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"No-crimp" connector idea
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ElectronicSupersonic:
While working on a project (one of many which most probably never be finished), I had to design an easy to assemble connector (like IDC type connectors). Here is what I came up with.

Since my goal was to design something which wouldn't require expensive crimping tools, the usual crimp style was not an option. Instead omega shaped contacts are used. Where wire is inserted in to an "eyelet" and affixed in place by the spring action of the contact. Thus special tools are not needed.

Same idea could be used for both round (3.5mm headphone jack style) and the usual rectangular connectors. Bellow are attached screenshots of both types. Note that these are only to illustrate the idea - not the actual working solutions.
Dubbie:
You should make some and see if they work.
T3sl4co1l:
Hmmm...

Heh, I can see where you're going with these.  It's nice thinking, but it's missing something.


Have you held a piece of stranded wire in your life?  How the heck are you going to coax every single strand into a just-perfectly-sized space?  (If you have a solution for that, I would honestly like to see it.  Every so often I find myself wrestling very fine strands (might be welding cable, might be litz cable) into a crimp lug.  Such a PITA when they're tight fitting!)

Even if it's solid core wire, how are you going to have adequate retention force, while also being able to push the thing in?

For the phono jack: how are you going to insert the wires, or tension the springs, while also stretching the spring over the connector body?

For the square pin connector: the square pin spreads the terminal frame apart, loosening the wire, doesn't it?

Tim
Alex Eisenhut:
For solid wire something like that is used on electrical outlets.

ElectronicSupersonic:

--- Quote ---For the square pin connector: the square pin spreads the terminal frame apart, loosening the wire, doesn't it?
--- End quote ---

The pin is held in place by the housing. Housing has a groove intended to press-fit both the wire (sleeve) and the contact. Thus contact, then inserted, is "squished" by the housing and accordingly provides retention. Since housing is tight, pin insertion shouldn't cause problems, there is simply no place to spread inside the housing.



--- Quote ---For the phono jack: how are you going to insert the wires, or tension the springs, while also stretching the spring over the connector body?
--- End quote ---

Well pre-cut wires would be inserted first (in the correct location leaving striped ends not inserted), then rings are to be mounted then strands go.


--- Quote ---Even if it's solid core wire, how are you going to have adequate retention force, while also being able to push the thing in?
--- End quote ---

Wires are to be press-fit in to the housing, thus a good amount of retention should be present. That is housing is designed to provide retention via tight fit of grooves where wires would go.
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