Insulation Displacement Contact Device With Spring-Biased Segmented Blades
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional insulation displacement contact (IDC) devices face challenges in terminating larger wires and wires with multiple strands, as they often struggle with varying conductor sizes due to material properties and flexibility limitations, leading to unreliable connections and difficulty in repeated repairs.
Innovation Solution
The IDC device features two physically separated blade elements biased by a spring mechanism, allowing for adjustable contact deflection and translational movement within a single plane, enabling connection of a wider range of cable sizes and facilitating repeated repairs through enhanced flexibility and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single thin metal plate is used for IDC contact, then manufacturing simplicity is maintained, but flexibility and adaptability to different conductor sizes are limited
Solution Approach 1:
The single metal plate is divided into two separate blade elements that can move independently relative to each other. This segmentation allows each blade to adapt to different conductor sizes while maintaining manufacturing simplicity through modular construction
Solution Approach 2:
The blade elements are made movable relative to each other through spring means, transforming the static single-plate structure into a dynamic system that can adjust to various conductor diameters and strand configurations
2Adaptability or versatility
If blade elements are made movable relative to each other, then contact deflection range is increased, but device complexity increases
Solution Approach 1:
Spring means are incorporated to enable movable blade elements with adjustable contact deflection. The spring mechanism provides the necessary elasticity and movement capability while maintaining a relatively simple overall device structure
Solution Approach 2:
The spring means allow adjustment of contact deflection parameters, enabling the blade elements to move optimally for different conductor sizes and types without requiring complex mechanical structures
3Ease of manufacture
If conventional IDC design is used, then manufacturing costs remain economical, but repeated repairs are difficult
Solution Approach 1:
The movable blade elements with spring means can be repeatedly positioned and repositioned, allowing for repeated insertion and removal of conductors without compromising connection quality, thus enabling repeated repairs
Solution Approach 2:
The separation into movable blade elements allows independent adjustment and repair of individual blades, facilitating easier maintenance and repeated repairs while keeping manufacturing costs economical
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 reliable connection of larger and multi-strand wires by providing a high contact deflection range and improved durability, reducing material property limitations and enabling repeated repairs, while maintaining economical manufacturing costs.
Implementation Method 1
two physically separated blade elements which are biased against each other by the spring means
Implementation Method 2
The spring force and the range allowing the blade elements to move relative to each other can be freely adjusted
Data Source
Figure 1a~2b
Figure 2c~2e
Figure 3a~3c
AI summary
The present invention relates to an insulation displacement contact device (IDC) having a contact slot provided with an insertion opening and wishes to provide such IDC having an improved capability of contacting conductors with a wider range of conductor diameter and/or number of strands forming the conductor. As a solution to the above problem, the contact slot (40) of the IDC device of the present invention is defined between blade surfaces (12; 22) of a first blade element (10) and a second blade element (20), wherein said first and second blade elements (10; 20) are physically separated from each other, movable relative to each other and biased against each other by spring means (30).