Wire Tap Connector Structure for Stable Field Termination
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Solution Overview
Problem
Existing wire tap connectors often fail to ensure a positive electrical connection, especially in field applications, due to limited contact points or surfaces, which can be problematic in varying environments.
Innovation Solution
An electrical connector with a housing containing an electrical terminal featuring both insulation displacement and quick disconnect portions, allowing for field termination with strain relief sections to secure conductors of different gauges, ensuring stable and effective electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If insulation displacement connections are used to connect wires together, then the connector can be easily operated in field applications, but it becomes difficult to ensure a positive electrical connection
Solution Approach 1:
The electrical terminal is divided into multiple contact points (first contact point, second contact point, third contact point) instead of using a single contact point. This segmentation allows the terminal to engage with the wire at multiple locations simultaneously, providing both ease of operation through insulation displacement and reliable electrical connection through multiple engagement points.
Solution Approach 2:
The patent combines insulation displacement connection capabilities with quick disconnect functionality into a single terminal structure. The terminal integrates both the insulation displacement portion for easy field termination and the quick disconnect portion for reliable connection, merging two previously separate functions into one unified component.
2Device complexity
If a limited amount of contact points or surfaces are used, then the device complexity is reduced, but the electrical connection becomes problematic in varying environments
Solution Approach 1:
The terminal structure is segmented into multiple distinct contact points (first, second, and third contact points) that engage with different portions of the wire. This segmentation increases the number of contact surfaces without significantly increasing overall device complexity, as the contact points are integrated into a single terminal body. The multiple contact points ensure reliable electrical connection in varying environmental conditions.
3Ease of operation
If insulation displacement slots are provided at the first end of the terminal, then field termination is facilitated, but the structural complexity of the terminal increases
Solution Approach 1:
The insulation displacement slots are integrated directly into the terminal body structure, merging the insulation displacement function with the terminal's contact points and strain relief features. This integration facilitates field termination while avoiding the need for separate insulation displacement tools or additional complex components, as the slots work in conjunction with the terminal's existing structural elements.
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
The connector provides a reliable and stable electrical connection by using insulation displacement slots and quick disconnect portions, facilitating easy termination and strain relief, thus addressing the limitations of existing connectors in field applications.
Implementation Method 1
The curved resilient contact portions have arcuate sections which extend from the planar portion and tab engaging sections which extend from free ends of the arcuate sections
Implementation Method 2
The insulation displacement portion has insulation displacement slots provided at a first end of the terminal
Implementation Method 3
strain relief sections to secure conductors of different gauges, ensuring stable and effective electrical connections
Data Source
AI summary
An electrical connector which can be used to field terminate a cable. The electrical connector includes a housing having a base member and a cover member. An electrical terminal is positioned in a terminal receiving cavity of the housing. The electrical terminal includes an insulation displacement portion and a quick disconnect portion. The insulation displacement portion has insulation displacement slots provide at a first end of the terminal. The quick disconnect portion is positioned at a second end of the terminal.