Insulation Displacement Connection for High Current

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Solution Overview

Problem

Existing insulation displacement connections in electric motor applications often result in tilting of plug pins during insertion due to non-linear alignment, leading to unreliable high-current connections and potential strain issues under temperature fluctuations and long service lives.

Innovation Solution

The solution involves arranging insulation displacement elements transversely to the direction of displacement, forming a plane that ensures both elements are aligned straight during connection, with a ribbon connection design featuring a bending area and support shoulders to absorb joining forces, creating a high-current, low-impedance connection that is deformable to compensate for tolerances and securely attached via press fits or soldered joints.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If insulation displacement elements are arranged along the direction of insertion to facilitate easy insertion, then ease of operation is improved, but the elements tilt relative to each other during insertion, worsening connection reliability

Engineering Contradiction:

Improveease of insertionVSAvoidconnection reliability

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent applies dimensionality change by arranging insulation displacement elements in a plane transverse to the direction of displacement rather than along the insertion direction. This transverse arrangement in a different dimensional orientation prevents tilting during insertion while maintaining ease of operation, as the elements remain aligned perpendicular to the insertion direction throughout the connection process.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Adaptability or versatility

If insulation displacement elements are made movable to accommodate tolerance compensation, then adaptability is improved, but strain relief and connection stability deteriorate under temperature fluctuations

Engineering Contradiction:

Improvetolerance compensationVSAvoidconnection stability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent employs flexible connection paths with bending areas that can deform to compensate for tolerances while maintaining connection stability. The flexible design allows the connection path to adapt to dimensional variations without compromising the strain relief or stability under temperature fluctuations, as the flexibility is built into the connection path geometry rather than through loose mechanical arrangements.

Inventive Principle:

Principle #30Flexible shells and thin films

3Device complexity

If a simple one-piece connection path is used, then device complexity is reduced, but the ability to absorb joining forces and protect the substrate deteriorates

Engineering Contradiction:

Improveconnection structure simplicityVSAvoidsubstrate damage from joining forces

Core Design Contradiction:

Device complexityVSObject-affected harmful factors

Solution Approach 1:

The patent applies segmentation by dividing the connection structure into distinct functional elements: a simple one-piece connection path for electrical conduction, separate support shoulders for absorbing joining forces, and bending areas for flexibility. This segmentation allows the force-absorbing functions to be isolated from the substrate connection points, protecting the substrate while maintaining overall structural simplicity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The support shoulders act as intermediary elements between the joining force and the substrate. These intermediaries absorb and redirect the joining forces away from the substrate, preventing direct transmission of harmful forces while maintaining the simplicity of the overall connection structure.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Reliability

If insulation displacement elements are arranged transverse to the joining direction to prevent tilting, then connection reliability is improved, but ease of insertion and alignment worsens

Engineering Contradiction:

Improveconnection reliabilityVSAvoidease of insertion

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent applies preliminary action by pre-positioning the insulation displacement elements in a fixed transverse arrangement before the insertion process begins. This preliminary positioning ensures that the elements are already aligned perpendicular to the insertion direction, eliminating the need for real-time alignment adjustments during insertion and maintaining both reliability and ease of operation.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentEP2089936B1Insulation displacement connection, and method for connecting two components

Publication Date: 2016.07.13 ROBERT BOSCH GMBH

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AI summary

The invention relates to an insulation displacement connection (37) and to a method for connecting two components (52, 54) - especially for high current application - said connection comprising a first insulation displacement element (15) which is fixed to a first component (52), and a second insulation displacement element (22) which is fixed to a second component (54). The two insulation displacement elements (15, 22) can be inserted into each other in the direction of assembly, the first and/or second insulation displacement element (15, 22) being fixed to the first and/or second component (52, 54) in such a way that the insulation displacement element (15) is moveably arranged in a plane (49) transversal to the direction of assembly (50).