Modular IDC Connection System for Branching Continuous Conductors
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Solution Overview
Problem
Existing connection systems for electrical conductors are inefficient in creating branches without cutting through continuous conductors and are not suitable for retrofitting already installed cables, with complex structural designs that complicate wiring and require excessive space.
Innovation Solution
A connection system with a modular design that uses IDC contacts and eccentric actuating devices, allowing for easy assembly and wiring of continuous and branching conductors without screws, and can be retrofitted to existing cables, with a compact structure that minimizes space usage and simplifies the wiring process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional connection devices with screw terminals and insulation-penetrating contacts are used, then reliable electrical connections can be established, but the structural complexity increases and wiring becomes more difficult
Solution Approach 1:
The connection device is divided into modular components: a base plate with conductor receptacles, connection disks with IDC contacts that can be independently inserted and actuated, and functional covers. This segmentation allows each component to be optimized independently and simplifies the overall wiring process.
Solution Approach 2:
Traditional screw terminals are replaced with IDC (Insulation Displacement Contact) technology that creates electrical connections by displacing the insulation material directly, eliminating the need for screw fastening and insulation stripping. This substitution dramatically simplifies the wiring process while maintaining connection reliability.
2Adaptability or versatility
If connection devices are designed to create branches on continuous conductors without cutting, then cable retrofitting becomes possible, but the device structure becomes more complex
Solution Approach 1:
The base plate design with multiple conductor receptacles and the ability to accommodate various connection disks enables the device to handle multiple wiring scenarios: creating branches on continuous conductors, connecting individual conductors, and retrofitting existing cable installations. This universal design achieves versatility without proportionally increasing complexity.
Solution Approach 2:
The connection disks are pre-configured with IDC contacts and actuating mechanisms during manufacturing. During installation, these pre-assembled units are simply inserted into the base plate receptacles and actuated, eliminating the need for complex on-site assembly or cable cutting operations.
3Adaptability or versatility
If multiple functional elements are integrated into connection devices, then the possibilities of using the connection device increase, but the space required increases
Solution Approach 1:
Functional elements such as connection disks, actuating mechanisms, and electrical contacts are nested within the compact base plate structure. The connection disks themselves contain multiple contacts and are inserted into recesses in the base plate, creating a space-efficient nested arrangement that maximizes functionality within minimal footprint.
Solution Approach 2:
The connection device utilizes vertical stacking and three-dimensional arrangement of components. Connection disks are positioned above the base plate plane, and functional elements are arranged in multiple layers, effectively using the vertical dimension to increase functionality without proportionally increasing the horizontal footprint.
4Productivity
If IDC contacts with actuating mechanisms are used instead of screw terminals, then wiring becomes simpler and faster, but the device structure becomes more complex
Solution Approach 1:
The actuating mechanisms are designed to be self-contained on each connection disk, with the operator simply needing to press or actuate the disk to make contact. The IDC contacts automatically penetrate the insulation and establish electrical connection without requiring separate screw fastening operations or insulation stripping tools, making the wiring process self-service and tool-free.
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
Enables efficient and secure creation of branches on continuous conductors without cutting, supports high wiring forces, and allows for easy retrofitting of existing cables, reducing complexity and space requirements while ensuring defined and secure electrical connections.
Implementation Method 1
IDC contacts that can be actuated without screws, in particular fork contacts
Implementation Method 2
eccentric actuating devices
Data Source
Figure 1
Figure 2a~2b
Figure 3
AI summary
The system (1) has a connection module arranged in a base plate (2) with a module frame (3) and a number of receptacle chambers (6) for retaining connecting washers (4). The connection washers have insulation penetrating contacts that contact with conductors (21). A top housing retains the base plate. A cover is placed on the top housing. The cover realizes various types of connecting devices, which form the connection system.