IDC Connector Slit Layout to Prevent Conductor Cutting
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Solution Overview
Problem
Connectors with insulation-displacement connection (IDC) portions often cut conductors when a cable with multiple conductors is pushed into the narrow slit, leading to reliability issues.
Innovation Solution
A connector design featuring two insulation-displacement blades with a narrow and wide slit, where the blades are positioned differently to reduce pressure on the core wire, preventing excessive cutting during cable insertion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a narrow slit is used in the insulation-displacement connection portion, then the connector can accommodate cables with smaller core wires, but conductors forming the core wire may be cut when multiple conductors are pushed into the narrow slit
Solution Approach 1:
The patent applies asymmetry by creating two different slit configurations (narrow and wide) with different blade arrangements. The narrow slit has blades positioned to handle smaller core wires, while the wide slit has blades positioned to accommodate larger core wires with multiple conductors. This asymmetric design allows the same connector to adapt to different cable sizes without cutting conductors.
Solution Approach 2:
The insulation-displacement connection portion is segmented into multiple independent blade elements (first insulation-displacement blade and second insulation-displacement blade) that can be independently positioned. This segmentation allows each blade to be optimally positioned for its specific function, with the first blade corresponding to the narrow slit and the second blade corresponding to the wide slit, preventing conductor cutting in both configurations.
2Manufacturing precision
If two insulation-displacement blades are positioned to define a narrow slit, then the connector can connect to cables with small core wires, but excessive pressure is applied on the core wire causing conductors to be cut
Solution Approach 1:
The patent applies local quality by providing different blade positioning configurations for different regions. The first insulation-displacement blade and second insulation-displacement blade are positioned at specific locations to create either a narrow or wide slit depending on the connection requirement. This localized adaptation ensures precise connection for small core wires while preventing excessive pressure and conductor cutting in the appropriate region.
Solution Approach 2:
Instead of using a single narrow slit configuration that applies excessive pressure, the patent inverts the approach by providing a wide slit configuration with appropriately positioned blades for larger core wires. This inversion allows the connector to reduce pressure on core wires when necessary, preventing conductor cutting while maintaining connection precision.
Data Source
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AI summary
In a first contact of a connector, an insulation-displacement connection portion has two insulation-displacement blades and has a narrow slit and a wide slit. The insulation-displacement blades are different from each other in position in a first direction and correspond to the narrow slit. The insulation-displacement blades are obliquely intersected with the first direction. The narrow slit and the wide slit extend in the front-rear direction. In the first direction, the insulation-displacement blade is located between the narrow slit 362 and the wide slit 364. In a second direction, a middle of the wide slit 364 is different from a middle of the narrow slit 362 in position. When covered wire is pushed into the narrow slit, it is pressed on the insulation-displacement blades at different timings in order.