Insert for a modular connector

Abstract

A connector assembly comprising a housing and a plurality of inserts, each insert being adapted to receive two terminals, wherein the housing comprises an insert receiving chamber adapted to receive an insert. A method of connecting an insert of a connector assembly with a wire pair, comprising the steps of: a) providing the insert, the wire pair and a stranding machine; b) twisting the wire pair on the stranding machine; c) connecting the insert with the stranded wire pair without removing the stranded wire pair from the stranding machine; and d) after steps a) to c): mounting the insert into the housing.

Description

Technical Field

[0001] This disclosure relates to a connector assembly and a method for connecting inserts with stranded wire pairs. Specifically, this disclosure relates to a modular connector assembly having a housing including a plurality of insert receiving chambers and a plurality of sub-housings having connection means, and to a method for integrating stranded wire pairs into the assembly. Background Technology

[0002] In the field of electrical connectors, connector assemblies are commonly used to facilitate the connection of cables and terminals for a variety of applications, including telecommunications, automotive, and industrial systems. Known systems typically involve complex housing structures that accommodate multiple terminals and cables, often requiring precise alignment and secure retention to ensure reliable electrical connections. These systems often utilize complex designs, which can be challenging to assemble and maintain in environments such as automated manufacturing.

[0003] Traditional connector assemblies typically rely on fixed housing designs, which limit flexibility and adaptability. Integrating terminals and cables into these housings can be cumbersome, requiring manual intervention to ensure proper alignment and secure holding. This can lead to increased assembly time and potential errors, especially when dealing with high-density connectors that require precise positioning of multiple terminals. Furthermore, the need for manual assembly processes can increase production costs and limit scalability in high-volume manufacturing environments.

[0004] Despite significant advancements in the field of electrical connectors, there remains a need for more efficient and flexible systems to accommodate diverse terminal configurations and cable types. Current approaches often lack modularity, making it difficult to adapt to different application requirements without substantial redesign or customization. This lack of modularity also hinders the automation of assembly processes, as traditional designs may be incompatible with automated equipment or processes.

[0005] Furthermore, existing connector assemblies may not adequately address the challenges associated with maintaining secure and reliable connections in dynamic environments. Factors such as vibration, temperature fluctuations, and mechanical stress can compromise the integrity of electrical connections, leading to potential failures or performance issues. Therefore, there is a growing demand for connector systems that offer enhanced reliability and durability, particularly in demanding applications where environmental conditions can change significantly.

[0006] Therefore, one technical problem under this disclosure is to provide a connector assembly that at least partially overcomes the shortcomings of known systems. Summary of the Invention

[0007] The above objectives are achieved at least in part by the subject matter of independent claim 1. Preferred embodiments are the subject matter of the dependent claims, and those skilled in the art will find hints of other suitable aspects of this disclosure within the overall disclosure of this application.

[0008] A first aspect of this disclosure relates to a connector assembly comprising: a housing and a plurality of inserts, each insert being adapted to receive two terminals, wherein the housing includes an insert receiving chamber adapted to receive the inserts.

[0009] The connector assembly includes a housing and multiple inserts. Each insert is designed to accommodate two terminals. The housing itself contains an insert receiving chamber specifically designed to hold the insert.

[0010] The advantages of this construction include modularity, ease of assembly and disassembly, and the ability to securely accommodate multiple terminals within a single housing. This design enhances the robustness and flexibility of the connector assembly, making it suitable for a wide range of applications, including automated processes and complex wiring systems.

[0011] A further improvement that can be achieved is that the housing includes a retaining device adapted to hold the inserts in their respective receiving chambers.

[0012] This connector assembly enhances the housing's functionality by incorporating retaining devices. These retaining devices are designed to secure the inserts within their respective receiving chambers. This feature ensures that the inserts are firmly positioned within the housing's insert receiving chambers. Adding retaining devices provides a more robust and reliable connection by preventing the inserts from shifting or misaligning during use.

[0013] A further improvement that can be made is to crimp each terminal onto the cable.

[0014] This feature ensures a safe and reliable electrical connection between the terminals and the cable, improving the overall performance and durability of the connector assembly. By using a crimp connection, the assembly enhances reliability while minimizing the risk of electrical contacts loosening or failing over time.

[0015] This embodiment can be further improved when the cable is part of a stranded pair cable, and preferably, each insert is adapted to receive exactly two terminals.

[0016] This implementation introduces the feature that the cable is part of a twisted-pair cable, which can improve signal integrity and reduce electromagnetic interference. Furthermore, each insert is preferably adapted to receive exactly two terminals. This new feature ensures that the insert is specifically designed to accommodate two terminals, which aligns with the structure of the twisted-pair cable, thereby facilitating proper connection and organization of the terminals within the connector assembly.

[0017] A further achievable improvement is that at least one insert includes: a rear grille disposed on the rear side of the insert, the grille having a plurality of feedthrough openings suitable for receiving electrical contacts; a sealing insert mountable to the rear grille, preferably made of an elastomeric material, wherein the sealing insert has feedthrough openings for receiving electrical contacts; and an elongated insert module mountable to the sealing insert, clamping the sealing insert between the rear grille and the elongated insert module, the module including at least two cavities suitable for receiving electrical contacts.

[0018] This implementation introduces several specific communication mechanisms between components within the connector assembly. A rear grille, located behind the insert, has multiple feedthrough openings designed to receive electrical contacts. This grille serves as a base element for subsequent components. A sealing insert, preferably made of an elastomeric material, is mounted to the rear grille and includes feedthrough openings for receiving electrical contacts. This insert provides a sealing function. An elongated insert module can then be mounted to the sealing insert, effectively clamping the sealing insert between itself and the rear grille. This module contains at least two cavities designed to receive electrical contacts, facilitating secure placement and alignment of these contacts within the assembly. Introducing these features in this implementation enhances the structural integrity and environmental protection of the assembly while ensuring precise alignment and secure placement of the electrical contacts, thereby improving the overall reliability and performance of the connector assembly. Those skilled in the art will understand that the rear side of the insert is the rear side relative to the insertion direction. Electrical contacts should be understood as terminals, cables, etc.

[0019] A further achievable improvement is that the insert has a substantially flat rectangular shape with a length l, a height h, and a width w in the insertion direction, wherein the ratio of l / h and / or l / w is at least 7, preferably at least 9, more preferably 11, and most preferably 13.

[0020] This implementation specifies that the insert has a generally flat rectangular shape with defined dimensions, including length, height, and width in the insertion direction. A new feature introduces a length-to-height and / or length-to-width ratio, which can be at least 7, preferably at least 9, more preferably 11, and most preferably 13. This feature provides the insert with a specific geometric proportion, which can improve the stability, alignment, or ease of use of the insert when inserted into the housing receiving chamber.

[0021] A further possible improvement is that each insert has two channels extending from one end of the insert along the insertion direction to the opposite end for receiving electrical contact terminals.

[0022] This mechanism ensures that the structure of each insert can accommodate two terminals. Communication between components is facilitated by guiding the terminals to their designated locations via channels. This feature enhances the functionality of the connector assembly and facilitates automated assembly processes by ensuring proper terminal positioning and secure retention within the insert.

[0023] A further improvement that can be achieved is that at least one insert has a T-shape, and the encoding device and the fixing device are arranged in the crossbar of the T-shape.

[0024] This geometry facilitates the integration of additional components, such as coding and securing devices, strategically positioned within the T-shaped crossbar. The coding ensures proper alignment or orientation of the insert within the housing. Simultaneously, the securing devices are designed to hold the insert firmly within the housing. The introduction of the T-shaped insert with integrated coding and securing devices represents an improvement in the fundamental structure of the connector assembly, resulting in a more robust and correctly oriented connection interface.

[0025] In a further implementation of the connector assembly, the housing includes a TPA (Terminal Position Assurance) device.

[0026] This feature enhances the reliability and robustness of the connector assembly by providing an additional layer of fixation for the terminals and / or inserts, ensuring their secure positioning within the housing. Communication between components involves the housing containing these TPA devices, which interact with the inserts to maintain their correct position. Including the TPA devices within the housing provides a robust solution to common problems associated with terminal and / or insert misalignment or displacement.

[0027] In a further embodiment of the connector assembly, each insert includes a TPA device.

[0028] TPA devices can provide a mechanism to ensure that the insert and terminals are properly positioned and secured within the housing. This feature improves the reliability and stability of the electrical connection by preventing the insert from retracting or loosening during operation.

[0029] A further achievable improvement is that the housing comprises at least two paired sub-housings, each sub-housing including a sub-housing connection device adapted to resemble two pieces of a piece. Figure 1 The samples are assembled together to connect the two sub-shells to each other to form a shell, wherein the sub-shell connecting device preferably includes a dovetail joint, and more preferably includes a sliding dovetail joint.

[0030] This modular housing design facilitates assembly and disassembly, making it advantageous for applications requiring flexible construction or rapid maintenance. The use of dovetail joints enhances mechanical stability, ensures robust interlocking, and allows for smooth sliding engagement. This design improves structural integrity, further prevents accidental separation, and provides a compact and robust housing for electrical connections.

[0031] A further possible improvement is that the sub-housing connection includes a locking device adapted to lock the sub-housing in its final position.

[0032] This type of sub-housing connection device refers to a component that facilitates the connection of sub-housings within a connector assembly. The locking mechanism is adapted to secure the sub-housings in their final position, ensuring they remain fixed and stable after connection. This feature is advantageous because it prevents the sub-housings from shifting or misaligning, which is crucial for maintaining the integrity and functionality of modular connectors.

[0033] A further possible improvement is that the insert includes a polarization device (positioning device) adapted to allow only one insertion orientation into the receiving chamber, wherein the polarization device is preferably a polarization rib (positioning rib) that extends axially in the mating direction of the insert.

[0034] This embodiment introduces the concept of an insert including a polarization device designed to ensure that the insert can only be inserted into the receiving chamber in a specific orientation. This feature enhances the functionality of the connector assembly by preventing incorrect insertion, which could lead to an incorrect connection or potential damage to the components. The polarization device is preferably a polarization rib, which is an axially extending feature in the mating direction of the insert. This rib ensures proper alignment of the insert with the receiving chamber, thereby facilitating a strong and accurate connection.

[0035] Another aspect of this disclosure is a method of connecting an insert to a connector assembly according to any embodiment using stranded wire pairs, comprising the steps of: a) providing an insert, wire pairs, and a stranding machine; b) twisting the wire pairs on the stranding machine; c) connecting the insert to the stranded wire pairs without removing the stranded wire pairs from the stranding machine; and d) after steps a) to c) installing the insert into a housing.

[0036] This method optimizes the manufacturing process by holding the wire pairs on the stranding machine during insert connection. The advantage of this method is that it maintains the crimped position of the stranded wire pairs' terminals, preventing loss of position when the machine fixtures open. This ensures a reliable connection and facilitates automation of the assembly process. Those skilled in the art will understand that the method of connecting inserts with stranded wire pairs can be implemented in various ways, depending on production requirements. In one case, the stranded wire pairs can be inserted into the insert before assembly, and then the insert can be installed into the connector module. In another case, each single straight wire terminated with a crimped terminal can be first assembled into the insert, and then the insert and wires can be introduced together into the stranding machine to form stranded pairs.

[0037] The method can be further improved when the stranding machine includes a clamping device and the stranded wire pairs engage with the clamping device at the beginning, during and / or end of step c).

[0038] In this method, the clamping device engages with the stranded wire pairs at various stages of the connection process, particularly at the beginning, middle, and / or end of the step where the insert is connected to the stranded wire pairs. The addition of the clamping device provides a mechanism to firmly hold the stranded wire pairs in place, ensuring stability and accuracy during the connection process. This feature enhances the method by potentially reducing the risk of wire pair misalignment or movement. By holding the wire pairs in a fixed position, the clamping device helps to connect the insert to the stranded wire pairs more efficiently and reliably. Attached Figure Description

[0039] Preferred embodiments of the present disclosure are disclosed below with reference to the accompanying drawings.

[0040] Figure 1 An embodiment of a connector assembly having a housing and an insert is shown.

[0041] Figure 2 An exploded view of the insert with a rear grille, sealing insert, and elongated insert module is shown.

[0042] Figure 3 Another embodiment of a connector assembly having a housing and an insert inserted into the housing is shown.

[0043] Figure 4a This illustrates an embodiment of a sub-housing having a connecting device and a locking device.

[0044] Figure 4b Another embodiment of the sub-housing with a dovetail joint and connecting device is shown.

[0045] Figure 5a This illustrates the assembly of inserts using stranded wire pairs on a stranding machine.

[0046] Figure 5b This shows an insert assembled with stranded wire pairs on a stranding machine. Detailed Implementation

[0047] The present disclosure will be described in detail in the following sections, with reference to the accompanying drawings for clarity. These descriptions are illustrative only and are not intended to limit the scope of the disclosure. Throughout the drawings and text, the same reference numerals denote the same parts. These illustrations may not reflect actual dimensions or scale; for better understanding and visual convenience, descriptions of dimensions, scales, and components may be added.

[0048] Figure 1 A connector assembly 1000 is shown, comprising a housing 1100 and a plurality of (six) inserts 100. The housing 1100 includes an insert receiving chamber 1110 adapted to receive an insert 100. The housing 1100 is depicted as a generally rectangular block having a plurality of (six in the illustrated example) chambers 1110 arranged in a grid pattern on one side. Each chamber 1110 is designed to accommodate one insert 100. The housing 1100 also has a retaining device 1200, which is a mechanism designed to securely hold the inserts 100 within their respective chambers 1110. Furthermore, the housing 1100 includes a TPA device 1120, a secondary locking mechanism, to ensure that the inserts (preferably also including terminals accommodated within the inserts) are fully in place and locked in place.

[0049] The insert 100 shown is a generally flat rectangular component with a length l, a height h, and a width w, wherein the ratio of l / w is at least 7. The insert 100 has a T-shape, with its encoding device 140 and fixing device 150 arranged in the crossbar of the T-shape. The insert 100 also includes a channel 130 extending along the insertion direction from one end of the insert to the opposite end, designed to receive electrical contact terminals. The insert 100 is adapted to receive exactly two terminals, such as part of a twisted pair cable.

[0050] Figure 2 An exploded view of the insert 100 is shown, detailing its components. The insert 100 includes a rear grille 110, a sealing insert 120, and an elongated insert module 130. The rear grille 110 is disposed at the rear of the insert 100 and has a plurality of (two in the illustrated embodiment) feedthrough openings 112 adapted to receive electrical contacts. The sealing insert 120, preferably made of an elastomeric material, is mountable to the rear grille 110 and has a plurality of (two in the illustrated embodiment) feedthrough openings 122 for receiving electrical contacts. The elongated insert module 130 is mountable to the sealing insert 120, clamping the sealing insert 20 between the rear grille 110 and the elongated insert module 130. The elongated insert module 130 includes two cavities 132 adapted to receive electrical contacts.

[0051] The feed holes 112 in the rear grille 110 are small, evenly spaced holes aligned with the feed holes 122 in the sealing insert 120. The sealing insert 120 fits snugly against the rear grille 110. The elongated insert module 130 is a rectangular component with two elongated cavities 132 designed to accommodate electrical contacts. The cavities 132 extend longitudinally along the length of the insert module 130, providing a fixed channel for the electrical contacts.

[0052] The housing 1100 and insert 100 are designed to work together to provide a robust and reliable connection for the electrical contacts. The insert receiving chamber 1110 and retaining device 1200 of the housing 1100 ensure that the insert 100 is securely held in place, while the TPA device 1120 provides an additional layer of fixation. The rear grille 110, sealing insert 120, and elongated insert module 130 of the insert 100 work together to protect and organize the electrical contacts, ensuring a reliable connection. The T-shaped design of the insert 100, along with the coding device 140 and fixing device 150, ensures that the insert 100 can only be inserted in the correct orientation, preventing incorrect connection.

[0053] Figure 3 A connector assembly 2000 with a housing 2100 and an insert 200 is shown. A retaining device 2200 is located on the top surface of the housing 2100. It consists of a series of parallel hooks 2220 that extend longitudinally along the surface along the mating direction of the insert. These hooks are evenly spaced to retain the inserts in their respective receiving chambers. The hooks are aligned in the insertion direction, firmly grip the inserts, and prevent them from moving or dislodging after insertion into the housing. The insert includes a polarization device in the form of polarization ribs 240 extending along the insertion direction, and also includes channels 230 for inserting terminals.

[0054] Figure 4a and Figure 4bSub-housings 2300 and 2400 are shown, which can form part of housing 2100. Each sub-housing 2300, 2400 includes sub-housing connecting means 2310, 2410, which allow the sub-housings to be assembled like two pieces of a jigsaw puzzle. Sub-housing connecting means 2310, 2410 include dovetail joints 2312, 2412, which are preferably sliding dovetail joints. In addition, sub-housing connecting means 2310, 2410 include a locking means 2314 for locking the sub-housings 2300, 2400 in their final position, ensuring a secure and stable connection between the sub-housings. Element 2314 is a locking mechanism integrated into the side of sub-housing 2300. It is characterized by a protruding structure extending outward from the side surface of the sub-housing. The protrusion has a rectangular shape with flat top and bottom surfaces, and it includes a small notch or recess designed to engage with a corresponding snap-fit ​​feature on another component to secure the sub-housing in place. The overall shape of element 2314 ensures that it can effectively lock the sub-housing together during assembly.

[0055] Figure 5A illustrates the connector assembly during the connection of the stranded wire pair to the insert. The stranded wire pair 1 is shown entering the stranding machine 2. The stranding machine 2 is designed to twist the individual wires 12 and 22 of the stranded wire pair 1. The individual wires 12 and 22 extend toward the inserts 500 and 500' arranged on the stranding machine 2. The clamping device 3, part of the stranding machine 2, is a clamp-like structure that holds the wires in place, ensuring stability during the connection process. The clamping device 3 secures the stranded wire pair 1 and maintains its position as the wires 12 and 22 approach the inserts 500 and 500'. The insert 500 is depicted as a rectangular component with a generally flat shape, adapted to receive terminals 10 and 20 crimped onto the ends of the wires 12 and 22. The terminals 10 and 20 are shown as elongated elements extending from the ends of the wires 12 and 22, respectively. The insert 500' has a similar structure and is located directly behind the insert 500 as a series arrangement for subsequent connections. Thus, the stranded wire pair 1 is held in place by the clamping device 3, and the insert 500 can be fitted with terminals 10 and 20.

[0056] Figure 5B illustrates the setup of Figure 5A, where terminals 10 and 20 of the stranded wire pair 1 mate with the insert 500 (inserted into the insert 500). When the insert 500 is mounted onto terminals 10 and 20, the stranded wire pair 1 is held in place by the clamping device 3. Figures 5A and 5B together depict the process of connecting the stranded wire pair 1 to the insert 500 using the stranding machine 2 and the clamping device 3.

[0057] List of reference numerals

[0058] 1: Twisted pair

[0059] 2: Twisting machine

[0060] 3: Clamping equipment

[0061] 10: Terminal

[0062] 12: Cables

[0063] 20: Terminal

[0064] 22: Cables

[0065] 100: Embedded component

[0066] 110: Rear grille

[0067] 112: Feedthrough orifice

[0068] 120: Sealing insert

[0069] 122: Feedthrough hole

[0070] 130: Slender Insertion Module / Channel

[0071] 132: A cavity suitable for receiving electrical contacts.

[0072] 140: Encoding device

[0073] 150: Fixture

[0074] 200: Embedded component

[0075] 230: Channel

[0076] 240: Polarization device

[0077] 500: Embedded component

[0078] 500': Embedded component

[0079] 1000: Connector assembly

[0080] 1100: Housing

[0081] 1110: Embedded Component Receiving Chamber

[0082] 1120: TPA device

[0083] 1200: Holding device

[0084] 2100: Housing

[0085] 2110: Embedded Component Receiving Chamber

[0086] 2200: Holding device

[0087] 2220: Hook

[0088] 2000: Connector assembly

[0089] 2300: Subshell

[0090] 2310: Sub-shell connecting device

[0091] 2312: Swallowtail-shaped joint

[0092] 2314: Locking device

[0093] 2400: Subshell

[0094] 2410: Sub-shell connecting device

[0095] 2412: Swallowtail-shaped joint

Claims

1. A connector assembly (1000, 2000), comprising: The housing (1100, 2100) and a plurality of inserts (100, 200, 500, 500') are provided, each insert (100, 200, 500, 500') being adapted to receive two terminals (10, 20), wherein the housing (1100, 2100) includes an insert receiving chamber (1110, 2110) adapted to receive the inserts (100, 200, 500, 500').

2. The connector assembly (1000, 2000) according to claim 1, characterized in that, The housing includes retaining devices (1200, 2200) adapted to hold the inserts (100, 200, 500, 500') within their respective receiving chambers (1110, 2110).

3. The connector assembly (1000, 2000) according to any one of the preceding claims, characterized in that, Each terminal (10, 20) is crimped onto the cable (12, 22).

4. The connector assembly (1000, 2000) according to the preceding claims, characterized in that, The cables (12, 22) are part of a twisted pair cable (1), and preferably, each insert (100, 200, 500, 500') is adapted to receive exactly two terminals (10, 20).

5. The connector assembly (1000, 2000) according to any one of the preceding claims, characterized in that, At least one insert (100, 200, 500, 500') includes: A rear grille (110) is disposed on the rear side of the inserts (100, 200, 500, 500'), the grille (110) having a plurality of feed through holes (112) adapted to receive electrical contacts. A sealing insert (120) is mountable to the rear grille (110) and is preferably made of an elastomeric material, wherein the sealing insert (120) has a feed hole (122) for receiving an electrical contact. An elongated insert module (130) is mounted to the sealing insert (120) and clamps the sealing insert (120) between the rear grille (110) and the elongated insert module (130). The module includes at least two cavities (132) adapted to receive electrical contacts.

6. The connector assembly (1000, 2000) according to any one of the preceding claims, characterized in that, The inserts (100, 200, 500, 500') have a generally flat rectangular shape and have a length l, a height h, and a width w in the insertion direction, wherein the ratio of l / h and / or l / w is at least 7, preferably at least 9, more preferably 11, and most preferably 13.

7. The connector assembly (1000, 2000) according to any one of the preceding claims, characterized in that, Each insert (100, 200, 500, 500') has exactly two channels (130, 230) extending from one end of the insert (100, 200, 500, 500') in the insertion direction to the opposite end for receiving electrical contact terminals (10, 20).

8. The connector assembly (1000, 2000) according to any one of the preceding claims, characterized in that, At least one insert (100, 200, 500, 500') has a T-shape, and the encoding device (140) and the fixing device (150) are arranged in the crossbar of the T-shape.

9. The connector assembly (1000, 2000) according to any one of the preceding claims, characterized in that, The housing (1100) includes a terminal position guarantee device (1120).

10. The connector assembly (1000, 2000) according to any one of the preceding claims, characterized in that, Each insert (100, 200, 500, 500') includes a terminal position guarantee device (112).

11. The connector assembly (1000, 2000) according to any one of the preceding claims, characterized in that, The housing includes at least two paired sub-housings (2300, 2400), each sub-housing including a sub-housing connecting device (2310, 2410) adapted to be assembled together like two puzzle pieces to connect the two sub-housings (2300, 2400) to each other to form the housing. The sub-shell connecting device preferably includes a dovetail-shaped joint (2312, 2412), and more preferably includes a sliding dovetail-shaped joint.

12. The connector assembly (1000, 2000) according to any one of the preceding claims, characterized in that, The sub-shell connecting devices (2310, 2410) include a locking device (2314) adapted to lock the sub-shells (2300, 2400) in their final positions.

13. The connector assembly (1000, 2000) according to any one of the preceding claims, characterized in that, The inserts (100, 200, 500, 500') include a polarization device (240) adapted to allow only one insertion orientation into the receiving chamber (1110, 2110), wherein the polarization device (240) is preferably a polarization rib that extends axially in the mating direction of the inserts (100, 200, 500, 500').

14. A method of connecting an insert (100, 200) to a connector assembly (1000, 2000) according to any one of claims 1 to 13 using a stranded wire pair (1), comprising the steps of: a) Provide the inserts (100, 200, 500, 500'), wire pairs (1), and stranding machine (2); b) Twist the wire pair (1) on the stranding machine (2); c) Connecting the inserts (100, 200, 500, 500') to the stranded wire pair (1) without removing the wire pair (1) from the stranding machine (2); and d) After steps a) to c): Install the inserts (100, 200, 500, 500') into the housing (1100, 2100).

15. The method for connecting the inserts (100, 200, 500, 500') according to claim 14, characterized in that, The stranding machine (2) includes a clamping device (3), and the stranded wire pair (1) engages with the clamping device (3) at the beginning, during and / or end of step c).

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