Two-Material IDC Housing for Flammability-Resistant Cable Connectors
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Solution Overview
Problem
Existing insulation displacement connectors fail to meet current safety standards for flammability resistance, particularly in extreme conditions such as the Nichrome Wire Test, leading to potential fire hazards.
Innovation Solution
The connector is designed with two mechanically coupled portions made of different materials, where the first portion, subjected to higher thermal stress, is made of a material with higher flammability resistance, such as polyamide with 30% glass fiber or polyphenyl sulfide, while the second portion is made of materials like polyamide or polybutylene terephthalate, ensuring differential thermal and flammability properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the entire connector is made of high-temperature-resistant material, then flammability resistance is improved, but manufacturing cost increases
Solution Approach 1:
The connector is divided into two portions with different material properties: the first portion (housing) is made of high-temperature-resistant material for flammability resistance, while the second portion (terminal) is made of conventional material for cost-effectiveness. This local differentiation allows the connector to meet safety requirements only where thermal stress is expected, rather than requiring the entire connector to be made of expensive high-temperature material.
Solution Approach 2:
The connector is segmented into two distinct portions that can be manufactured separately and then assembled. The housing (first portion) and terminal (second portion) are made from different materials and connected through mechanical engagement, allowing independent optimization of each portion's material properties based on functional requirements.
2Reliability
If the connector is made of high-temperature-resistant material, then flammability resistance is improved, but production cost increases
Solution Approach 1:
High-temperature-resistant material is applied only to the housing portion where flammability resistance is critical, while the terminal portion uses conventional, less expensive material. This localized material selection reduces the overall quantity of expensive high-temperature material required, thereby reducing production costs while maintaining necessary safety performance.
Solution Approach 2:
The material composition parameter is changed differently for different portions of the connector. The housing uses materials with high flammability resistance (such as polyamide with 30% glass fiber, polybutylene terephthalate with 30% glass fiber, or polyphenyl sulfide), while the terminal uses standard materials, optimizing the balance between safety and cost.
3Reliability
If different materials are used for different portions, then flammability resistance is improved, but device complexity increases
Solution Approach 1:
The connector is divided into two portions that are manufactured separately and then assembled through mechanical engagement. The housing includes a receiving portion and the terminal includes connection elements, with the two portions connected through standardized mechanical interfaces, allowing modular manufacturing and assembly.
Solution Approach 2:
Two portions made of different materials are merged into a single functional connector unit through mechanical engagement. The housing and terminal are connected in a way that maintains both the flammability resistance of the housing and the electrical functionality of the terminal, creating an integrated assembly with optimized material distribution.
Data Source
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AI summary
The present invention relates to an insulation displacement connector (10) for sheathed insulated cables which is configured so as to connect at least one cable to said connector (10), said connector (10) comprising a terminal configured so as to enable electrical connection between a cable and said connector (10) and a housing (11, 12) configured so as to house said terminal inside it and to isolate said terminal with respect to the exterior. In this connector (10), said housing (11, 12) comprises a first portion (11) and a second portion (12) configured so as to mechanically engage with said first portion (11), wherein said first portion (11) is made of a different material from said second portion (12).