Insulation Displacement Terminal for Enameled Wire Miniaturization
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Solution Overview
Problem
Current insulation displacement connection systems for enameled wires are too bulky, fail to meet miniaturization requirements, and often reduce the current flow cross-section or are not suitable for capillary wires, while also being prone to shear stress and requiring precise dimensional tolerances.
Innovation Solution
A compact IDC system with a single tab and spirally wound enameled wire on a polymer pin, where the tab elastically interacts with the wire to remove the enamel without cutting it, ensuring a reliable 'gas-tight' electrical connection and accommodating a wide range of wire diameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional IDC systems use terminal fins that enter over the wire in a special seat, then electrical connection is achieved, but the system becomes too bulky and requires precise dimensional tolerances
Solution Approach 1:
The terminal is segmented into a body and a separate tab element. The tab is the active connection element that protrudes into the pocket to contact the wire, while the body provides structural support. This segmentation allows the connection function to be achieved with minimal material, reducing overall system volume while maintaining connection reliability.
Solution Approach 2:
The active connection function is extracted from the entire terminal structure and concentrated in the tab element only. The tab is the sole component that interacts with the wire, removing unnecessary material and reducing system bulk while preserving the essential electrical connection function.
2Reliability
If terminal fins are used to cover the enameled wire during insertion, then electrical connection is achieved, but the wire diameter is reduced and current flow cross-section is compromised
Solution Approach 1:
The tab's elastic deformation, which could be considered harmful force, is converted into a beneficial abrasive action. The tab is designed to elastically deform and scrape against the wire insulation during insertion, removing the enamel coating to expose the conductor. This converts the potentially damaging insertion force into a useful insulation removal mechanism that enables reliable electrical connection without compromising wire diameter.
3Volume of moving object
If the system is designed for miniaturization with small pocket sizes, then compactness is achieved, but the range of applicable wire diameters is limited
Solution Approach 1:
The tab is designed as an elastic, deformable element rather than a rigid structure. During wire insertion, the tab dynamically adapts its shape and contact pressure to match the wire diameter. This elastic deformation capability allows the same compact tab design to accommodate various wire sizes within the pocket, maintaining both miniaturization and adaptability.
Solution Approach 2:
The tab's physical parameters (shape, contact area, deformation amount) change dynamically during the connection process based on the wire diameter. This parameter adaptation enables a single compact tab design to effectively connect wires of different diameters without requiring multiple specialized terminals, thus maintaining versatility within the miniaturized system.
4Reliability
If the tab elastically intercepts the wire to remove enamel, then insulation removal is achieved without cutting, but manufacturing precision requirements increase
Solution Approach 1:
The tab is designed to perform multiple functions through its elastic deformation: it intercepts the wire, removes the insulation coating through abrasive action, and establishes electrical contact. This self-service capability consolidates multiple precise operations into a single elastic element, reducing the need for separate precisely-manufactured components while maintaining high insulation removal quality.
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 system provides a reliable, compact, and efficient electrical connection that maintains current flow without reducing wire diameter, suitable for miniaturized applications and resistant to thermal and vibrational stress, while avoiding the limitations of prior art systems.
Implementation Method 1
the tab elastically intercepts the wire to remove the enamel without cutting it
Implementation Method 2
the tab elastically intercepts the wire to remove the enamel
Data Source
AI summary
An insulation displacement connection system having a connection terminal, a pocket for accommodating the connection terminal, and an enameled wire spirally wound around a pin is provided. The pocket is frontally delimited by the pin, at the back by a rear wall and laterally by a pair of side guide walls suitable for guiding the connection terminal during an insertion of the connection terminal into the pocket. The connection terminal is provided with a single tab shaped to elastically intercept the pin so as to exert an abrasive action on the enameled wire during the insertion of the connection terminal into the pocket and to elastically bias the enameled wire to abut against the pin upon the insertion of the connection terminal into the pocket, ensuring an electrical connection between the single tab and the enameled wire.