Insulation Displacement Connector Wedge Stripping Mechanism
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Solution Overview
Problem
Existing insulation displacement connectors (IDCs) require manual stripping of insulation from electrical conductors and often involve complex mechanisms like piercing or rotating wheels, which can be cumbersome and inefficient, especially when dealing with multi-conductor cables like NM-B or Romex®, which have a bare ground wire and insulated conductors encased in an outer jacket.
Innovation Solution
A stripping and contact device featuring a body with a lid and metallic contact plates, along with insulating wedges that cut through the outer jacket of an insulated cable, separate and expose the conductors, and push excess insulation into a reservoir, creating a gas-tight connection without manual stripping, using angled surfaces to efficiently strip and support the contact plates for a secure connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual stripping of insulation is used, then the connector can be operated with simple mechanisms, but the operation time and labor intensity increase significantly
Solution Approach 1:
The insulating wedge is designed to automatically perform multiple functions during the closing action: cutting the outer jacket, separating conductors, stripping insulation, and pushing excess insulation into the reservoir. The wedge's angled surfaces and geometry enable it to self-effectuate these stripping actions without requiring separate manual operations or additional complex mechanisms.
Solution Approach 2:
The insulating wedge serves multiple functions simultaneously: it acts as a cutting tool for the outer jacket, a separator for conductors, a stripping element for insulation removal, and a pusher for excess insulation. This multi-functional design eliminates the need for separate tools or mechanisms for each operation, thereby increasing productivity without proportionally increasing device complexity.
2Ease of operation
If piercing or rotating wheel mechanisms are used, then insulation displacement can be achieved, but the device becomes more complex and harder to operate
Solution Approach 1:
The invention extracts the complex piercing or rotating wheel mechanisms from the connector design and replaces them with a simple insulating wedge that achieves insulation displacement through a straightforward cutting and pushing action. This extraction simplifies the overall device structure while maintaining the essential function of insulation displacement.
Solution Approach 2:
Instead of using active mechanisms like rotating wheels to pierce and displace insulation, the invention uses a passive insulating wedge that relies on the closing force to automatically cut and push insulation. The approach inverts the traditional active mechanism concept into a passive, force-driven system that is easier to operate and simpler in structure.
3Reliability
If the lid closes to contact the conductors, then electrical connection is established, but the contact plates must be precisely positioned to avoid insulation interference
Solution Approach 1:
The insulating wedge performs preliminary actions by cutting the outer jacket, separating conductors, and stripping insulation before the contact plates make electrical contact. By preparing the conductors in advance and removing insulation barriers beforehand, the contact plates can reliably contact the conductors without requiring complex positioning mechanisms to navigate through insulation.
Solution Approach 2:
The insulating wedge acts as an intermediary element that facilitates the connection process. It prepares the conductors by removing insulation and positioning them appropriately, thereby enabling the contact plates to make reliable electrical contact without requiring precise positioning of the contact plates themselves through complex mechanisms.
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
Enables quick and efficient termination of insulated electrical cables by automatically stripping the insulation and creating a gas-tight seal, allowing for easy connection and disconnection of cables without manual intervention, meeting electrical safety standards and simplifying the process for users.
Implementation Method 1
A stripping and contact device featuring a body with a lid and metallic contact plates, along with insulating wedges that cut through the outer jacket of an insulated cable
Implementation Method 2
push excess insulation into a reservoir, creating a gas-tight connection
Implementation Method 3
creating a gas-tight connection without manual stripping
Data Source
AI summary
A stripping and contact device for an insulation displacement connector is provided. The device has a body which has a cavity therein sized to receive an unstripped end of insulated electrical cable. A lid is pivotally connected to a body and moves around an axis of rotation between and open position and a closed position. Plural metallic contact plates, including a hot contact plate, a neutral contact plate, and at least one ground contact plate, are spaced apart and attached to the lid. When the lid is in open position the contact plates do not extend within said cavity and when the lid in a closed position the contact plates do extend within said cavity. A pair of insulating wedges is provided. A first wedge is juxtaposed between said hot contact plate and a ground contact plate. A second wedge is juxtaposed between a ground contact plate and a neutral contact plate. Angled surfaces on the wedges perform multiple functions during a closing operation of the device.