Foldable Electrical Connector with Inclined Fitting Sleeve
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Solution Overview
Problem
Existing electrical connectors require a large force for manual assembly, making in-situ repairs difficult due to the need for perpendicular force application, which is not feasible for simple assembly.
Innovation Solution
The design features two connector portions that can be folded relative to each other, with one having an insulation displacement contact and the other a cable pressing face, and a fitting sleeve with inclined outer and inner faces, converting the fitting movement into a perpendicular cutting motion, reducing the force required for assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If perpendicular force is applied to press the insulation displacement contact onto the cable, then secure electrical contact is achieved, but manual assembly becomes impossible due to the large force required
Solution Approach 1:
The patent changes the direction of force application from perpendicular to the cable axis to oblique relative to the cable axis. The insulation displacement contact is pressed onto the cable at an oblique angle, allowing the assembly force to be applied in a different dimensional direction that requires less magnitude while achieving the same contact security.
Solution Approach 2:
The patent employs a folding mechanism where the connector housing can be folded from an open state to a closed state, dynamically changing the geometry during assembly. This folding action converts a small linear displacement into a larger perpendicular motion that presses the insulation displacement contact onto the cable, reducing the force required from the user.
2Ease of operation
If simple assembly is implemented by reducing the assembly force, then manual assembly becomes possible, but the cutting force on the insulation may be insufficient for reliable contact
Solution Approach 1:
The folding mechanism dynamically amplifies the small linear force applied by the user into a large perpendicular pressing force on the insulation displacement contact. As the housing folds closed, the geometric leverage increases the force magnitude just when it is needed to cut through the insulation, maintaining reliability while enabling manual operation.
Solution Approach 2:
By applying force obliquely rather than perpendicularly, the patent allows the assembly force to have two components: one component presses the contact onto the cable (providing cutting action), while the other component is absorbed by the oblique geometry. This dimensional change allows sufficient cutting force to be generated from a smaller overall applied force.
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 design allows for easy manual assembly of electrical connectors by reducing the force needed, enabling secure and efficient insulation displacement contact creation without additional tools, facilitating in-situ repairs and simplifying the assembly process.
Implementation Method 1
outer faces of the connector portions and/or inner faces of the fitting sleeve being inclined towards each other counter to the fitting direction... the fitting movement is converted at least partially into a cutting movement which is perpendicular thereto
Implementation Method 2
the insulation displacement contact automatically separates the insulation and a contact is produced
Data Source
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AI summary
An arrangement for an electrical connector is disclosed. The arrangement has a first connector portion and a second connector portion which can be folded relative to each other, the first connector portion having an insulation displacement contact and the second connector portion having a cable pressing face facing the insulation displacement contact, and a fitting sleeve having inner faces fitting over the first and second connector portions in a fitting direction, the inner faces extending towards each other counter to the fitting direction.