The development of our IDC thin wire terminal connection system started in 2009.
During 2010 and 2011, the first samples were produced and the automatic winding and assembling process fine-tuned. In the meantime, electrical tests proved the validity of our IDC connection solution.
The system is patented.
Late 2015, TSG Omega s.r.l. opened its activity in Italy, for European market Customers.
The IDC Connection
The IDC terminal connection (Insulation-Displacement Connection) is a well-known technology with a wide range of applications, from automotive to household appliances to electrical devices and, in general, wherever is required a connection between magnet wire and a terminal.
This system provides a cleaner solution to a problem which is commonly solved with the use of resistance welding and or soldering techniques, such as brazing, arc welding, laser welding, induction soldering and similar. All these technologies require, however, a thermic process that deteriorates the magnet wire's electrical and mechanical properties.
The use of IDC terminals realizes the connection without soldering. Standard IDC connectors, on the other hand, cut the magnet wire and can reduce its section consistently. Consequently, IDC connection still finds little application in the automotive industry, where it fails to meet specifications with vibration and temperature tests. Average IDC terminals available on the market are suitable for applications with magnet wire sizes greater than ø 0.14 mm / 35 AWG.
TSG Omega IDC connection solution is set to overcome the limitations of all previous solutions and, at the same time, provide significant advantages in terms of quality, sustainability and inexpensiveness of the final product.
The TSG Omega Solution
Like all standard IDC applications, the magnet wire is first positioned inside a plastic pocket. Next, the terminal is inserted inside the pocket. The electrical connection between the magnet wire and the terminal is purely mechanical – no heat is involved in the process.
Where is the difference? TSG Omega terminals do not work on a single portion of the magnet wire; instead, the magnet wire is wound on a plastic pin built in the pocket and, once the terminal is inserted into the pocket, contact happens in multiple points. This guarantees a huge contact area.
At the beginning of the coil winding process, the magnet wire is wrapped from top to bottom on the pin of the entrance pocket. Next, the wire is wound on the coil body. Then, the wire is wrapped from bottom to top on the pin of the exit pocket. The pin secures the connection with the TSG Omega terminal: during the insertion, the magnet wire positioned on the upper portion of the pin slightly expands the terminal beams and helps reduce the force it exerts on the lower portion of the wire.
The peculiarity of this technique is that it applies seamlessly to thin wire sizes, which commonly prevent the application of ordinary IDC solutions.
The TSG Omega IDC terminal’s unique design can accommodate, with a same pocket dimension, a wide range of magnet wire sizes.
Designed to cover a range ø 0.030 – 0.51 mm / 48 – 24 AWG, the terminal is particularly suitable, but not limited, for thin wire terminations.
Magnet wire ø 0.030 / 48 AWG
Magnet wire ø 0.045 mm / 45 AWG
Magnet wire ø 0.14 mm / 35 AWG
Aluminium magnet wire ø 0.56 mm / 23 AWG
TSG Omega IDC connectors allow the possibility of overmolding or resining after termination.
Overmolding is commonly required, especially in automotive applications, which may prevent the use of ordinary IDC solutions.
Industrial bobbin with LW terminal connection
NEW MINI terminal
- Terminates all copper magnet wire film insulations
- The terminal unique design allows the application with a wide range of magnet wire sizes with a single terminal
- IDC magnet wire connector ø ≥ 0.080 mm / # 40 AWG
- Mechanical insert connection without soldering/welding
- Eliminates need to skeining process for thin MW
- High-speed automatic coil winding machine terminations provide uniform reliability at the lowest cost
- Clean metal-to-metal interface produces a stable, gas-tight electrical connection, free of oxides and other contaminants
Versatility. One article, that adapts to a wide range of applications.
The TSG Omega terminal is fully customizable based on the requirements and necessities of the particular application.
Quality contact. Compared to other IDC or non-mechanical solutions, the TSG Omega connection increases the contact area between the magnet wire and the terminal. This greatly improves the performance of the contact, especially with the thinnest wire sizes.
The terminal has a proven resistance to vibrations and thermal shocks, and can terminate all types of magnet wire film insulation.
Automated termination. As typical with poke-in connectors, the TSG Omega terminal allows for a fast and reliable termination. The insertion process is more accurate and it lends itself to being automated. Terminals are available in strip form for a fully automated insertion, which can be possibly completed with overmolding or resining.
Environmental sustainability. Termination using the IDC connector is purely mechanical and does not involve any soldering/welding process. There is no emission of substances related to soldering, welding or enamel removal. The result is a clean metal-to-metal interface, that realizes a stable, gas tight electrical connection, free of oxides and other contaminants. No waste or dross is produced. Products using our solutions will be in full compliance with European and international standards; in one word, green.
Cost reduction. The IDC connection eliminates the need for any soldering/welding machine, together with the related complexities and maintenance costs. It also eliminates the need for skeining devices (where required) for processing the wire before the connection. In addition, TSG Omega solutions can be applied to standard enameled magnet wires (e.g. A200, A220), no special solderable enamels are required. All this will reduce investment efforts, as well as contain the cost of the final product.