Rugged Insulation Displacement Connector with Fixed Contact and Retaining Structure
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Solution Overview
Problem
Existing insulation displacement connectors (IDCs) are complex and not well-suited for stressful environments with prolonged shock and vibrations, as they require movable parts for connection and are prone to wire dislodgment.
Innovation Solution
A rugged IDC design with fixed contact elements and a retaining structure that includes pinch points or V-shaped notches to secure the wire in place, preventing dislodgment, and is configured for surface mounting technology (SMT) applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If movable parts are used for connection in existing IDCs, then ease of operation is improved, but reliability deteriorates in stressful environments with prolonged shock and vibrations
Solution Approach 1:
The patent inverts the conventional IDC approach by using fixed contact elements instead of movable parts. The contact elements are rigidly mounted in the connector body, eliminating the movement mechanism that causes reliability issues in vibrating environments while maintaining the insulation displacement connection capability.
Solution Approach 2:
The patent introduces a dynamic retention mechanism where the retaining structure can flex or deform during wire insertion to allow the insulation displacement action, then locks into a fixed position to secure the wire against dislodgment from vibrations and shock.
2Reliability
If fixed contact elements with retaining structure are used, then reliability in high-vibration environments is improved, but device complexity increases
Solution Approach 1:
The patent merges the contact element and retaining structure into a single integrated component. The retaining structure is formed as part of the contact element itself, eliminating the need for separate retention mechanisms and reducing overall device complexity while maintaining wire security.
Solution Approach 2:
The contact element serves multiple functions: it provides electrical contact, performs insulation displacement, and secures the wire through its integrated retaining structure. This multi-functionality reduces the number of separate components needed, simplifying the overall device.
3Ease of manufacture
If conventional IDC design is used, then ease of manufacture is maintained, but adaptability to SMT applications deteriorates
Solution Approach 1:
The patent segments the connector into a modular design with distinct contact elements that can be individually manufactured and then assembled into the final connector. This segmentation allows for specialized manufacturing processes suitable for SMT applications while maintaining ease of manufacture through standardized components.
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 provides a reliable and secure connection for insulated wires in high-vibration environments, ensuring the wires remain in place without the need for wire stripping or crimping, and is suitable for conventional pick-and-place manufacturing processes.
Implementation Method 1
A common feature of IDCs is one or more contact elements incorporating a set of blades or jaws that cut through the insulation around the wire and make electrical contact with the conductive core
Implementation Method 2
The present invention provides an improved IDC design that is rugged, reliable, and particularly well suited for SMT applications... ensuring the wires remain in place without the need for wire stripping or crimping
Data Source
AI summary
An electrical insulation displacement connector includes a body having at least one channel with an open top side configured for receipt of an insulated conductive core wire therein. A contact element is fixed in the body with a first insulation displacement end defined by opposed blades oriented across the channel, and a second end extending from a bottom surface of the body and configured for electrical contact with a PCB. The body includes retaining structure extending into the channel at a location relative to a depth of the blades within the channel such that the insulation portion of a wire inserted into the channel and pressed down into the first end of the contact element is pushed below the retaining structure, thereby preventing the wire from being inadvertently pulled out from the first end of the contact.