IDC Splice Connector with Hinging Members for Compact Assembly
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Solution Overview
Problem
Existing electric connectors, particularly insulation displacement connectors (IDC), are complex and labor-intensive to assemble, especially when connecting multiple wires, and miniature versions are fragile and prone to breakage.
Innovation Solution
A compact IDC connector with hinging members and bifurcated terminals that snap closed to establish electrical contact with wires, allowing for easy assembly without specialized tools and providing a robust connection for miniature applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional IDC splice connectors are used to connect multiple conductors, then electrical connection is achieved, but the termination procedure becomes complex and labor intensive requiring multiple separate assemblies
Solution Approach 1:
The patent combines multiple separate IDC connector assemblies into a single integrated connector body that can simultaneously connect multiple pairs of conductors. The connector includes a housing with multiple contact elements arranged to receive and connect corresponding conductors from first and second cables in one operation, eliminating the need for multiple separate assemblies and reducing termination complexity.
Solution Approach 2:
The connector is designed as a universal multi-functional device that can connect multiple pairs of conductors simultaneously through a single assembly operation. The housing contains multiple contact elements that can terminate different wire pairs in one connector, making the device versatile for various wiring configurations without requiring different separate connectors for each pair.
2Volume of moving object
If miniature IDC connectors are used in lighting products, then space is reduced, but the connectors become fragile and break easily
Solution Approach 1:
The connector incorporates flexible contact elements that can bend and deform elastically to accommodate slight misalignments and stress during installation and use. This dynamic flexibility allows the miniature connector to absorb mechanical stress without breaking, enhancing durability while maintaining a compact size suitable for lighting applications.
Solution Approach 2:
The connector housing is made from a composite material combining rigid structural support with flexible contact elements. This composite construction provides both the strength needed to prevent breakage in miniature applications and the flexibility required for reliable electrical contact, resolving the contradiction between small size and durability.
3Manufacturing precision
If separate termination is performed for each pair of corresponding wires, then precise electrical connection is achieved, but the process becomes time consuming and labor intensive
Solution Approach 1:
The connector merges multiple termination functions into a single integrated structure where multiple contact elements are simultaneously positioned to connect corresponding conductors. This allows precise electrical connections for multiple wire pairs to be achieved in one insertion and termination operation, dramatically increasing productivity while maintaining connection precision through the structured arrangement of contact elements.
Solution Approach 2:
The contact elements are pre-positioned and pre-aligned within the housing during manufacturing, so that when cables are inserted, the connections are automatically precisely aligned. This preliminary preparation of the connector structure eliminates the need for manual alignment during installation, maintaining manufacturing precision while reducing termination time and labor requirements.
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 solution simplifies the connection process, enhances the durability of miniature connectors, and enables efficient termination of multiple wires in a single assembly step, making it suitable for use in miniature lighting systems without requiring extensive tooling.
Implementation Method 1
Each bifurcated end pierces the insulative layer of a respective wire and establishes electrical contact with the respective wire
Implementation Method 2
A main body includes first and second hinging members. A positive terminal and a negative terminal electrically connect pairs of wires of corresponding conductors by insulation displacement method when the first and second hinging members are snapped closed
Data Source
AI summary
A connector electrically connects corresponding conductors of at least first and second cables. The connector comprises a connecting portion into which the conductors of the first and second cables are inserted opposing one another to electrically connect corresponding conductors of each cable. A positive terminal and a negative terminal terminate and electrically connect corresponding conductors of each cable.