Insulation Displacement Connector for Fine Wire
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Solution Overview
Problem
Existing methods for connecting thin and fragile coil wires, such as those below 35 AWG, are inadequate due to the limitations of soldering, which is hazardous, unreliable, and faces regulatory bans, while alternative methods like wire wrapping are insufficient for fine wires due to breakage concerns.
Innovation Solution
A system and method involving wire wrapping around rectangular sectioned pins with sharp edges to penetrate insulation, using gentle skiving to remove insulation and create multiple points of contact, and employing bobbin structures to anchor and secure the wire wraps, allowing for robust connections without soldering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldering is used to connect thin and fragile coil wires below 35 AWG, then reliable electrical connections can be achieved, but hazardous materials are used, regulatory compliance becomes difficult, and the process is unsafe and inconsistent
Solution Approach 1:
The patent replaces the thermal/chemical soldering process with a purely mechanical connection system. The connector uses a resilient body with a contact member that mechanically engages the coil wire through insulation displacement and metal contact, eliminating the need for solder, flux, and heating equipment. This mechanical substitution resolves the harmful factors associated with soldering while maintaining connection reliability.
Solution Approach 2:
The invention extracts and removes the harmful soldering process from the connection system. By designing a connector that achieves reliable electrical connection through mechanical means alone - using the resilient body to apply controlled force for insulation displacement and metal-to-metal contact - the patent eliminates hazardous materials and unsafe processes while preserving the essential function of electrical connection.
2Ease of manufacture
If traditional wire wrapping methods are used to connect thin and fragile coil wires, then solder-free connections are achieved, but the wire is distorted, notched, squeezed and scraped causing breakage
Solution Approach 1:
The patent changes the force parameter applied to the wire by using a resilient body that provides controlled, limited force during insulation displacement. Unlike traditional wire wrapping that applies excessive force causing distortion and breakage, this resilient mechanism applies just enough force to penetrate the insulation and establish metal contact while preserving wire integrity. The force parameter is optimized to balance connection establishment with wire protection.
Solution Approach 2:
The resilient body acts as a cushioning element that absorbs and limits the force applied to the wire during the connection process. This beforehand cushioning prevents excessive force from reaching the fragile wire, avoiding distortion, notching, and breakage while still enabling sufficient force for insulation displacement and reliable electrical contact.
3Reliability
If high forces are applied to break through insulation and make connections, then electrical contact is established, but fragile wires breakage occurs rendering them useless
Solution Approach 1:
The patent optimizes the force parameter by using a resilient body that provides controlled, limited force. The resilient mechanism ensures the force is sufficient to penetrate insulation and establish reliable metal-to-metal contact while remaining below the threshold that causes wire breakage. This parameter optimization resolves the contradiction between contact quality and wire strength.
Solution Approach 2:
The resilient body serves as an intermediary between the connector and the wire, mediating the force transmission. It translates the connector's closing force into controlled insulation displacement and contact pressure without transmitting excessive force to the wire. This intermediary function enables reliable electrical contact while protecting wire integrity.
Data Source
AI summary
An apparatus and method are disclosed that may include a contact pin; and a plurality of loops of conductive wire, coated with insulation material, disposed in proximity to the contact pin, wherein along at least one portion of the conductive wire, at least one edge of the contact pin extends through the insulation material and thereby forms conductive electrical contact with the conductive wire.