming the limitations of existing systems by ensuring a consistent contact area and preventing wire breakage, while accommodating wires of varying diameters.
Implementation Method 1
a central pin that abrades the enamel insulation without cutting the wire
Implementation Method 2
A terminal with elastic inner tabs and a central pin that abrades the enamel insulation
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
A mechanical insulation displacement connection system (4) which creates an electrical connection between an enamel insulated wire (100) and a terminal (10) inserted in a special seat or pocket (81). The enamel insulated wire (100) is wound at the beginning and end of the winding onto a central pin (85) in the seat (81). The terminal (10) is provided with two, sufficiently- flexible inner tabs (14, 54) which, during insertion of the terminal (10) in the seat (81), slide over the enamel insulated wire (100) removing the enamel and permitting electrical contact with the copper wire. Said tabs (14, 54) once in position, press the wire (100) against the central pin (85) to ensure constant electrical contact over time.