Spring Connector Spiral Terminals Small Cable Severance
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Solution Overview
Problem
Conventional connectors face challenges with small diameter cables, leading to severed cables and soldering difficulties, especially when insulation displacement connection (IDC) terminals are used, limiting the application of cables with small diameters.
Innovation Solution
A spring connector with an insulating case and spiral-shaped spring terminals that securely clamp small diameter cables through a four-point connection, preventing severance and facilitating electrical connection without soldering issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional connectors with IDC terminals are used to connect small diameter cables, then the connector can be compact in size, but the cables are prone to severance and soldering difficulties occur
Solution Approach 1:
The patent changes the terminal structure from rigid IDC terminals to elastic spring terminals with spiral contacting portions. This parameter change in terminal flexibility allows the terminal to adapt to small diameter cables without causing severance, while maintaining compact connector size. The elastic deformation capability of spring terminals resolves the contradiction between compact size and connection reliability.
Solution Approach 2:
The spring terminals incorporate dynamic elastic elements that can deform and recover. The spiral contacting portions can elastically deform to accommodate cables of varying diameters and then recover to maintain reliable electrical connection. This dynamic behavior prevents cable severance while keeping the connector compact, resolving the technical contradiction.
2Productivity
If the connector is designed with smaller size to accommodate more contacts, then the connector compactness is improved, but cable severance and soldering difficulties worsen
Solution Approach 1:
The patent changes the terminal geometry from rigid to elastic spring structure with spiral contacting portions. This parameter change enables the terminal to flexibly adapt to small diameter cables in compact connectors, preventing cable severance during assembly and eliminating soldering requirements, thus improving both contact density and manufacturing ease.
Solution Approach 2:
The spring terminals perform self-alignment and self-adjustment through elastic deformation. The spiral contacting portions automatically adapt to the cable diameter and position, eliminating the need for precise manual alignment and soldering operations. This self-service mechanism enables high contact density while simplifying the manufacturing process.
3Volume of moving object
If IDC terminals are used in compact connectors, then the connector size is reduced, but the application to small diameter cables is limited
Solution Approach 1:
The patent transforms the terminal from rigid IDC type to elastic spring type with spiral contacting portions. This parameter change in material behavior and geometry enables the terminal to adapt to various small diameter cables while maintaining compact connector size, significantly improving cable diameter adaptability.
Solution Approach 2:
The spring terminals provide dynamic adaptability through elastic deformation. The spiral contacting portions can flex to accommodate different cable diameters and then recover to maintain reliable electrical connection. This dynamic characteristic enables the compact connector to work with various small diameter cables, resolving the contradiction between size and adaptability.
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 spring connector effectively connects cables with small diameters without severing them and addresses soldering difficulties, enabling reliable electrical connections in compact designs.
Implementation Method 1
the contacting portion is formed in a spiral shape so as to have a gap... each of the connecting end portions is sandwiched by the corresponding contacting portion in a four-point connection
Data Source
AI summary
A spring connector includes an insulating case and a plurality of spring terminals. The insulating case includes a plurality of cable slots spaced apart from each other. The spring terminals are disposed on the insulating case, and each of the spring terminals has a contacting portion and a tail portion. The contacting portion of each of the spring terminals is formed in a spiral shape so as to have a gap. The cables are respectively disposed in the cable slots of the insulating case, the cables are respectively arranged in the gaps of the contacting portions of the spring terminals, and each of the cables is sandwiched by the corresponding contacting portion, so that the spring terminals are electrically connected to the cables.