Insulation-Piercing Terminal With Rotary Contact for Tool-Free Wiring

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Solution Overview

Problem

The complex and time-consuming process of stripping insulating material from electrical conductors to establish electrical contact, requiring high assembly forces and additional tools, poses a challenge in efficiently connecting insulated conductors.

Innovation Solution

A terminal with a rotatable actuating part and an insulation-piercing contact featuring a cutting edge that extends arcuately about the axis of rotation, allowing for easy cutting through insulating material without high forces, and a compact design that reduces actuating forces and enables easy electrical contacting without stripping.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If traditional stripping method is used to remove insulating material, then electrical contact can be established, but high assembly forces are required and additional tools are needed

Engineering Contradiction:

Improveease of electrical contactingVSAvoidassembly forces

Core Design Contradiction:

Ease of operationVSForce

Solution Approach 1:

The patent changes the geometric parameters of the cutting edge by extending it arcuately along the rotation path, transforming the cutting action from a linear process to a rotational one. This parameter change allows the cutting edge to engage the insulating material at multiple points simultaneously, distributing the required force and reducing peak assembly forces while eliminating the need for additional stripping tools.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If traditional stripping method is used, then electrical contact can be established, but the procedure is time-consuming

Engineering Contradiction:

Improvespeed of electrical contactingVSAvoidstripping time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The patent incorporates the cutting edge directly into the insulation-piercing contact, which is already positioned to establish electrical contact. This preliminary integration means the insulating material is cut and pierced in a single continuous motion without requiring separate stripping and contacting steps, significantly reducing the time loss associated with traditional multi-step stripping procedures.

Inventive Principle:

Principle #10Preliminary action

3Force

If cutting edge extends arcuately along rotation path, then actuating forces are reduced, but device complexity increases

Engineering Contradiction:

Improveactuating forcesVSAvoidterminal structure

Core Design Contradiction:

ForceVSDevice complexity

Solution Approach 1:

The patent merges the cutting function and the electrical contact function into a single integrated insulation-piercing contact component. The cutting edge is formed as an integral part of the contact element itself, combining what would traditionally be separate tools (a stripping tool and a contact tool) into one unified component, thereby reducing overall device complexity while maintaining the force-reducing benefits of the arcuate geometry.

Inventive Principle:

Principle #5Merging (Combining)

4Ease of manufacture

If arcuate cutting edge is used, then cutting effectiveness is improved, but manufacturing complexity increases

Engineering Contradiction:

Improveease of cutting through insulating materialVSAvoidcutting edge geometry

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent applies curvature to the cutting edge by extending it arcuately along the rotation path of the insulation-piercing contact. This curved geometry matches the natural rotation path, allowing the cutting edge to engage the insulating material continuously throughout the rotation arc. The curvature is designed to be manufacturable using standard forming processes, balancing cutting effectiveness with manufacturing feasibility.

Inventive Principle:

Principle #14Spheroidality (Curvature)

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

The solution significantly reduces the forces required to cut through insulating material, facilitates easy electrical contacting, and results in a compact terminal design that can efficiently connect conductors of various cross-sections and diameters with reduced assembly time and effort.

Implementation Method 1

The insulation-piercing contact has a cutting edge for cutting through the insulating material

Methodology Applied

Scientific EffectMechanical Force: Mechanical Force

Data Source

PatentUS11881669B2Terminal

Publication Date: 2024.01.23 ELECTRO TERMINAL GMBH

AI summary

A terminal (1) for connection of an electrical conductor (2) without stripping, having at least one conductor insertion area (13) for inserting an electrical conductor (2), insulated with an insulating material, into the terminal (1) in a conductor insertion direction. The terminal (1) has, for each conductor insertion area (13), an actuating part (50) and an insulation-piercing contact (30) having a cutting edge (33) for cutting through the insulating material and establishing electrical contact with the electrical conductor (2). The cutting edge (33) extends about an axis of rotation along an arc. By rotating the actuating part (50) about the axis the insulation-piercing contact (30) moves between a contacting position, in which the cutting edge (33) intersects the conductor insertion area (13) for establishing electrical contact with an inserted electrical conductor (2), and a release position, in which the cutting edge (33) clears the conductor insertion area.