Surface Mount Connector for Isolating Zipcord Conductors
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing surface mount connectors fail to effectively secure and electrically isolate zipcords without damaging wire strands, require pre-treatment, and are not easily mountable on printed circuit boards (PCBs) in a single action.
Innovation Solution
A surface mount connector design featuring a pair of electrical contacts with integrally-formed piercing fingers and non-conductive tape to maintain spacing, allowing for secure, strain-relieved, and isolated connections to zipcords without pre-treatment, using a curling action for piercing and soldering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a connector pierces the insulation to make contact with internal wires, then good electrical connection is achieved, but damage to wire strands occurs
Solution Approach 1:
The connector features localized piercing elements (fingers or keyhole openings) that concentrate the piercing action to specific points on the insulation, rather than damaging the entire wire structure. This allows effective electrical contact while minimizing collateral damage to wire strands.
Solution Approach 2:
The connector uses an intermediary mechanism (piercing fingers or keyhole openings) that facilitates contact through the insulation without requiring direct forceful penetration that would damage the wire. The intermediary structure controls the piercing action to achieve connection while protecting the conductor integrity.
2Strength
If a connector provides strain relief to hold the wire securely, then mechanical strength is improved, but the complexity of the connector increases
Solution Approach 1:
The connector combines multiple functions into a single integrated structure: the piercing elements, electrical contacts, and strain relief features are merged into one unified component. This integration provides secure mechanical holding and electrical connection simultaneously without requiring separate strain relief devices, thus reducing overall complexity.
Solution Approach 2:
The connector is designed as a multi-functional element that performs piercing, electrical contact, and strain relief all in one component. This universal design eliminates the need for additional separate parts, maintaining simplicity while achieving multiple objectives.
3Ease of manufacture
If a connector is designed for surface mounting on PCB, then ease of manufacture is improved, but the ability to maintain predetermined spacing between conductors becomes difficult
Solution Approach 1:
Electrically non-conductive tape is used as an intermediary element between the connector components and the PCB surface. This tape maintains predetermined spacing between the connector and the board, enabling precise positioning during surface mounting while simplifying the manufacturing process. The tape acts as a spacing datum that ensures accurate placement without requiring complex alignment mechanisms.
4Productivity
If a connector engages two insulated conductors simultaneously, then productivity is improved, but electrical isolation between conductors becomes difficult to maintain
Solution Approach 1:
The electrical non-conductive tape extracts or removes the conductive path between the two conductors by placing an insulating barrier between them. This allows the connector to engage both conductors simultaneously for efficient termination while the extracted conductive continuity is replaced by the insulating tape, maintaining electrical isolation.
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
Enables rapid, secure, and efficient termination of zipcords on PCBs with minimal wire damage, allowing for easy surface mounting and continued wire termination, while maintaining electrical isolation and mechanical strength.
Implementation Method 1
Electrically non-conductive tape is secured to said upper surface of said spaced base portions for maintaining said contacts spaced at a set predetermined distance from each other
Implementation Method 2
said lower surface being suitable for soldering to a pad or land on a printed circuit board (PCB)
Data Source
AI summary
A surface mount connector includes a pair of electrical contacts spaced from each other a predetermined distance. Each contact includes a substantially flat base portion having upper and lower surfaces, the lower surface being suitable for soldering to a pad or land on a printed circuit board (PCB). Each contact is provided with an integrally-formed conductor-engaging portion extending from a base portion in a direction substantially normal to the base portion. Electrically non-conductive tape is secured to the upper surfaces of the spaced base portions for maintaining the contacts spaced at a set or predetermined distance from each other. The contacts each including member for physically and electrically engaging another insulated conductor so that the connector can physically and electrically engage and secure two separate insulated or clad conductors while maintaining them electrically isolated.