Surface Mount Insulation Displacement Connector With Vacuum Pickup
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Solution Overview
Problem
Existing insulation displacement connectors (IDCs) are not suitable for surface mounting on printed circuit boards (PCBs) due to size, weight, heat resistance, and compatibility with common soldering techniques, and lack a suitable flat surface for vacuum nozzle pickup, making them unsuitable for automated pick-and-place machines.
Innovation Solution
A compact, lightweight IDC assembly with a flat surface for vacuum nozzle attachment, featuring slideable piercing blades that pierce insulated conductors upon downward pressure, allowing for quick and reliable connection with minimal labor and compatibility with surface mounting technology and soldering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional IDC designs are used, then wire termination speed is improved, but the connector size and weight are too large for surface mounting
Solution Approach 1:
The connector is divided into separate components: a housing that mounts to the PCB and contains wire channels, and separate piercing contacts that insert into the housing. This segmentation allows the housing to be lightweight for surface mounting while the contacts provide the wire termination function, resolving the contradiction between speed and weight.
Solution Approach 2:
The piercing contacts are designed to insert vertically into the housing from the top surface, while the housing mounts horizontally to the PCB. This dimensional arrangement allows the connector to maintain compact footprint for surface mounting while preserving the vertical piercing action needed for quick wire termination.
2Productivity
If traditional IDC designs are used, then wire termination efficiency is improved, but heat resistance and soldering compatibility deteriorate
Solution Approach 1:
The housing is made of heat-resistant material suitable for soldering processes, while the piercing contacts are made of conductive metal for electrical connection. This local quality differentiation ensures the soldering areas can withstand heat treatment while the wire termination function is provided by the metal contacts, resolving the heat resistance issue.
3Productivity
If traditional IDC designs are used, then wire termination speed is improved, but compatibility with vacuum pickup for automated mounting deteriorates
Solution Approach 1:
The housing is designed as a separate component with a flat top surface that can be picked up by vacuum nozzles. This segmentation allows the housing to be handled by automated pick-and-place machines while containing the wire channels and contacts, resolving the contradiction between termination speed and automated mounting compatibility.
Solution Approach 2:
The flat top surface of the housing serves dual functions: it provides a mounting surface for vacuum pickup by automated machines, and also serves as the structural base for the wire channels and contacts. This multi-functionality resolves the contradiction between termination efficiency and ease of automated operation.
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 efficient, automated surface mounting of fine wire conductors with reduced labor, ensuring reliable connections and heat resistance while being compatible with common soldering techniques and automated pick-and-place machines.
Implementation Method 1
a mounting end that extends from the main body. The mounting end of the contact is attached to a printed circuit board. An insulated conductor, such as a wire, cable and/or ribbon, can be quickly and easily inserted in the channel without being pierced by the piercing end of the contact. When a user pushes down on the IDC, the contact slides into the channel and pierces the insulated conductor.
Data Source
AI summary
There is provided an insulation displacement connector (IDC) assembly having a main body defining at least one wire channel. The main body has at least one substantially flat surface to which a vacuum nozzle can be affixed in order to pickup the IDC assembly. The IDC assembly has at least one contact member with a piercing, cutting or slicing end that is slideably disposed within the main body, and a mounting end that extends from the main body. The mounting end of the contact is attached to a printed circuit board. An insulated conductor, such as wire, cable, and/or ribbon, can be quickly and easily inserted in the channel without being pierced by the piercing end of the contact. When a user pushes down on the IDC, the contact slides into the channel and pierces the insulated conductor.