Split module for modular connector assembly

Abstract

A split module for a modular connector assembly, comprising: a module housing; and at least one terminal cavity adapted to accommodate an electrical terminal and formed along a longitudinal axis of the module housing; wherein the module housing comprises a fastening element for fastening the module housing to a second module housing of a second split module. A hybrid module comprising at least two such split modules, wherein the split modules are connected to each other by means of their fastening elements. A modular connector assembly for automotive applications, comprising: a connector housing having at least one module slot; wherein the at least one module slot accommodates such a hybrid module. A method of manufacturing such a modular connector assembly.

Description

Technical Field

[0001] This disclosure relates to systems and methods for using modular connector assemblies in automotive applications. Specifically, this disclosure relates to separate modules that can be connected to form a hybrid module, which can then be inserted into a connector housing to form a modular connector assembly. This disclosure also relates to a method of manufacturing a modular connector assembly. Background Technology

[0002] In the field of automotive electrical systems, modular connector assemblies are commonly used to facilitate the connection of various electrical components. These connectors are crucial for ensuring reliable communication and power distribution throughout the vehicle. Known systems typically involve connector housings with multiple slots to accommodate different (monomeric) modules, each containing several terminal cavities for electrical terminals. However, these systems often face challenges related to flexibility and adaptability. For example, the need to accommodate various terminal configurations and sizes can increase the complexity of the design and manufacturing processes. Furthermore, ensuring a robust and stable connection between modules within the connector housing can be problematic, especially when dealing with vibrations and other environmental factors common in automotive applications.

[0003] A common challenge in automotive connectivity systems is the need for high-density connections within limited space. As vehicle technology advances, the number of electronic components and sensors increases, necessitating more connections in the same or even smaller space. This demand for miniaturization without compromising connection reliability and performance presents significant design and engineering challenges. Furthermore, connectors must be robust enough to withstand harsh automotive environments, including extreme temperatures, humidity, and mechanical stresses, which can affect the integrity and performance of electrical connections over time.

[0004] Despite significant advancements in modular connector assemblies, improved systems are still needed to offer greater flexibility, ease of assembly, and reliability. Current solutions often lack the ability to easily customize and reconstruct modules to meet specific application requirements. This limitation can lead to increased production costs and longer development times, as manufacturers may need to design and produce multiple connector variants to accommodate different terminal configurations. Furthermore, ensuring robust and stable connections between modules while allowing for easy assembly and disassembly remains a key challenge that has not yet been fully addressed by existing technologies.

[0005] Therefore, one technical problem upon which this invention is based is to provide a modular connector assembly that at least partially overcomes the shortcomings of known systems. Summary of the Invention

[0006] The purpose of this disclosure is to provide a separate module for a modular connector assembly, a hybrid module for a modular connection assembly, and a modular connector assembly that overcomes one or more drawbacks of known systems.

[0007] A first aspect of this disclosure provides a split module for a modular connector assembly, comprising: a module housing; and at least one terminal cavity adapted to receive electrical terminals and formed along a longitudinal axis of the module housing; wherein the module housing includes fastening elements for fastening the module housing to a second module housing of a second split module.

[0008] Therefore, the subject matter of the first aspect describes a modular module designed for use in modular connector assemblies. The modular module includes a module housing and at least one terminal cavity. The terminal cavity is particularly adapted to accommodate electrical terminals and is formed along the longitudinal axis of the module housing. The module housing also has fastening elements for securing the module housing to another module housing of another modular module.

[0009] In this context, a modular component refers to a part that can be combined with another similar component (i.e., another module) to form a hybrid module. A modular connector assembly is a system that allows the combination of different modules to create a customized connector solution. The module housing is the outer structure that houses the internal components, including terminal cavities. A terminal cavity is a space within the housing used to house electrical terminals, which are conductive elements used to connect circuits. Terminal cavities can have a circular or rectangular cross-section. The longitudinal axis is an imaginary line running longitudinally through the module housing, along which the terminal cavities are aligned. Fastening elements are features that enable one module housing to be securely attached to another module, facilitating the creation of hybrid modules.

[0010] The advantages of this design include increased flexibility and scalability in creating modular connector assemblies. By allowing the combination of separate modules, a wide variety of configurations can be created without requiring new tools or designs for each new combination. This reduces investment in tooling and allows for more efficient use of space within the connector assembly, as there is less unused cavity. Furthermore, the ability to assemble separate modules from different wire harness manufacturers enhances the system's adaptability to meet diverse requirements.

[0011] In a first embodiment of the split module according to the first aspect, the fastening element may be a slider or track extending along the guide axis, and preferably of the dovetail, L-shaped or T-shaped type.

[0012] This embodiment introduces a specific mechanism for the fastening elements of the modular module. This embodiment improves the modular module according to the first aspect by specifying the fastening element as a slider or track extending along a guide axis, preferably a dovetail slider or dovetail track. Specifying the fastening element as a slider or track for the communication between a module shell and a second module shell of another modular module introduces a precise mechanism. The guide axis provides a guiding path for the slider or track to operate along, ensuring a more controllable and stable connection between the two module shells. The preference for dovetail sliders or dovetail tracks enhances this connection by utilizing a design known for its interlocking capabilities, which provides greater mechanical strength and alignment accuracy. The dovetail design is characterized by its trapezoidal shape, which allows for a tight fit and prevents lateral movement, thereby improving the stability and reliability of the connection. This feature is particularly beneficial in applications where modular connector assemblies may be subjected to vibration or mechanical stress, as it ensures the connection remains secure. By specifying the nature of the fastening element, this embodiment not only enhances the functionality of the modular module but also provides a significant and tangible improvement over the more general fastening elements described in the first aspect. This specific design of the fastening element facilitates easier assembly and disassembly of the modular connector assembly, offering practical advantages in maintenance and reconfiguration. Furthermore, the use of dovetail slides or rails contributes to the overall compactness and efficiency of the modular connector assembly, as it allows for seamless integration of separate modules without the need for additional fastening components. Therefore, this improvement in the design of the fastening element represents a significant advancement in the capabilities of modular connector assemblies to provide robust and adaptable electrical connection solutions.

[0013] Slider and rails can also be L-shaped or T-shaped. These shapes help ensure proper alignment during assembly, reducing the risk of misalignment and potential damage to the modular components. L-shaped and T-shaped guides provide additional mechanical stability, helping to maintain a secure connection even in environments subject to vibration or movement. These guides also act as physical barriers, preventing connectors from being inserted in the wrong orientation, thus protecting the integrity of the connection and improving the assembly process. Furthermore, the different shapes of L-shaped and T-shaped guides can facilitate faster and more precise alignment of modular components during automated assembly, reducing the time required for each connection.

[0014] In a further embodiment of the split module according to the first aspect, the guide axis may be perpendicular to or parallel to the longitudinal axis of the module housing.

[0015] This implementation introduces a specific orientation of the guide axis, indicating that it is perpendicular or parallel to the longitudinal axis of the module housing. This feature significantly improves the mechanical stability and reliability of the modular assembly. By ensuring that the guide axis is perpendicular to the longitudinal axis, this design facilitates safer and more precise alignment of the modular modules during assembly. This vertical arrangement means that when two modular modules are connected to each other, the mounting direction of the electrical terminals differs from the connection direction of the modules themselves. This separation of movement reduces the possibility of accidental disconnection, as the forces applied during the insertion of the electrical terminals do not directly affect the connection between the modular modules. This is particularly advantageous in automated processes where accuracy and reliability are critical. The vertical guide axis ensures that any mechanical stress or movement during terminal assembly will not compromise the integrity of the module connection. This feature enhances the overall robustness of the modular connector assembly, making it more suitable for applications requiring secure and stable electrical connections. Furthermore, this orientation simplifies the assembly process, as it provides a clear and unambiguous path for each action, reducing the possibility of errors and improving the efficiency of the assembly process.

[0016] A guide axis parallel to the longitudinal axis of the module housing can improve the speed of the assembly process because the axis of the mating terminal cavity is the same as the axis of the electrical terminals and the axis of fastening the two separate modules.

[0017] In another embodiment of the split module according to the first aspect, the fastening element may include a hook and / or a locking shoulder.

[0018] In this embodiment, the modular components are enhanced by including fastening elements containing hooks and / or locking shoulders. A hook is a fastening mechanism, typically involving a hook-like structure, that latches onto a corresponding feature, providing a secure and quick connection. A locking shoulder, on the other hand, is a structural feature that engages with a corresponding element, such as a hook, to lock the two components together. The interaction between the hook on the first modular component and the locking shoulder on the second modular component contributes to a secure connection between the two modules. This interaction ensures the modules are firmly secured together, preventing accidental disconnection and maintaining the integrity of the modular connector assembly. This embodiment introduces a specific construction of the fastening element, which may include one or both of the hook and the locking shoulder. This construction provides versatility in the design of the modular components, allowing for the use of different combinations of fastening elements depending on the specific requirements of the application. For example, a modular component may include a first fastening element with a hook and a second fastening element with a locking shoulder, enabling it to be securely connected to another module with complementary fastening elements. This feature enhances the adaptability and reliability of the modular connector assembly because it allows for more customizable and robust connections between modules. By combining these specific fastening elements, the modular design allows for a more robust and stable connection, which is particularly beneficial in applications where modular connector assemblies may be subjected to mechanical stress or vibration.

[0019] In another embodiment of the split module according to the first aspect, the split module may include 1 to 20 terminal cavities, preferably a total of 1, 2, 3, 6, 8 or 12 terminal cavities.

[0020] This implementation introduces a specific range and preferred number of terminal cavities within the modular module. The modular module comprises one to twenty terminal cavities, preferably a total of one, two, three, six, eight, or twelve. This feature provides flexibility and adaptability to the modular module, allowing it to accommodate different numbers of electrical terminals depending on the specific requirements of the modular connector assembly. The ability to have different numbers of terminal cavities enhances the versatility of the modular module, making it suitable for a wide range of applications. By specifying a preferred number, this implementation also highlights common configurations that may be particularly useful or efficient in certain situations. For example, a single-channel modular module with a single terminal cavity can be used for simple connections, while a 12-channel modular module with twelve terminal cavities can be used for more complex assemblies requiring multiple connections. This range and preference for a specific number of terminal cavities provides a clear framework for designing and manufacturing modular modules that meet a variety of electrical and mechanical requirements. Including these details in the implementation adds a layer of specificity, which can guide the development and implementation of modular modules in various modular connector assemblies.

[0021] The terminal cavities of the split module can be arranged in one or two rows.

[0022] In another embodiment of the split module according to the first aspect, the spacing between the two terminal cavities can be between 0.1 mm and 5 mm, preferably 0.5 mm, 0.63 mm, 1.2 mm, 2.8 mm or 4.8 mm.

[0023] This implementation introduces specific features related to the spacing between the two terminal cavities within the modular module. This spacing is defined within a range of 0.1 mm to 5 mm, with preferred values ​​of 0.5 mm, 0.63 mm, 1.2 mm, 2.8 mm, or 4.8 mm. Spacing is a critical parameter that affects the module's ability to accommodate electrical terminals and influences the overall density and compactness of the modular connector assembly. By specifying a spacing range, this implementation provides flexibility in the design and manufacture of the modular module, allowing it to be customized to different application requirements and standards. The preferred values ​​provide specific options consistent with industry specifications or specific use cases, enhancing the module's adaptability and functionality. This feature brings several advantages to modular module design. First, it allows for precise control over the spacing of the electrical terminals, which is crucial for ensuring reliable electrical connections and minimizing interference between adjacent terminals. Smaller spacing allows for a more compact design, which is beneficial in applications with limited space. Conversely, larger spacing is preferred when ease of handling and installation is prioritized, or when larger terminals need to be accommodated. Furthermore, specifying the spacing can facilitate compatibility with existing systems and components, making the modular design a common option for various modular connector assemblies. Including optimal values ​​provides guidance for optimized construction, potentially simplifying the design process and reducing the need for extensive customization.

[0024] The spacing also allows the modular design to conform to known connector designs, such as High Speed ​​Cable Assembly (HSCA), High Speed ​​Data (HSD), High Frequency Miniature (HFM), or High Speed ​​Modular Twisted Pair Data (HMTD).

[0025] A second aspect of the invention provides a hybrid module comprising at least a first split module and a second split module according to the first aspect; wherein the first split module and the second split module are connected to each other by their fastening elements.

[0026] The described subject matter relates to a hybrid module comprising at least a first split module and a second split module. These split modules are connected to each other using their fastening elements.

[0027] In this context, a hybrid module refers to a modular component that can combine different or similar types of separate modules. Separate modules are the individual parts of the hybrid module, and can be implemented as described above. Fastening elements are components of the separate modules that allow them to be securely connected to each other.

[0028] The advantage of this construction is that it allows for greater flexibility and customization when creating modular connectors. By using modular components, different combinations can be achieved without requiring new tools or designs each time a new construction is needed. This reduces the overall investment in tooling and makes assembly easier for different wire harness manufacturers. Furthermore, it minimizes unused cavity space, allowing for a smaller overall connector size, making it more efficient and suitable for a wider range of applications.

[0029] In a first embodiment of the hybrid module according to the second aspect, the fastening element can prevent the separate modules from moving relative to each other along the longitudinal axis by means of a form fit.

[0030] This implementation introduces specific features regarding the fastening elements of the separate modules forming the hybrid module. The fastening elements are designed to prevent relative movement of the separate modules along the longitudinal axis through a form-fit. This feature adds significant advantages to the structural integrity and operational reliability of the hybrid module. The form-fit can be established through the interaction between rails and sliders, particularly dovetail rails and dovetail sliders. The form-fit ensures that once the separate modules are connected, they remain firmly in place without moving or loosening along the longitudinal axis. This is particularly beneficial in applications where the modules may be subjected to vibration, external forces, or any conditions that could cause movement. Preventing relative movement along the longitudinal axis is crucial for maintaining the alignment and connection integrity of the modules, especially when they are equipped with electrical terminals. In automation processes, accuracy and reliability are paramount, and the form-fit feature ensures that the modules are correctly aligned and remain in place during operation. This reduces the risk of accidental disconnection or misalignment, which can lead to operational failures or the need for frequent maintenance. Furthermore, the form-fit provides a mechanical interlock, enhancing the overall stability of the hybrid module assembly. By preventing movement along the longitudinal axis, the form-fit helps improve the durability and lifespan of the hybrid module because it minimizes wear that may be caused by relative movement between the individual modules. This feature is particularly advantageous in environments where the hybrid module may be exposed to dynamic loads or where precise positioning is critical to module functionality. Overall, the form-fit of the fastening elements improves the performance of the hybrid module by ensuring a robust and stable connection between the individual modules, thereby enhancing the reliability and efficiency of systems using hybrid modules.

[0031] In another embodiment of the hybrid module according to the second aspect, the separate modules may together include a total of 2 to 40 terminal cavities.

[0032] This implementation specifies that the total number of terminal cavity combinations within the modular unit ranges from 2 to 40, with preferred specific numbers such as 2, 3, 4, 5, 14, 18, or 26. This feature introduces a degree of flexibility and customizability into the hybrid module, allowing it to be adapted to specific applications or requirements by varying the number of terminal cavities. The specified range and preferred number of terminal cavities mean that the hybrid module can be adapted to different constructions and functions according to the needs of the user or application. This flexibility is crucial because it allows for the creation of a hybrid module that can be used in a variety of situations, potentially reducing the need for multiple different modules and thus simplifying inventory and production processes. By specifying the range and preferred numbers, this implementation ensures that the hybrid module can meet a variety of requirements while still maintaining a level of standardization that facilitates use and integration. This feature enhances the versatility and adaptability of the hybrid module, making it more attractive to users who require reliable and customizable solutions to meet specific needs.

[0033] In another embodiment of the hybrid module according to the second aspect, the total number of terminal cavities of the first split module may be the same as or different from the total number of terminal cavities of the second split module.

[0034] This implementation introduces a specific feature regarding the total number of terminal cavities in the first and second split modules. Specifically, the total number of terminal cavities in the first split module can differ from the total number of terminal cavities in the second split module. This feature introduces a new dimension to the hybrid module by allowing variation in the number of terminal cavities between the two split modules. This variation provides flexibility in the design and functionality of the hybrid module, enabling it to accommodate different types of connections or electrical components that may require different numbers of terminal cavities. This difference in the number of terminal cavities also helps to tailor the hybrid module for specific applications where the requirements for terminal connections may differ. Furthermore, this feature enhances the modularity of the hybrid module, making it easier to adapt and reconfigure the module for different uses without requiring major modifications. The ability to have split modules with different numbers of terminal cavities also improves the efficiency of the hybrid module by optimizing the use of space and resources, ensuring that each split module is tailored to its specific function throughout the system. This improves the performance and reliability of the hybrid module because the design of each split module can meet the exact requirements of its intended application.

[0035] The total number of terminal cavities in the first split module can also be the same as the total number of terminal cavities in the second split module. In this way, a known connector can be divided into two equal split modules, which simplifies the assembly process.

[0036] A third aspect of the invention provides a modular connector assembly for automotive applications, comprising: a connector housing having at least one module slot; wherein the at least one module slot accommodates a hybrid module according to the second aspect.

[0037] The modular connector assembly is designed for automotive applications and includes a connector housing with at least one module slot. This module slot is specifically designed to accommodate a hybrid module constructed according to the second aspect, which involves a combination of separate modules according to the first aspect.

[0038] Modular connector assemblies are systems that allow the connection of various electrical components within a vehicle. The connector housing acts as a protective enclosure, securely holding the internal components. Module slots are designated spaces within the connector housing used to hold modules, which are units containing electrical terminals within terminal cavities.

[0039] The advantage of using modular components in modular connector assemblies is that they offer greater flexibility and scalability. It allows for easier customization and adaptation to different constructions without requiring new tools or designs. For example, it enables the combination of different types of connections, such as power terminals and signal terminals, within a single (hybrid) module.

[0040] This reduces connector size, minimizes unused space, and lowers tooling investment. Furthermore, it enables the next level (higher level) of automation for wiring harness manufacturers, making electrical systems in vehicles more efficient and versatile.

[0041] In a first embodiment of the modular connector assembly according to the third aspect, the connector housing may include a plurality of module slots, preferably four module slots.

[0042] This implementation introduces a modular connector assembly for automotive applications, extending this aspect by specifying multiple module slots, preferably four. This enhancement allows for greater versatility and scalability in the design and application of the connector assembly. By incorporating multiple module slots, the assembly can support a variety of standard (monomeric) and hybrid modules, thereby increasing customization possibilities and adaptability to different automotive systems and requirements. The feature of having multiple, particularly four, module slots offers several advantages. It allows for the integration of multiple hybrid modules within a single connector housing, thereby enhancing the functionality and performance of the automotive system. This configuration facilitates the connection and communication of various components through hybrid modules, supporting complex electrical and electronic systems. Furthermore, the presence of multiple module slots improves system maintainability and upgradeability. With multiple slots, individual modules can be replaced or upgraded without replacing the entire connector assembly, reducing downtime and maintenance costs. The preference for four module slots indicates an optimal balance between size, functionality, and cost, providing sufficient capacity for most automotive applications while maintaining a compact and efficient design. This feature also allows manufacturers to customize the connector assembly according to specific applications and customer needs.

[0043] In another embodiment of the modular connector assembly according to the third aspect, the length of at least one module slot may be between 20 mm and 30 mm, and the height may be between 5 mm and 10 mm.

[0044] This embodiment introduces specific dimensional characteristics to the module slots of the modular connector assembly. This embodiment further improves upon this by specifying that the length of the module slot ranges from 20 mm to 30 mm, and the height ranges from 5 mm to 10 mm, with a preferred length of 25.3 mm and a preferred height of 8.3 mm. This improvement introduces precise dimensional constraints, which are crucial for ensuring compatibility and proper mating with the hybrid modules designed to be accommodated by the slot. Specific dimensions facilitate the design and manufacturing process by providing clear guidelines for the dimensions of the module slot, which helps maintain consistency among the different units of the modular connector assembly. The communication mechanism between the module slot and the hybrid module is inherently mechanical, as the dimensions of the slot determine the physical space available for inserting and securing the module. By defining these dimensions, this embodiment ensures that the module slot can reliably accommodate hybrid modules without issues associated with improper assembly or mechanical instability. The introduction of these dimensions may also affect the thermal and electrical performance of the connector assembly, as the dimensions of the slot can influence heat dissipation characteristics and the spatial arrangement of electrical contacts within the housing. Furthermore, specific preferred dimensions can optimize the performance of the connector assembly in specific automotive applications where space constraints and precise alignment are often critical. Size constraints ensure compliance with industry standards or regulations governing the design and use of automotive connectors.

[0045] In another embodiment of the modular connector assembly according to the third aspect, the assembly may include a plurality of hybrid modules, each of which is housed in a module slot of the connector housing, and each module includes a different total number of terminal cavities.

[0046] The introduction of multiple hybrid modules, each with a different number of terminal cavities, brings several new features and advantages to modular connector assemblies. First, it enhances the flexibility of connector assemblies by allowing customization based on specific application requirements. Different automotive systems may require different numbers of terminal connections, and the ability to accommodate hybrid modules with varying numbers of terminal cavities allows the assembly to be customized to meet these diverse needs. This feature is particularly useful in complex automotive systems where different components may have different connection requirements. Furthermore, using multiple hybrid modules with different terminal cavity configurations improves the scalability of the connector assembly. As automotive systems evolve and expand, the connector assembly can easily accommodate additional connections by simply introducing hybrid modules with different / more terminal cavity configurations. This scalability is crucial in modern automotive applications, as technological advancements and increasing system complexity necessitate more sophisticated connection solutions. Moreover, the modular nature of the assembly allows for easier maintenance and replacement of individual modules without requiring the replacement of the entire connector assembly. Since faulty or obsolete modules can be replaced with minimal disruption, this saves costs and reduces downtime in automotive systems.

[0047] A fourth aspect of the invention provides a method for manufacturing a modular connector assembly according to a third aspect, the method comprising the steps of: forming a hybrid module according to a second aspect by connecting a first split module and a second split module according to a first aspect; and inserting the hybrid module along the longitudinal axis of the split modules of the hybrid module into a module slot in a connector housing.

[0048] This topic describes a method for manufacturing a modular connector assembly. The method involves forming a hybrid module by connecting a first split module and a second split module. The hybrid module is then inserted into a module slot in a connector housing along the longitudinal axis of the split modules.

[0049] The advantages of this approach include increased flexibility and scalability for wire harness manufacturers, reduced connector size due to fewer unused cavities, the ability to assemble separate modules from different wire harness manufacturers, and low tooling investment because different hybrid connector constructions do not require new tools. This approach allows for the creation of various modular combinations using standard connector housings, thereby supporting future applications with intelligently designed modular connections. Attached Figure Description

[0050] Figure 1 This illustrates a connector assembly from the prior art.

[0051] Figure 2 This demonstrates how to combine separate modules into a hybrid module.

[0052] Figure 3This illustrates a hybrid module formed by connecting a first split module and a second split module.

[0053] Figure 4 This illustrates one embodiment of the split module.

[0054] Figure 5 This illustrates an embodiment of a modular connector assembly. Detailed Implementation

[0055] Figure 1 Connector assembly 1 is shown, representing prior art in the field of electrical connectors. This assembly houses a module with a monolithic structure, meaning it is constructed as a single, unified component, rather than composed of multiple detachable parts. The assembly integrates various types of terminal cavities 2, allowing different electrical terminals to be accommodated within a single housing 3.

[0056] The modular connector assembly 1 is depicted as a housing 3 having an encapsulated terminal cavity 2. The housing 3 serves as a structural frame to hold the terminal cavity 2 in place and provides protection against environmental factors such as dust and moisture. The housing is typically made of a durable material, usually a plastic or composite material, which ensures the integrity and lifespan of the connector assembly in a variety of applications, including automotive and industrial environments.

[0057] The terminal cavities 2 within the housing 3 are arranged in a grid pattern, allowing for efficient organization and connection of multiple electrical terminals. These cavities are designed to securely hold the terminals in place, ensuring reliable electrical connections. The configuration of the terminal cavities can be varied to accommodate different sizes and types of terminals, which is crucial for the versatility of modular connector assemblies when interfacing with various electrical systems.

[0058] The monolithic structure of the module may limit the flexibility of connector assembly 1 in terms of customization and scalability, because if the construction of connector assembly 1 needs to be changed, the entire module must be replaced or modified.

[0059] Figure 2 The possibility of replacing prior art modules 10 and 20 with modular modules 100, 200, 300, and 400 that can be combined to form hybrid modules is illustrated. The figure shows two examples of such a replacement.

[0060] In the first example, the left side of the figure depicts module 10, a known module in the prior art. Module 10 includes a module housing 11 and terminal cavities 12 arranged in two rows. Module 10 can be replaced by combining two separate modules, specifically separate module 100 and separate module 200. Separate module 100 includes a module housing 101 and terminal cavities 102 arranged in two rows. It also includes fastening elements 104 for connection to another separate module. Separate module 200 includes a module housing 201, terminal cavities 202 arranged in a row, and fastening elements 204. When separate modules 100 and 200 are connected via their respective fastening elements 104 and 204, they form a hybrid module that can replace the prior art module 10.

[0061] In the second example, module 20 is shown on the right side of the figure. Module 20 is another known module in the prior art. Module 20 includes a module housing 21 and a terminal cavity 22. Module 20 can be replaced by combining two separate modules, specifically, separate module 300 and separate module 400. Separate module 300 includes a module housing 301 and a terminal cavity 302. It also includes a fastening element 304 for connecting to another separate module. Separate module 400 includes a module housing 401, a terminal cavity 402, and a fastening element 404. When separate modules 300 and 400 are connected via their respective fastening elements 304 and 404, they form a hybrid module that can replace the prior art module 20.

[0062] This diagram illustrates the modularity and flexibility of the split-module design, allowing for the creation of hybrid modules to replace existing standard modules in modular connector assemblies. This approach offers the advantage of customizable construction, enabling assemblies to meet diverse electrical terminal requirements by combining different split modules. Fastening elements ensure secure connections between the split modules, maintaining the structural integrity and functionality of the hybrid module.

[0063] Figure 3 The assembly process of the hybrid module 500, which consists of a first sub-module 100 and a second sub-module 400, is illustrated. The figure provides a visual representation of the components and their interactions during assembly.

[0064] Terminal cavity 102 is designed to accommodate electrical terminals and is aligned along longitudinal axis 40 of module housing 101. Module housing 101 is equipped with fastening element 104, which is integrated with the process of connecting the first split module 100 to the second split module 400.

[0065] The second modular module 400 has a similar structure. This module also includes a fastening element 404, which is designed to engage with the fastening element 104 of the first modular module 100. Fastening elements 104 and 404 are crucial for the secure connection between the two modules, ensuring a stable and reliable connection. Fastening element 104 is a dovetail track, while fastening element 404 is a dovetail slider.

[0066] The assembly process is described in a series of steps. Initially, the first modular module 100 and the second modular module 400 are positioned such that their respective fastening elements 104 and 404 are aligned. A guide axis 30, perpendicular to the longitudinal axis 40, facilitates the alignment and connection of the modules. Then, as indicated by the directional arrows in the figure, the modules are assembled together along the guide axis 30.

[0067] After fastening elements 104 and 404 are successfully aligned and engaged, the modules are securely connected to form hybrid module 500. A "click" sound indicates successful connection, symbolizing the completion of the assembly process. Hybrid module 500 then includes combined terminal cavities 102 and 402, allowing for a universal configuration of electrical terminals.

[0068] The fastening elements 104 and 404 are designed to prevent relative movement between the separate modules 100 and 400 along the longitudinal axis 40, thus ensuring a form-fit. This robust connection is crucial for maintaining the integrity and functionality of the hybrid module 500 in a variety of applications.

[0069] Figure 4 An embodiment of a split module 300 for a modular connector assembly is shown. The split module 300 includes a module housing 301 and a terminal cavity 302 formed along a longitudinal axis 40 of the module housing 301. The module housing 301 includes fastening elements 304 at the top and bottom, which are designed to fasten the module housing 301 to a second module housing of a second split module.

[0070] In this embodiment, the fastening element 304 is shown as a dovetail-shaped track (at the top) and a dovetail-shaped slider (at the bottom) extending along the guide axis 30. Figure 3 As shown, the guide axis 30 is perpendicular to the longitudinal axis 40 of the module housing 301. The top fastening element 304 also includes a hook 305, and the bottom fastening element 304 includes a locking shoulder 306, which helps to securely attach the module housing 301 to the second module housing.

[0071] The split module 300 also includes a terminal position assurance device (TPA) 701, which ensures the correct positioning of the electrical terminals within the terminal cavity 302. The terminal position assurance device 701 is an important component for maintaining the reliability and integrity of electrical connections within the split module 300.

[0072] The terminal cavities 302 are arranged at a specific spacing 70, which can range from 0.1 mm to 5 mm. This spacing is crucial for accommodating various electrical terminals and ensuring proper alignment and spacing within the module housing 301.

[0073] Figure 4 The illustrated embodiment shows a modular module 300 that can be easily connected to another modular module using fastening elements 304, hooks 305, and locking shoulders 306. This modular design allows for flexible construction of connector assemblies to meet specific requirements, such as the number of terminal cavities and the spacing between them.

[0074] Figure 5 A modular connector assembly 600 designed for automotive applications is shown. The assembly includes a connector housing 602, and a hybrid module 500 is shown inserted into one of the module slots 601. The connector housing 602 is configured to accommodate multiple module slots; the depicted embodiment has four module slots 601. These module slots are configured to accommodate the hybrid module 500 as described in this invention and a standard monolithic module 603, demonstrating the assembly's versatility in accommodating different module types.

[0075] The hybrid module 500, composed of separate modules, is inserted along the longitudinal axis 40 of the module slot 601. This design ensures that once fully inserted, the separate modules forming the hybrid module 500 remain securely in place. This is because the connector housing 602 prevents any relative movement of the separate modules along the guide axis 30, thereby ensuring a stable connection.

[0076] The separate modules forming the hybrid module 500 have different numbers of terminal cavities, highlighting the modularity of the modular connector assembly 600.

[0077] The figure also highlights the presence of the standard single-unit module 603 within the assembly, demonstrating that the modular connector assembly 600 can accommodate both the hybrid modules of this invention and conventional single-unit modules. This capability emphasizes the flexibility and adaptability of the assembly in a variety of applications, allowing for the combination of different module types to meet specific electrical or mechanical requirements.

[0078] The component is equipped with a mating assist lever 604, which interacts with a mating assist device 605. This interaction facilitates easier connection of the modular connector assembly 600 to the mating connector, enhancing the user experience by simplifying the process of establishing a secure connection. The mating assist lever 604 is strategically positioned to provide leverage, thereby reducing the effort required during the mating process.

[0079] Furthermore, module slot 601 has a coding recess 606. This recess is designed to interact with coding ribs on the module housing to ensure proper insertion of the module into the slot. The coding recess 606 acts as a guide to prevent incorrect orientation and insertion of the module, which could otherwise lead to connection errors or component damage. In the depicted example, hybrid module 500 does not provide coding ribs for interacting with the coding recess; however, in another embodiment, one of the separate modules forming hybrid module 500 may include coding ribs on the module housing.

[0080] Figure 3 and Figure 5 A method for manufacturing a modular connector assembly 600 is jointly illustrated. According to... Figure 3 Two separate modules, 100 and 400, are connected to form a hybrid module 500. According to... Figure 5 Then, the mixing module 500 is inserted into the module slot 601 of the connector housing 602 along the longitudinal axis 40. Figure 5 The longitudinal axis 40 in Figure 3 The longitudinal axis 40 is the same, that is, the longitudinal axis of the split module 100 and 400 of the split module 500.

Claims

1. A split module (100, 300) for a modular connector assembly (600), comprising: Module housings (101, 301); as well as At least one terminal cavity (102, 302) adapted to receive an electrical terminal and formed along the longitudinal axis (40) of the module housing (101, 301); The module shell (101, 301) is characterized in that it includes fastening elements (104, 304) for fastening the module shell (101, 301) to the second module shell (201, 401) of the second split module (200, 400).

2. The split modules (100, 300) according to claim 1. Its features are, The fastening element (104) is a slider or track extending along the guide axis (30), and is preferably of the dovetail, L-shaped or T-shaped type.

3. The split module (100) according to claim 2. Its features are, The guide axis (30) is perpendicular to or parallel to the longitudinal axis (40) of the module shell (101, 301).

4. The split module (100, 300) according to any one of claims 1 to 3. Its features are, The fastening elements (104, 304) include a hook (305) and / or a locking shoulder (306).

5. The split module (100) according to any one of claims 1 to 4. Its features are, The split module (100) includes 1 to 20 terminal cavities (102, 302), preferably a total of 1, 2, 3, 6, 8 or 12 terminal cavities (102, 302).

6. The split module (100) according to any one of claims 1 to 5. Its features are, The spacing (70) between the two terminal cavities is between 0.1 mm and 18 mm, preferably 0.5 mm, 0.63 mm, 1.2 mm, 2.8 mm or 4.8 mm.

7. A hybrid module (500), comprising: At least a first split module (100, 300) and a second split module (200, 400) according to any one of claims 1 to 6; The first split module (100, 300) and the second split module (200, 400) are connected to each other by means of their fastening elements (104, 204, 304, 404).

8. The hybrid module (500) according to claim 7. Its features are, The fastening elements (104, 204, 304, 404) prevent the separate modules (100, 200, 300, 400) from moving relative to each other along the longitudinal axis (40) by means of shape fit.

9. The hybrid module (500) according to claim 7 or 8. Its features are, The total number of terminal cavities (102, 202, 302, 402) included in the separate modules (100, 200, 300, 400) is between 2 and 40, preferably 2, 3, 4, 5, 14, 18 or 26.

10. The hybrid module (500) according to any one of claims 7 to 9. Its features are, The total number of terminal cavities (102, 302) of the first split module (100, 300) is the same as or different from the total number of terminal cavities (202, 402) of the second split module (200, 400).

11. A modular connector assembly (600) for automotive applications, comprising: Connector housing (602) having at least one module slot (601); The feature is that the at least one module slot (601) accommodates the hybrid module (500) according to any one of claims 7 to 9.

12. The modular connector assembly (600) according to claim 11. Its features are, The connector housing (602) includes a plurality of module slots (601), preferably four module slots (601).

13. The modular connector assembly (600) according to any one of claims 11 or 12. Its features are, The length of the at least one module slot (601) is between 20 mm and 30 mm, and the height is between 5 mm and 10 mm, preferably 25.3 mm in length and 8.3 mm in height.

14. The modular connector assembly (600) according to any one of claims 11 to 13, characterized in that, Also includes: Multiple hybrid modules (400), each module being housed in a module slot (601) of the connector housing (602), and each module including a different total number of terminal cavities (102, 202, 302, 402).

15. A method for manufacturing a modular connector assembly (600) according to any one of claims 11 to 14, the method comprising the steps of: By connecting the first separate module (100, 300) and the second separate module (200, 400) according to any one of claims 1 to 6 to form the hybrid module (500) according to any one of claims 7 to 9; and The hybrid module (500) is inserted into the module slot (601) of the connector housing (602) along the longitudinal axis (40) of the split modules (100, 200, 300, 400) of the hybrid module (500).

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