Rotated IDC Plug Connector for Vibration-Stable Cable Contact
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Solution Overview
Problem
Existing electrical connectors with insulation displacement contact technology experience reduced service life due to micro-movements caused by cable bending or vibration, leading to wear and loss of electrical connection.
Innovation Solution
The design features two insulation displacement elements with cutting edges that are rotated relative to each other by an angle between 40° and 140° about the longitudinal axis, providing enhanced clamping and absorption of relative movements, ensuring a more durable electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single insulation displacement connector is used to contact the cable, then the assembly process is simple, but the connector experiences reduced service life due to micro-movements causing wear
Solution Approach 1:
The connector is divided into two separate insulation displacement connectors instead of using a single connector. Each connector independently contacts the cable at different angular positions, creating multiple contact points that distribute mechanical stress and prevent wear from micro-movements while maintaining electrical contact stability.
2Ease of operation
If the receiving openings of the two IDCs are aligned parallel (0° rotation), then the cable insertion is straightforward, but the connector cannot effectively absorb relative movement between cable and contact
Solution Approach 1:
The two insulation displacement connectors are positioned at different angular positions around the longitudinal axis (e.g., 90° apart), creating an asymmetric configuration. This asymmetric arrangement allows the connectors to effectively absorb relative movements in multiple directions while maintaining straightforward cable insertion, as the cable passes through both connectors along the longitudinal axis.
3Strength
If the receiving openings are rotated by 180° around the longitudinal axis, then the cable can be held securely, but the forces opposing movement in the slot direction remain insufficient
Solution Approach 1:
Instead of rotating the receiving openings 180° around the longitudinal axis, the invention positions the two insulation displacement connectors at different angular positions (e.g., 90° apart) around the axis. This three-dimensional arrangement creates opposing forces in multiple directions, effectively restraining cable movement in the slot direction while maintaining secure cable holding, thereby resolving the force deficiency in the conventional 180° configuration.
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 configuration improves the stability and longevity of the connector by securely holding the cable against thermal and vibration loads, maintaining reliable electrical contact and simplifying assembly, while eliminating the need for crimping and stripping processes.
Implementation Method 1
the cable's insulation is usually cut or, in the case of a coating layer, scraped off
Implementation Method 2
the wire then comes to rest in a narrow part of the slot and is electrically connected to the tabs or cutting edges by the high normal forces
Data Source
Figure 1~2
Figure 3a~3b
AI summary
The invention relates to an electrical plug connector (1) having a contact body (2) for electrically contacting a counter contact. The contact body (2) comprises a contacting section (3) for electrically contacting the counter contact, and a connection region (4) for electrically and mechanically contacting a cable (30). Two cutting-clamping elements (10, 20) are arranged in the connection region (4), which extends along a longitudinal axis (A) defining an axial direction, each having two opposing blades (11a, 11b, 21a, 21b), wherein the two blades (11a, 11b, 21a, 21b) of a cutting-clamping element (10, 20) each define a receiving opening (12, 22) for the cable (30) pointing outwards transverse to the longitudinal axis. The two receiving openings (12, 22) of the two cutting-clamping elements (10, 20) are rotated relative to one another about the longitudinal axis (A) by an angle (a), wherein the angle (a) is in a range between 40° and 140°.