Grooved Wiring Connector for Narrow-Terminal Pressure Contact
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Solution Overview
Problem
Existing methods for connecting wirings to substrates, such as soldering, are difficult to perform and require precise soldering work, especially when the interval between terminals is narrow, and can result in poor electrical connections due to twisting of wires and challenges in passing wires through small diameter holes.
Innovation Solution
A wiring device with a plate, first protrusion, holder, and cover that accommodates wiring coatings and conductors, allowing for easy insertion and pressure contact with terminals, reducing twisting and short circuits, and providing uniform force for strong connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldering is used to connect wiring to substrate terminals, then electrical connection can be achieved, but the process becomes difficult and time-consuming especially when terminal intervals are narrow
Solution Approach 1:
The patent replaces the thermal soldering process with a mechanical pressing system. The pressing device applies direct mechanical force to crimp the wiring onto the terminal, eliminating the need for soldering irons, flux, and heating processes. This mechanical substitution makes the operation much easier and faster while maintaining reliable electrical connection.
Solution Approach 2:
The pressing device is designed to be self-aligning and self-positioning. The pressing member automatically positions itself over the terminal and wiring intersection, and the pressing action itself creates the connection without requiring precise manual alignment or additional fixing steps. The structure enables the operation to complete itself with minimal operator intervention.
2Volume of moving object
If narrow terminal intervals are used to reduce device size, then compactness is improved, but wiring insertion and connection become more difficult
Solution Approach 1:
The pressing device is segmented into multiple independent pressing members, each capable of independently pressing individual terminals. This segmentation allows each pressing action to be localized and precise, making it easier to handle narrow terminal intervals without interference from adjacent operations. The modular structure adapts to compact layouts while maintaining operational ease.
Solution Approach 2:
The pressing device operates in a vertical dimension (pressing direction) rather than requiring horizontal manipulation. By approaching terminals from above and pressing downward, the device bypasses the constraints of narrow horizontal spacing between terminals. This dimensional change allows easy operation even when terminal intervals are reduced for compactness.
3Reliability
If manual soldering is performed, then connection can be made, but wire twisting and short circuits may occur reducing connection quality
Solution Approach 1:
The patent replaces manual soldering with a controlled mechanical pressing operation. The pressing member applies uniform, controlled force that crimps the wiring onto the terminal without the thermal distortion and manual manipulation that cause wire twisting. This mechanical process inherently prevents short circuits by maintaining precise positioning throughout the connection process.
Solution Approach 2:
The device is designed to pre-position the wiring and terminal in the correct alignment before the pressing action occurs. The pressing member approach path and positioning structure ensure that the wiring is already properly oriented and spaced, preventing twisting during the connection process. This preliminary positioning guarantees connection precision before the actual crimping force is applied.
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 device facilitates easy and reliable electrical connections between conductors and terminals, maintaining high workability and reducing connection variations, even when multiple wires are involved, with the use of materials like metal and insulating members to minimize thermal expansion and deterioration.
Implementation Method 1
a first upper surface including a plurality of first grooves provided parallel to a first direction, each of the first grooves capable of accommodating a coating of a wiring including a conductor and the coating provided around the conductor
Implementation Method 2
a second protrusion capable of bringing the conductor into pressure contact with the terminal between the first protrusion and the holder
Data Source
AI summary
A wiring device has a plate having a first surface and a second surface and a first protrusion having a side surface capable of locking a first substrate and a first upper surface with a plurality of first grooves and the first substrate including a terminal on a surface of the first substrate. Each of the first grooves accommodates a coating of a wiring including a conductor and the coating, the first protrusion extending in a third direction. The holder includes a plurality of connection portions, and the holder includes a plurality of second grooves, each of the second grooves capable of accommodating the conductor exposed from the coating. The cover is rotatably openable and closable with respect to the plate, and the cover brings the conductor into pressure contact with the terminal between the first protrusion and the holder.