Insulation Displacement Crimp Connector for Simultaneous Wire Tapping
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Solution Overview
Problem
Existing electrical connectors require laborious and time-consuming multiple individual taps for midway connections in multiple wire runs, limiting efficiency in installations like lighting or control wiring.
Innovation Solution
A connector assembly with a termination block and plug connector body featuring insulation displacement crimp (IDC) connectors that allow simultaneous tapping into multiple insulated wires by penetrating the insulating layer and making electrical contact with the conductive core, facilitated by alignment recesses and detent elements for secure positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If multiple individual taps are made using existing tap connectors, then each wire can be tapped individually, but the installation process becomes laborious and time-consuming
Solution Approach 1:
The patent combines multiple individual tap connector functions into a single multi-position connector assembly. The connector body contains multiple IDC (insulation displacement connector) elements arranged to simultaneously contact multiple conductors, allowing one connector installation to replace what would otherwise require multiple separate tap operations. This merging of functions directly reduces installation time while maintaining the ability to tap individual wires.
Solution Approach 2:
The connector assembly is designed with multi-functionality to handle various wiring configurations. The connector body can simultaneously perform multiple tapping operations on different conductors, and the design allows it to adapt to different wire arrangements and positions. This universal design enables a single connector type to replace multiple specialized tap connectors, improving operational efficiency.
2Reliability
If multiple individual taps are made in sequence, then proper electrical contact can be achieved, but the installation process becomes complex and tedious
Solution Approach 1:
The patent merges multiple electrical contact functions into a single connector assembly where multiple IDC elements are integrated into one body. Each IDC element maintains reliable electrical contact with its corresponding conductor, while the unified connector structure simplifies the installation process by reducing the number of separate operations required. This integration maintains contact reliability while reducing installation complexity.
Solution Approach 2:
The connector assembly is pre-configured with multiple IDC elements positioned and oriented to contact specific conductors. This preliminary arrangement of contact elements within the connector body eliminates the need for complex现场 positioning and adjustment during installation. The pre-engineered contact geometry ensures reliable electrical connection while simplifying the installer's task to a single insertion operation.
3Adaptability or versatility
If traditional tap connectors are used for each wire, then individual wire connections can be made, but the overall wiring installation efficiency decreases
Solution Approach 1:
The connector assembly achieves universality by incorporating multiple IDC elements that can simultaneously connect to multiple different conductors. This multi-functional design allows the single connector to perform what would traditionally require multiple separate tap connectors, thereby maintaining the adaptability to tap individual wires while dramatically improving installation speed and productivity.
Solution Approach 2:
The patent combines the functionality of multiple individual tap connectors into one integrated assembly. The multiple IDC elements are merged within a single connector body, allowing simultaneous connection to multiple conductors. This merging approach preserves the versatility of individual wire tapping while eliminating the need for sequential installation of multiple separate connectors, thus boosting overall wiring productivity.
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 efficient simultaneous tapping into multiple wires, reducing installation time and labor by allowing multiple midway taps to be made simultaneously, enhancing the speed and efficiency of wiring installations.
Implementation Method 1
Socket portions include an insulation displacement crimp (IDC) connector portion configured to penetrate a corresponding external insulating layer of a corresponding one of the plurality of electrical conductors to place the IDC connector portion in electrical communication with the conductive core portion
Data Source
AI summary
An electrical connector assembly includes a first connector portion for supporting a plurality of insulated electrical conductors, and a second connector portion removably engageable with the first connector portion. The first connector portion includes a plurality of detent elements to secure the electrical conductors to the first connector portion, and at least one alignment recess. The second connector portion includes socket portions corresponding to the plurality of electrical conductors of the first portion, and an alignment member cooperative with the alignment recess to guide the second connector portion into engagement with the first connector portion. Socket portions include an insulation displacement crimp (IDC) connector portion configured to penetrate a corresponding external insulating layer of a corresponding one of the plurality of electrical conductors to place the IDC connector portion in electrical communication with the conductive core portion of the corresponding electrical conductor.