Insulation Piercing Connector for Zipcord Termination
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Solution Overview
Problem
Existing connectors are not suitable for reliably and automatically securing and terminating zipcords to printed circuit boards, as they either require separation of wires or are not designed for surface mounting, leading to electrical shorts and manufacturing inefficiencies.
Innovation Solution
A through-the-hole/surface mount insulation piercing connector with a vertical plate and L-shaped hook design that allows direct mounting to a PCB or header, enabling secure termination of zipcords without wire separation, using a crimping mechanism for strain relief and retention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing connectors are used to terminate zipcord to PCB, then wire separation is required to avoid electrical shorts, but this increases manufacturing complexity and reduces productivity
Solution Approach 1:
The connector is segmented into multiple independent contact elements, each capable of piercing and contacting individual conductors within the zipcord. This allows simultaneous termination of multiple conductors through a single connector body, eliminating the need to separate wires before termination while maintaining reliable electrical connections.
Solution Approach 2:
The connector is designed with universal functionality to handle both insulated and bare conductors, and can terminate multiple conductors simultaneously. The piercing elements can penetrate insulation material while making electrical contact, allowing the connector to work with zipcords that have conductors running parallel without requiring separation.
2Ease of manufacture
If existing connectors are used for zipcord termination, then manual wire separation and preparation is needed, but this increases device complexity and manufacturing cost
Solution Approach 1:
The connector incorporates pre-formed piercing elements with sharp tips that are ready to penetrate conductor insulation upon insertion. The contact elements are pre-positioned and pre-shaped to automatically engage conductors in their original bundled state, eliminating the need for preliminary wire stripping or separation operations.
Solution Approach 2:
The piercing elements are designed to automatically penetrate the insulation and make contact with conductors during the insertion process itself. The spring-loaded or elastic contact elements self-adjust to accommodate variations in conductor position and insulation thickness, enabling automated termination without complex alignment or preparation mechanisms.
3Extent of automation
If connectors are designed for surface mounting, then automated pick-and-place can be used, but existing designs are not suitable for this mounting method
Solution Approach 1:
The connector is designed with universal mounting capability, featuring both through-hole mounting holes and surface-mount compatible footprints. The same connector body can be mounted using either traditional through-hole insertion or automated surface-mount technology, allowing manufacturers to choose the most appropriate method for their production line capabilities.
Solution Approach 2:
The connector incorporates mounting features in multiple dimensions - through-hole mounting holes extending through the connector body for vertical insertion, and surface-mount pad patterns on the mounting surface for horizontal attachment. This multi-dimensional mounting approach enables compatibility with both mounting methodologies.
4Strength
If wire retention strength is improved through crimping, then strain relief is enhanced, but this requires additional crimping steps that increase manufacturing time
Solution Approach 1:
The electrical contact function and mechanical retention function are merged into a single integrated contact element. The same piercing element that makes electrical contact also provides mechanical anchoring through its geometry, eliminating the need for separate crimping operations while maintaining strong wire retention and strain relief.
Solution Approach 2:
The contact elements are designed with self-retention features such as barbed surfaces, expanded tips, or elastic deformation zones that automatically grip the conductor during insertion. This self-retention mechanism provides adequate strain relief without requiring additional manual or automated crimping steps.
Data Source
AI summary
A through-the-hole (TTH)/surface mount (SMT) insulation piercing connector includes one or two spaced electrical contacts. Each contact has a flat plate portion and integrally-formed legs. An L-shaped hook portion on the flat plate portion has a piercing tip pointed in a direction away from the legs. The piercing tip is spaced from the flat plate portion, the flat plate portion being configured and dimensioned to bend in the direction towards the piercing tip when pressed to urge an insulated wire onto said piercing tip to cause it to penetrate the wire insulation and make electrical contact with the internal conductive wires or strands within the wire. The legs are insertable into mounting holes in a substrate for direct TTH mounting in a PCB or to be secured to a header provided with mounting holes by TTH soldering and surface mounting by a pick-and-place machine acting on the header.