Comprehensive Optimization Of Some Dimensions Of Insulation Piercing Connectors

Cable management and spatial reuse

Challenge: Cable direction conflicts with piercing electrical connectors layout.

Solution:

Cable integration: Use flat flexible cable (FFC) or flexible printed circuit (FPC) to replace traditional round wires, reduce cable diameter and bending radius.

Spatial reuse technology: Reduce the need for independent wiring by sharing ground plane or power layer.

Case: Wearable devices use 0.3mm thick piercing wire connector to achieve 12-way signal transmission in a 3mm×3mm area while keeping the device thin and light.

Blind plug and self-locking structure

Challenge: Difficult operation in a small space, and the assembly process needs to be simplified.

Solution:

Blind plug design: Use conical guide columns or magnetic positioning to achieve quick plugging and unplugging without visual alignment.

Self-locking mechanism: Such as push-pull lock or elastic buckle, reduce tool dependence and improve assembly efficiency.

Case: Push-pull self-locking wire piercing connector is used inside medical equipment to complete one-hand plugging and unplugging in a 5mm gap, reducing the difficulty of surgical robot maintenance.