IDCC Connector Assembly With Compliant PCB Pin Retention
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Solution Overview
Problem
Existing IDC connector systems require additional components for securing header pins, such as plastic covers or pronged terminal systems, which complicates the connection process and increases complexity in automotive and similar applications.
Innovation Solution
An Insulation Displacement Contact Compliant (IDCC) connector system that includes IDCC header pins with pin barbs for anchoring into a housing and a compliant retention feature for secure attachment to a printed circuit board, eliminating the need for additional securing components by using a housing with strain relief and retention posts for secure wire insertion and electrical contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional components such as plastic covers or pronged terminal systems are used to secure IDCC header pins, then the header pins can be retained in the housing, but the device complexity increases
Solution Approach 1:
The housing structure is merged with the retention function by integrating pin retention features directly into the housing body. The housing includes recesses and engagement features that directly retain the IDCC header pins without requiring separate retention components, thus simplifying the overall device structure while maintaining reliable pin retention.
2Reliability
If additional securing components are used for IDCC header pins, then the connection is more secure, but the manufacturing process becomes more complex
Solution Approach 1:
The housing is designed as an integrated assembly where the retention features are built-in rather than added separately. This merging of functions allows for simpler manufacturing and assembly processes, as the housing itself provides the retention mechanism without requiring additional securing components to be installed separately.
3Ease of manufacture
If a compliant pin structure is used for PCB attachment, then soldering is eliminated, but the retention mechanism becomes more complex
Solution Approach 1:
The IDCC header pin structure includes built-in compliant retention features that automatically engage with the PCB holes and provide self-retention. The pin design incorporates flexible or compliant sections that allow the pin to secure itself to the PCB without requiring external retention mechanisms or soldering, thus simplifying the overall attachment system.
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. There are several options for the assembly process including a) a pin-to-housing insertion process; b) a housing assembly-to-PCB process or a connector-to-PCB process; and c) a wired housing assembly-to-PCB assembly process or a wire harness-to-PCB assembly process.