Terminal Slot and Tool Interface for Large-Conductor PCB Connections
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Solution Overview
Problem
Existing insulation displacement connections (IDCs) face challenges in connecting electrical conductors of larger cross-sections, which can apply undesirably high forces, potentially damaging printed circuit boards and requiring complex adaptations for different conductor types.
Innovation Solution
A terminal design with groove-shaped cutouts on opposite side wall sections for tool reception, combined with a tool featuring a guide frame and slide unit, allows for a form-fitting connection that minimizes mechanical loads on circuit boards and adapts to various conductor sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional insulation displacement connections are used for electrical conductors of larger cross-section, then the connection can be established, but correspondingly higher forces must be applied which can damage the terminal or circuit board
Solution Approach 1:
The terminal is divided into a housing and a clamping element that can move independently relative to the housing. The clamping element is further segmented into a clamping portion and a bearing portion, allowing the clamping force to be applied locally to the conductor while the bearing portion absorbs and distributes the mechanical load to the housing, preventing damage to the circuit board.
Solution Approach 2:
The clamping element acts as an intermediary between the tool and the conductor. It receives the connection force from the tool through the bearing portion and transfers it to the conductor through the clamping portion, while the resilient design of the clamping element absorbs excess forces and protects the terminal housing and circuit board from damage.
2Productivity
If conventional insulation displacement connectors are used, then connections can be made, but the insulation of the electrical conductor must be severed which adds complexity
Solution Approach 1:
The terminal is designed to accommodate multiple conductor types (solid, stranded, enameled wire) and cross-sections (0.01 mm² to 6 mm²) without requiring different terminal designs or insulation cutting. The open terminal slot and resilient clamping element allow the terminal to adapt to various conductor configurations, making the insulation cutting step unnecessary.
3Productivity
If conventional terminals are used, then connections can be established, but the terminal must be adapted to and selected for each specific conductor type and insulating material
Solution Approach 1:
The terminal design with an open terminal slot and resilient clamping element provides universal compatibility across different conductor types (solid, stranded, enameled wire) and cross-sections (0.01 mm² to 6 mm²). The clamping element's resilient design allows it to adapt to various conductor diameters and insulation materials, eliminating the need for multiple specialized terminal designs.
Solution Approach 2:
The clamping element is designed with resilient properties that allow it to dynamically adapt to different conductor sizes and types. The element can deform elastically to accommodate varying conductor diameters and then exert appropriate clamping force, providing a single terminal design that works universally across different conductor specifications.
Data Source
AI summary
A terminal for connecting an electrical conductor with a sheath includes: a first side wall section and a second side wall section, which are arranged opposite one another and/or spaced apart from one another. The first side wall section has a first terminal element and the second side wall section has a second terminal element which are assigned to one another to form a terminal slot and are arranged at least sectionally at a distance from one another. The first side wall section has a cutout in its end face, at which the electrical conductor is guided on the terminal slot for connection to the terminal, which cutout is groove-shaped to at least sectionally receive in the cutout a tool placed on the terminal in a form-fitting manner.