Single Element Wire-to-Board Connector Design
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Solution Overview
Problem
Conventional Insulation Displacement Connectors (IDCs) for connecting wires to components like printed circuit boards (PCBs) are complex, large, and costly, requiring multiple parts and valuable space, making them unsuitable for all applications, especially those requiring a simple and cost-effective solution.
Innovation Solution
A single-element electrical connector formed from a single conductive contact member, featuring a cage structure with a wire insert end and contact tines, designed for pick-and-place mounting and capable of surface or through-board configurations, eliminating the need for an insulative body and allowing secure wire connections without wire stripping or crimping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional IDC connectors are used, then reliable wire-to-board connections are achieved, but device complexity and space requirements increase
Solution Approach 1:
The patent combines the insulative body and contact elements into a single integrated connector unit. The insulative body includes integrally formed contact cavities that receive contact elements, eliminating the need for separate assembly steps and reducing the number of discrete parts while maintaining reliable electrical connections
2Reliability
If conventional IDC connectors are used, then secure wire connections are achieved, but valuable PCB space is consumed
Solution Approach 1:
The connector is designed with modular contact elements that can be independently positioned within the insulative body. This segmentation allows for optimized space utilization on the PCB while maintaining secure wire connections through the integrated structure
3Adaptability or versatility
If conventional IDC connectors with multiple parts are used, then functional requirements are met, but manufacturing cost increases
Solution Approach 1:
The insulative body and contact elements are designed as an integrated unit that can be manufactured as a single component or pre-assembled module, reducing the number of parts that need to be sourced, stored, and assembled, thereby lowering manufacturing costs while maintaining full functionality
4Ease of operation
If conventional IDC connectors are used, then wire insulation displacement is achieved, but the main body must be movable relative to contacts
Solution Approach 1:
The insulative body and contact elements are integrated such that the contact elements are directly supported by the insulative body structure, eliminating the need for relative movement between separate main body and contact components while still enabling wire insulation displacement through the contact element design
Data Source
AI summary
A single element electrical connector includes a single conductive contact element formed into a cage structure having a wire insert end and a wire contact end along a longitudinal centerline axis of the connector. The cage structure defines an upper pick-up surface having a surface area suitable for placement of a suction nozzle of a vacuum transfer device, as well as a pair of contact tines biased towards the centerline axis to define a contact pinch point for an exposed core of a wire inserted into the connector. A contact surface is defined by a member of the cage structure for electrical mating contact with a respective contact element on a component on which the connector is mounted.