Insulation-Piercing Contact Structure for Wire Retention
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Solution Overview
Problem
Forming electrical connections with insulated wire bundles is challenging due to difficulties in piercing or cutting the wire bundle insulation and complex connector structures.
Innovation Solution
An insulation piercing contact with a base portion, outer walls, and a piercing member that pierces the insulation to facilitate secure electrical connections, reducing the number of components and assembly steps by integrating wire retention features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional connectors are used to form connections with insulated wire bundles, then connection reliability can be maintained, but the difficulty of piercing or cutting the wire bundle insulation and the complexity of connector structure increase
Solution Approach 1:
The patent combines multiple functions (piercing, insulation cutting, wire retention, and electrical connection) into a single integrated contact structure. The contact includes a body with opposing walls forming a passage, a piercing member integrated into the body, and retention features built into the structure, eliminating the need for separate components and reducing assembly steps while maintaining reliable electrical connections.
2Stability of the object's composition
If traditional connectors are used to form connections with insulated wire bundles, then connection stability can be achieved, but the number of components and assembly steps increase
Solution Approach 1:
The contact structure is designed to perform multiple functions simultaneously: the piercing member pierces the insulation, the opposing walls form a passage that guides and retains the wire bundle, and the integrated structure provides both mechanical retention and electrical connection. This multi-functional design reduces the number of components needed while ensuring stable connections.
3Reliability
If insulation piercing is performed with traditional methods, then electrical connections can be formed, but the difficulty of piercing or cutting the wire bundle insulation increases
Solution Approach 1:
The piercing member is pre-positioned within the contact body structure, ready to pierce the insulation as the wire bundle is inserted into the passage. The opposing walls are pre-configured to guide the wire bundle into the correct position, making the piercing operation straightforward and reducing the skill level required for assembly.
4Reliability
If complex connector structures are used, then connection reliability can be maintained, but the assembly time and productivity decrease
Solution Approach 1:
By integrating the piercing member, retention walls, and electrical contact into a single unified structure, the patent eliminates multiple assembly steps. The contact can be installed in one action by inserting the wire bundle into the passage, which simultaneously positions the insulation for piercing and secures the wire, significantly improving assembly speed while maintaining reliable connections.
Data Source
AI summary
An electrical contact includes a base portion extending from a first end of the contact to a second end of the contact, a first set of outer walls extending upward from the base portion, the first set of outer walls being disposed on a first side. The electrical contact also includes a second set of outer walls extending upward from the base portion, the second set of outer walls being disposed on a second side opposite the first set of outer walls and the first side. The electrical contact also includes a piercing member disposed between the first set of outer walls and the second set of outer walls, the piercing member extending upward in a direction substantially parallel to at least one wall within the first set of outer walls and the second set of outer walls, the piercing member configured to pierce an insulated wire.