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"No-crimp" connector idea

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ElectronicSupersonic:

--- Quote from: T3sl4co1l on September 16, 2019, 07:22:20 am ---A slitted/opened figure-eight shape is probably practical, being an extrusion of the IDC connector spring-and-knife structure.  Or put another way, take what you've drawn but open the metal (opposite the open side) into another loop, to grant more spring (compliance range).  Vary material thickness to get required clamping force.  Possibly it could be used on two or three different wire gauges, rather than exactly one size (stranded or solid only).
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That's a very good idea! Thanks!

Yet another approach would be to make the omega shape more 0 like. Plus add some inward pointed leafs to provide better contact and prevent strands from being pulled out (wire should be oriented accordingly). Like so...


Simon:
But this is still all relying on moderate friction?

ebastler:

--- Quote from: ElectronicSupersonic on September 16, 2019, 08:59:55 am ---Yet another approach would be to make the omega shape more 0 like. Plus add some inward pointed leafs to provide better contact and prevent strands from being pulled out (wire should be oriented accordingly). Like so...

--- End quote ---

The inward-pointed leaf is moving this closer to an IDC connector -- it provides a small clamping area with high local pressure (force per area) for good contact, ideally gas-tight. Now you will need a tool to squeeze the wire in (or worse, multiple wires in one go).

But then, why do you need the narrower opening of the Omega shape? If that is needed to stop the wire from slipping out of the eyelet, then you are obviously not holding it tight enough for good contact. So omit the narrow opening, and shape your contact as an steep "groove" with two parallel side walls. That will also accommodate stranded wire bundles of slightly varying thickness, which will fill the groove to varying height, while always being squeezed tightly in the lateral direction.

Oh, now you have reinvented the IDC contact geometry.  ;)

Simon:
Of course contacts need to be manufactured and that will not be cheap. With the cheap connectors you will find a plastic housing is £0.05 but the pins are £0.30 each! It's the metal parts that cost the money.

ElectronicSupersonic:

--- Quote from: Simon on September 16, 2019, 09:01:33 am ---But this is still all relying on moderate friction?

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To a degree. It's more "the bite" that would provide retention in this instance.


--- Quote from: Simon on September 16, 2019, 10:39:29 am ---Of course contacts need to be manufactured and that will not be cheap. With the cheap connectors you will find a plastic housing is £0.05 but the pins are £0.30 each! It's the metal parts that cost the money.

--- End quote ---
True. The price would depend on quantities (i.e. how mass of a production it would be) and many over factors.


--- Quote from: ebastler on September 16, 2019, 10:33:04 am ---But then, why do you need the narrower opening of the Omega shape? If that is needed to stop the wire from slipping out of the eyelet, then you are obviously not holding it tight enough for good contact. So omit the narrow opening, and shape your contact as an steep "groove" with two parallel side walls. That will also accommodate stranded wire bundles of slightly varying thickness, which will fill the groove to varying height, while always being squeezed tightly in the lateral direction.
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The "bottle neck" is there for several reasons. One is to assist assembly — while inserting the conductor in to the contact, it spreads the thing apart (slightly) thus guiding it through.

Another function would be to affix it in the housing with dedicated protrusions. Plus it can serve as a spring to provide more pressure (provided the right shape of the contact and the housing).


--- Quote from: ebastler on September 16, 2019, 10:33:04 am ---Oh, now you have reinvented the IDC contact geometry.  ;)

--- End quote ---
To an extent. IDC (as I understand it) solves two issues at once 1) No need to stripe the wire — thus no special tools required 2) No crimping needed (just a press-fit action) — thus again no special tools required. In IDC it's accomplished via blade like geometry that both cuts through the insulation and "bites in" in to the core.

With the contacts in question only the second one is true since a wire does need to be striped. Plus there is a larger area that comes in contact with the core (albeit a secondary contact).

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