Terminal Block With Integrated Wire Displacement for Tool-Free IDC
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Solution Overview
Problem
Existing terminal block systems require complex mechanical assemblies or external tools to establish an insulation-displacement contact with non-stripped wire ends, complicating manufacturing and field use.
Innovation Solution
A terminal block design featuring an insulating casing, a conductive part with cooperating blades for insulation-displacement contact, and a displacement tool integrated with the casing, allowing for manual displacement of the wire end from a disconnected to a connected position without the need for additional tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rotating device is used to cut insulation and form electrical contact, then the insulation-displacement contact connection is achieved, but the mechanical assembly becomes complex
Solution Approach 1:
The patent extracts the cutting function from a complex rotating device and implements it through a simple displacement mechanism. The displacement tool moves linearly along the connection axis to push the wire end into the cooperating slot, eliminating the need for rotational motion and complex mechanical assemblies while still achieving insulation displacement and electrical contact.
Solution Approach 2:
Instead of using a rotating device to cut insulation through rotational force, the patent inverts the approach by using linear displacement to push the wire end into a pre-formed cooperating slot with cutting edges. The cutting action is achieved through the linear motion of the displacement tool rather than rotation, simplifying the mechanical assembly.
2Reliability
If an external tool is used to push the wire end from disconnected to connected position, then the connection is formed, but additional tools are required for field use
Solution Approach 1:
The patent merges the displacement tool with the terminal block by attaching it to the insulating casing through a connection element. This integration eliminates the need for separate external tools, as the displacement tool becomes part of the terminal block assembly. Users can perform the displacement action directly with the integrated tool, simplifying field use and eliminating the need to carry additional tools.
Solution Approach 2:
The terminal block becomes self-sufficient by including the displacement tool as an integrated component. The device serves itself by providing the necessary tool for wire end displacement within its own structure, eliminating dependency on external tools and making the system complete and self-contained for field operations.
3Ease of manufacture
If a displacement tool is integrated with the insulating casing, then the number of components is reduced, but the connection mechanism becomes more compact
Solution Approach 1:
The displacement tool is nested within or attached to the insulating casing structure. By integrating the displacement tool with the existing casing geometry and using the casing as part of the connection mechanism, the patent reduces the overall volume while maintaining functionality. The tool shares space with the casing structure rather than occupying separate volume.
Data Source
AI summary
A terminal block receiving non-stripped wire ends includes an insulating casing, a conductive part installed within the casing, and a displacement tool. The conductive part includes a cooperating slot defined by two cooperating blades forming an insulation-displacement contact connection of a non-stripped wire end. The cooperating blades are parallel to a connection axis of the connection part. The displacement tool displaces the non-stripped wire end in a direction of the connection axis from a disconnected position to a connected position. In the connected position, the two cooperating blades are in electrical contact with a central conducting core of the non-stripped wire end. The displacement tool is attached to the insulating casing by a connection element of the terminal block.