Plug With Integrated Insulation Displacement Contact
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Solution Overview
Problem
Existing connectors for single-core, insulated cables often require complex and cumbersome contacting solutions, especially when dealing with multiple cables, and struggle to achieve a compact design and efficient automated production.
Innovation Solution
A connector design featuring twisted insulation displacement contacts and clamping elements, where the spring or blade contact elements, carrier, insulation displacement contact, and clamping element are formed as a single stamped part, allowing for automated production and easy assembly with latching hooks, enabling secure and efficient contacting of multiple cables in a collinear arrangement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If insulation displacement contacts are arranged at an angle of 90° to the cables, then the connector can contact multiple cables, but the cables must be arranged at an angle which complicates the connector structure and reduces compactness
Solution Approach 1:
Instead of arranging contact elements at an angle to accommodate cables running in the insertion direction, the patent inverts the approach by arranging insulation displacement contacts perpendicular to the blade contact element, allowing cables to run collinearly with the insertion direction while maintaining effective contact
2Ease of manufacture
If multiple bending processes are used to create contact elements with insulation displacement contacts, then the contacts can be integrated, but the production process becomes complex and the design less compact
Solution Approach 1:
The patent combines the spring contact element and insulation displacement contact into a single integrated contact element that can be produced in one stamping process, eliminating the need for multiple bending operations and separate assembly steps
3Ease of manufacture
If contact elements are designed with multiple bent formations, then insulation displacement contacts can be integrated, but the design becomes less compact and requires larger connector dimensions
Solution Approach 1:
The contact element integrates the spring contact element and insulation displacement contact in a compact linear arrangement produced by single-step stamping, eliminating the space-consuming multiple bent formations of conventional designs
4Adaptability or versatility
If separate components are used for spring contact elements and insulation displacement contacts, then assembly is flexible, but the contacting process becomes cumbersome and less efficient
Solution Approach 1:
The spring contact element and insulation displacement contact are integrated into a single component that performs both functions simultaneously, eliminating the need for separate assembly operations and improving contacting efficiency
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 design allows for simple, secure, and efficient contacting of multiple single-core cables in a compact structure, with automated production capabilities, enhancing tensile strength and reducing manufacturing complexity by integrating clamping elements with the spring contact elements.
Implementation Method 1
a spring contact element (410) arranged in the first housing part (100)
Implementation Method 2
an insulation displacement contact (430) which is arranged on the carrier (405) perpendicular to a plug-in direction (R) and serves to contact and fix a single-core insulated cable (304)
Implementation Method 3
a clamping element (440) which is arranged on the carrier (405) and serves to clamp the insulating jacket of the single-core cable (304)
Data Source
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AI summary
A plug (10) comprising at least one spring or blade contact element (410) which is disposed in a housing and is connected in an electrically conducting manner to at least one insulation displacement contact (430) that contacts and secures at least one insulated single-core cable (301; 302, 303, 304) is characterized in that the at least one insulation displacement contact (430) extends at a 90° angle from the spring or blade contact element (410) in the plug-in direction (R) of the spring or blade contact element (410) in such a way that the at least one insulated single-core cable extending in the plug-in direction is contacted and secured by an insulation displacement contact.