Insulation-Displacement Terminal With Segmented Slot
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In electronic devices, such as vehicle motors, insulation-displacement terminals often cause unintended scraping of electric wire conductors, leading to separation and falling of conductor pieces during electrical connection, which can interfere with peripheral circuits.
Innovation Solution
The design of an insulation-displacement terminal with a slot that includes an introduction part, a scrape part with a gradually increasing contact portion, and a fix part, where the slot dimensions change to prevent conductor pieces from separating and falling, ensuring secure electrical connection by widening the cut piece, making it difficult to peel off.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the insulation-displacement terminal uses beams to scrape the insulation coating and press the conductor, then electrical connection is achieved, but conductor pieces are unintentionally scraped and separated, causing interference with peripheral circuits
Solution Approach 1:
The slot is divided into three distinct functional parts: introduction part (with larger dimension for wire insertion), scrape part (for insulation removal), and fix part (for conductor fixation). This segmentation allows each part to perform its specific function optimally without interfering with other functions, preventing unwanted conductor scraping while maintaining reliable electrical connection.
Solution Approach 2:
The slot dimension varies locally along its length, being larger at the introduction part and smaller at the scrape and fix parts. This local variation in geometry allows the wire to be guided and inserted easily at the introduction part while preventing conductor piece separation at the scrape and fix parts, thus resolving the contradiction between connection reliability and harmful factor generation.
2Ease of manufacture
If the slot dimension is uniform throughout, then manufacturing is simple, but conductor pieces can separate and fall during the connection process
Solution Approach 1:
The slot is segmented into three parts with different dimensions along its length. The introduction part has a larger dimension to facilitate wire insertion, while the scrape and fix parts have smaller dimensions to prevent conductor piece separation. This segmentation maintains manufacturing simplicity while significantly improving conductor fixation reliability.
3Productivity
If the scrape part has a large contact area, then insulation coating removal is effective, but conductor pieces are more likely to be scraped and separated
Solution Approach 1:
The scrape part is designed with a controlled contact area that is sufficient for insulation removal but limited in size to prevent excessive conductor scraping. The local quality of the scrape part geometry is optimized to balance insulation removal efficiency with prevention of conductor piece separation, resolving the contradiction between productivity and harmful factor generation.
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 effectively reduces the separation and falling of conductor pieces during electrical connection, ensuring reliable and stable electrical connections in electronic devices like vehicle motors.
Implementation Method 1
the insulation coating is scraped by the beams
Data Source
AI summary
An electronic device includes a connection unit having an electric wire and an insulation-displacement terminal. The electric wire includes a conductor and an insulation coating on an outer periphery of the conductor. The insulation-displacement terminal includes two beams facing each other in a first direction to define a slot, and receives the electric wire in the slot to have an electrical connection. The insulation-displacement terminal includes an introduction part defining an opening of the slot, a scrape part for scraping the insulation coating from the electric wire, and a fix part fixing the electric wire in order along a second direction from the opening to an innermost of the slot. The thickness of the scrape part gradually increases toward the second direction so that as the electric wire advances through the scrape part along the second direction the width of the conductor to be scraped gradually increases.