Insulation Displacement Terminal for Fine Wire Clamping
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Solution Overview
Problem
Conductive terminals of the prior art are not suitable for connecting wires with fine diameters, such as aluminum enameled wires less than 0.45 mm, as they apply excessive force, which can cut or deform the wire, leading to unreliable electrical connections.
Innovation Solution
A conductive terminal design featuring a pair of elastic arms with sub-arms and wire contact parts that pierce the insulation layer, providing a reduced clamping force to prevent wire damage, and a second pair of elastic arms for clamping, reducing internal stress and ensuring a secure electrical connection, made from materials like copper or brass.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conductive terminal of the prior art is used to connect with a fine diameter wire, then the wire can be clamped and electrically connected, but the positive force provided by the elastic arms is too large, which may cut off the wire or cause excessive internal stress and deformation
Solution Approach 1:
The elastic arms are divided into multiple pairs (first pair and second pair), with each pair having sub-arms that can independently contact and clamp the wire. This segmentation distributes the clamping force across multiple contact points, preventing excessive force concentration that would damage fine wires while maintaining reliable electrical connection.
Solution Approach 2:
Different pairs of elastic arms are designed with different functions: the first pair of elastic arms is optimized for electrical contact with wire contact parts, while the second pair provides additional clamping support. This local differentiation allows the terminal to apply appropriate force characteristics to different parts of the wire, ensuring connection reliability without causing damage.
2Reliability
If the clamping force is increased to ensure secure connection, then connection reliability improves, but the wire may be cut or deformed due to excessive force
Solution Approach 1:
The clamping function is segmented across two pairs of elastic arms, where the first pair provides primary electrical contact and the second pair provides additional mechanical support. This segmentation allows the terminal to achieve secure connection through distributed force application rather than concentrated high force, preserving wire integrity.
Solution Approach 2:
The terminal applies clamping force through multiple elastic arms in a controlled, progressive manner rather than applying full force through a single mechanism. This partial action approach ensures adequate connection security while avoiding excessive force that would damage the wire.
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 design effectively connects wires of diameters between 0.20 to 0.45 mm without cutting or deforming them, ensuring reliable electrical connections by distributing force evenly and minimizing stress on the wire.
Implementation Method 1
The first pair of elastic arms and the second pair of elastic arms are arranged directly adjacent to each other in a thickness direction of the terminal
Data Source
AI summary
An insulation displacement terminal adapted to connect to a wire includes a first pair of elastic arms and a second pair of elastic arms. The first pair of elastic arms has a first pair of elastic sub arms arranged opposite to each other in a width direction of the terminal. The first pair of sub arms has a first pair of wire contact parts disposed thereon and are adapted to pierce an insulation layer of the wire such that the first pair of wire contact parts electrically connects to the wire. The second pair of elastic arms is arranged directly adjacent to the first pair of elastic arms in a thickness direction of the terminal. The second pair of elastic arms has a second pair of sub arms arranged opposite to each other in the width direction.