IDC Connector Pin Retention Without Extra Assembly Parts
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Solution Overview
Problem
Existing insulation-displacement contact (IDC) connector systems for automotive applications require additional components like plastic covers or pronged terminal systems for securing header pins, which complicates the assembly process.
Innovation Solution
The IDCC connection system employs IDCC header pins with pin barbs that anchor into a housing, and a compliant retention feature that secures the pins to a printed circuit board (PCB), eliminating the need for additional components during assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional components like plastic covers or pronged terminal systems are used to secure header pins, then the header pins can be retained in the housing, but the assembly process becomes more complex
Solution Approach 1:
The patent combines the header pin retention function directly into the housing structure by integrating pin barbs and compliant retention features into the housing itself, eliminating the need for separate plastic covers or pronged terminal systems. This merging of functions reduces the number of components while maintaining reliable header pin retention.
Solution Approach 2:
The housing is designed with self-retaining features where the pin barbs and compliant retention features automatically secure the header pins during assembly without requiring additional components or complex assembly steps. The housing serves its own retention function, eliminating the need for external securing mechanisms.
2Reliability
If additional components are used to secure header pins, then retention is achieved, but the number of parts increases
Solution Approach 1:
The patent merges the retention function into the housing structure itself through integrated pin barbs and compliant retention features, eliminating the need for separate plastic covers or terminal systems. This reduces the total number of components while maintaining secure header pin retention.
Solution Approach 2:
The patent extracts the retention function from separate components and integrates it directly into the housing, removing the need for additional plastic covers or pronged terminal systems. This extraction and integration approach reduces component quantity while preserving retention reliability.
3Ease of manufacture
If traditional IDC connectors are used, then wire connection is achieved, but insulation stripping is required before connection
Solution Approach 1:
The patent incorporates preliminary action by designing the blade to automatically cut through insulation during the connection process itself, eliminating the need for pre-stripping insulation. The blade's geometry and force application are designed to penetrate and cut insulation as the wire is inserted, performing the insulation removal action at the moment of connection.
Solution Approach 2:
The IDC connector performs its own insulation stripping function through the blade design that automatically cuts through insulation during insertion, without requiring external tools or pre-processing steps. The connector serves the dual function of both connection and insulation removal.
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 solution simplifies the assembly process by securely retaining header pins within the housing and onto the PCB without the need for additional components, enhancing reliability and reducing assembly complexity.
Implementation Method 1
Each IDCC header pin has at least a first pin barb on its pin barb section, to allow it to be retained into the housing. The pin barbs anchor the header pin into the housing.
Implementation Method 2
The lower section of the pins has an associated compliant retention feature which allows the IDCC header pin to be retained into respective holes in the PCB.
Implementation Method 3
A compliant pin is a pin that adheres to a PCB through the application of normal force and interference fit.
Implementation Method 4
An insulation-displacement contact (IDC) is an electrical contact designed to be connected to the conductor(s) of an insulated cable by a connection process that forces a selectively sharpened blade or blades through the insulation, bypassing the need to strip the conductors of insulation before connecting.
Data Source
AI summary
An Insulation Displacement Contact Compliant connector system (IDCC) which includes a housing, header pins, and a Printed Circuit Board (PCB). Each header pin has at least a single barb to be retained into the housing. Each pin has a blade for contacting a wire. A compliant feature on the pin retains itself into holes in the PCB. The housing has a negative space similarly shaped to the pin. The housing includes a strain relief which provides a lead-in for a wire. When the system is fully assembled, the pins reside in the housing, and exit through the housing and into and through respective holes in the PCB. A wire can be inserted into the housing once the pins reside in the housing.