Plug Connector Hinge Mechanism for Translational Wire Insertion
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Solution Overview
Problem
Existing plug-type connectors with insulation displacement contacts face challenges in precise wire insertion due to complex mechanisms that cause unnecessary bending of ID terminations and wires, leading to unreliable connections and increased costs from multiple components.
Innovation Solution
A plug-type connector design featuring a first housing part with a plug contact and ID termination, a connection block with a wire channel, and a second housing part connected via a hinge mechanism allowing exclusive translational movement, ensuring wires are inserted straight into the ID termination without circular motion, thus reducing component count and production complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a separate pressing part and contact circuit board are used to press wires into ID terminations, then the wire insertion function is achieved, but the number of components increases and manufacturing cost increases
Solution Approach 1:
The patent combines the pressing part, contact circuit board, and housing into an integrated structure where the housing itself serves as the pressing mechanism. The ID terminations are directly mounted on the housing, eliminating the need for separate pressing parts and contact circuit boards, thereby reducing component count and manufacturing cost while maintaining the wire insertion function.
Solution Approach 2:
The housing is designed to serve multiple functions: it provides structural support, acts as the pressing mechanism during wire insertion, and serves as the mounting surface for ID terminations. This multi-functionality eliminates the need for separate dedicated components, reducing overall device complexity and cost.
2Reliability
If two housing parts are rotatably attached to enable circular insertion movement, then the wire clamping function is achieved, but the ID termination and wire are unnecessarily bent affecting connection reliability
Solution Approach 1:
The patent removes the rotational movement mechanism from the wire insertion process. Instead of using rotatable housing parts that cause circular motion and bending, the design extracts only the essential pressing function, achieving wire clamping through direct linear pressing motion that maintains wire and ID termination alignment.
Solution Approach 2:
Rather than using rotational movement to achieve pressing (as in prior art), the patent inverts the approach by using direct linear pressing motion. The housing parts are designed to press directly onto the wires and ID terminations in a straight line, eliminating the harmful bending effects of circular motion while maintaining the clamping function.
3Ease of manufacture
If complex housing mechanisms with multiple parts are used for wire insertion, then the wire clamping function is achieved, but the device complexity increases and manufacturing becomes more difficult
Solution Approach 1:
The patent merges multiple housing parts into a simplified integrated structure. The housing is designed as a unified component that incorporates the pressing mechanism, ID termination mounting, and wire guidance features, eliminating the need for multiple separate housing parts and reducing manufacturing complexity.
Solution Approach 2:
While reducing overall complexity, the housing is segmented into functional zones: a pressing surface for wire clamping, mounting areas for ID terminations, and wire guidance channels. This functional segmentation achieves the necessary wire insertion capability with a simplified single-piece or minimally-assembled housing structure.
Data Source
AI summary
A plug-type connector for connecting a cable with at least one wire to a respective plug contact includes a first housing part, a connection block and a second housing part. A hinge connection allows the second housing part to pivot out of a first position into a second position towards the first housing part. In the first position the wire can be inserted into a wire channel of the connection block and, in the second position, the second housing part presses the connection block against the insulation displacement contact. The second housing part can move into a third position in which the connection block is fully pressed onto the insulation displacement contact. The hinge connection allows an insertion movement from the second into the third position such that the second housing part inserts the wire into the insulation displacement contact in an exclusively translatory manner.