Insulation Displacement Contact Housing for Heavy Component Mounting
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Solution Overview
Problem
Existing electrical devices with insulation displacement contacts face challenges in securely mounting and reliably connecting large and heavy electrical components, especially under mechanical stress from vibrations or accelerations, leading to potential detachment or electrical disconnection.
Innovation Solution
The housing features a receiving chamber that encloses the lateral surface of the component, with a radially pivotable locking clip and insulation displacement contacts aligned with press-in contacts, allowing for secure mechanical and electrical connection, including resilient projections for vibration damping and a latching mechanism for axial stability, and double insulation displacement areas for enhanced electrical contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If plastic tabs are used to hold electrical components, then the components can be mechanically mounted, but heavy components can become detached or shift under mechanical loads such as vibrations or accelerations
Solution Approach 1:
The housing is divided into multiple receiving chambers, each capable of independently holding a component. This segmentation allows for distributed mechanical support and reduces the load on any single mounting point, improving overall reliability under vibration and acceleration forces.
Solution Approach 2:
The insulation displacement contact is nested within the receiving chamber structure, with the contact element positioned to engage with the component while being supported by the housing structure. This nested arrangement provides both mechanical holding and electrical connection through a single integrated structure, enhancing both strength and reliability.
2Ease of manufacture
If insulation displacement contacts are pushed into retaining pockets, then electrical connection can be made, but the connection is mechanically stressed under heavy component loads
Solution Approach 1:
The mechanical holding function and electrical connection function are merged into a single integrated structure. The insulation displacement contact is positioned within the receiving chamber such that it provides both electrical connection to the component and mechanical support through its integration with the housing structure, eliminating the separate retaining pocket structure and reducing mechanical stress on the electrical connection.
Solution Approach 2:
The insulation displacement contact acts as an intermediary element between the component and the housing structure. It provides electrical connection while its integration with the receiving chamber structure distributes mechanical loads, preventing direct stress on the electrical connection points and improving reliability.
3Ease of operation
If the component is pushed axially into the receiving chamber, then the component can be inserted, but tolerance-related distances cause instability under vibration
Solution Approach 1:
The insulation displacement contact incorporates resilient or flexible elements that can dynamically adapt to tolerance variations in component positioning. This dynamic capability allows the contact to maintain reliable electrical connection and mechanical support despite axial tolerance-related distances, while still enabling easy insertion of the component into the receiving chamber.
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 configuration ensures secure mechanical mounting and reliable electrical connection of heavy components, maintaining contact integrity under mechanical loads and providing a single-step connection to the printed circuit board with low contact resistance.
Implementation Method 1
these resilient projections act as vibration dampers for the component
Implementation Method 2
the latching clip springs back and thus secures the component axially in the receiving chamber
Implementation Method 3
the insulation displacement contact at least has an insulation displacement area whose opening direction is aligned in the extension direction of the press-in contacts
Data Source
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AI summary
An electrical appliance is described having a housing and having a printed circuit board which is held mechanically on the housing by means of insulation-displacement terminal contents which are joined in the housing, and having at least one electrical or electronic component which is held mechanically on the housing, and at least one of whose connections is electrically connected via an insulation-displacement terminal contact to the printed circuit board, wherein the housing has at least one integrally formed insert for holding the insulation-displacement terminal contact, wherein the housing forms a holding chamber for mechanically holding the component, which holding chamber completely surrounds the envelope surface of the component, at least in places, and wherein a latching clip which can pivot radially fixes the component, which has been inserted into the holding chamber, in the axial direction.