Split module for a modular connector arrangement

Abstract

Split module (100, 300) for a modular connector arrangement (600), comprising: a module housing (101, 301); and at least one connection cavity (102, 302) adapted to accommodate an electrical connection and formed along a longitudinal axis (40) of the module housing (101, 301); wherein the module housing (101, 301) comprises a fastening element (104, 304) for fastening the module housing (101, 301) to a second module housing (201, 401) of a second split module (200, 400).

Description

AREA OF REVELATION

[0001] The present disclosure relates to a system and a method for modular connector assemblies used in automotive applications. In particular, the present disclosure relates to split modules that can be joined to form mixed modules, which can then be inserted into a connector housing to create a modular connector assembly. The disclosure also relates to a method for manufacturing a modular connector assembly. BACKGROUND OF THE INVENTION

[0002] In automotive electrical systems, modular connector assemblies are commonly used to facilitate the connection of various electrical components. These connectors are essential for ensuring reliable communication and power distribution throughout the vehicle. Well-known systems typically include multi-slot connector housings to accommodate different (monoblock) modules, each containing multiple connection cavities for electrical connections. However, these systems often face challenges regarding flexibility and adaptability. For example, the need to accommodate a wide range of connection configurations and sizes can lead to increased complexity in the design and manufacturing process.Additionally, ensuring a secure 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] One of the common problems in automotive interconnection systems is the need for high-density connections in confined spaces. As vehicles become more technologically advanced, the number of electronic components and sensors increases, requiring more connections within the same or even smaller spaces. This demand for miniaturization, without compromising the reliability and performance of the connections, presents significant design and engineering challenges. Furthermore, the connectors must be robust enough to withstand harsh automotive environments, including extreme temperatures, humidity, and mechanical stress, which can affect the integrity and performance of the electrical connections over time.

[0004] Despite significant advances in modular connector assemblies, there remains a need for improved systems that offer greater flexibility, ease of assembly, and reliability. Current solutions often lack the ability to easily adapt and reconfigure modules to meet specific application requirements. This limitation can lead to increased manufacturing costs and longer development times, as manufacturers may need to design and produce multiple connector variants to accommodate different connection configurations. Furthermore, ensuring a secure and stable connection between modules while allowing for easy assembly and disassembly remains a critical challenge that existing technologies have not fully addressed.

[0005] Therefore, one of the technical problems underlying the present invention is to provide a modular connector arrangement that at least partially overcomes the disadvantages of known systems. SUMMARY OF THE REVELATION

[0006] It is an object of this invention to provide a split module for a modular connector arrangement, a mixed module for a modular connector arrangement and a modular connector arrangement that overcome one or more of the disadvantages of known systems.

[0007] A first aspect of the invention provides a split module for a modular connector arrangement, comprising: a module housing; and at least one connection cavity adapted to accommodate an electrical connection and formed along a longitudinal axis of the module housing; wherein the module housing comprises a fastening element for attaching the module housing to a second module housing of a second split module.

[0008] The subject of the first aspect thus describes a split module designed for a modular connector arrangement. This split module comprises a module housing and at least one connection cavity. The connection cavity is specifically adapted to accommodate an electrical connection and is formed along the longitudinal axis of the module housing. The module housing also has a fastening element that can be used to attach the module housing to another module housing of another split module.

[0009] In this context, a split module refers to a component that can be combined with another similar component, i.e., another split module, to form a hybrid module. The 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 contains the internal components, including the terminal cavity. The terminal cavity is a space within the housing designed to accommodate an electrical terminal, which is a conductive element used to connect electrical circuits. The terminal cavity can have a circular or rectangular cross-section. The longitudinal axis is an imaginary line running lengthwise through the module housing, along which the terminal cavity is oriented.The fastening element is a feature that allows one module housing to be securely attached to another, thus facilitating the production of mixed modules.

[0010] The advantages of this design include increased flexibility and scalability in creating modular connector assemblies. By allowing split modules to be combined, it is possible to create a wide variety of configurations without requiring new tooling or designs for each new combination. This reduces tooling investment and enables more efficient use of space within the connector assembly, as there are fewer unused cavities. Additionally, the ability to assemble split modules from different harness manufacturers improves 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 can be a slider or a rail extending along a guide axis and preferably dovetail-shaped, L-shaped or T-shaped.

[0012] This design introduces a specific mechanism for the Split Module's fastening element. It refines the Split Module, as described in the first aspect, by specifying that the fastening element is a slider or rail extending along a guide axis, with a preference for a dovetail slider or dovetail rail. This specification of the fastening element as a slider or rail introduces a precise mechanism for communication between the module housing and the second module housing of another Split Module. The guide axis provides a directional path along which the slider or rail operates, ensuring a more controlled and stable connection between the two module housings.The preference for a dovetail slide or dovetail rail improves this connection by utilizing a design known for its locking capability, which provides increased mechanical strength and alignment precision. The dovetail design is characterized by its trapezoidal shape, which allows for a tight fit and prevents lateral movement, thus improving the stability and reliability of the connection. This feature is particularly advantageous in applications where the modular connector assembly may be subject to vibration or mechanical stress, as it ensures that the connection remains secure. By specifying the type of fastener, the implementation not only enhances the functionality of the split module but also provides a clear and tangible improvement over the more generic fastener described in the first aspect.This specific design feature of the fastener facilitates easier assembly and disassembly of the modular connector assembly, offering practical advantages in terms of maintenance and reconfiguration. Furthermore, the use of a dovetail slide or dovetail rail contributes to the overall compactness and efficiency of the modular connector assembly by enabling seamless integration of the split modules without the need for additional fastening components. This refinement in the fastener design thus represents a significant advancement in the modular connector assembly's ability to provide a robust and adaptable electrical connection solution.

[0013] The slider and rail can also be L-shaped or T-shaped. These shapes help ensure correct alignment during assembly, reducing the risk of misalignment and potential damage to the split modules. L-shaped and T-shaped guides provide additional mechanical stability, which can help maintain a secure connection even in environments subject to vibration or movement. These guides can also act as a physical barrier to prevent connectors from being inserted incorrectly, thus protecting the integrity of the connection and improving the assembly process. Furthermore, the different shapes of L-shaped and T-shaped guides can enable faster and more accurate alignment of the split modules during an automated assembly process, reducing the time required for each connection.

[0014] In another version of the split module according to the first aspect, the guide axis can be perpendicular or parallel to the longitudinal axis of the module housing.

[0015] The design incorporates a specific orientation for 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 split module assembly. By ensuring the guide axis is perpendicular to the longitudinal axis, the design allows for safer and more precise alignment of the split modules during assembly. This perpendicular orientation means that when two split modules are connected, the direction for inserting the electrical connections is different from the direction for connecting the modules themselves. This separation of movements reduces the likelihood of unintentional separation, as the forces applied during the insertion of electrical connections do not directly affect the connection between the split modules.This is particularly advantageous in automated processes where precision and reliability are critical. The vertical guide axis ensures that any mechanical stress or movement during connector assembly does not compromise the integrity of the module connection. This feature improves the overall robustness of the modular connector assembly and makes it better suited for applications where secure and stable electrical connections are essential. Additionally, this orientation can simplify the assembly process by providing a clear and distinct path for each action, thereby reducing the potential for errors and improving assembly efficiency.

[0016] A guide axis that is parallel to the longitudinal axis of the module housing can increase the speed of the assembly process, as the axes for matching the connection cavities with electrical connections and for fastening the two split modules are the same.

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

[0018] In the context of the design, the split module is enhanced by the inclusion of a fastening element comprising a snap hook and / or a locking shoulder. A snap hook is a type of fastening mechanism that typically includes a hook-like structure that can engage with a corresponding feature, thus providing a secure and quick connection. The locking shoulder, on the other hand, is a structural feature that can engage with a corresponding element, such as a snap hook, to lock two components together. The interaction between a snap hook on a first split module and a locking shoulder on a second split module facilitates a secure connection between the two modules.This interaction ensures that the modules are held firmly together, preventing unintentional separation and maintaining the integrity of the modular connector assembly. The feature introduced by this design is the specific configuration of the fastener, which may include a snap hook and / or a locking shoulder. This configuration provides versatility in the design of the split module, allowing for the use of different combinations of fasteners depending on the specific requirements of the application. For example, a split module may include a first fastener with a snap hook and a second fastener with a locking shoulder, enabling it to be securely connected to another module that has complementary fasteners.This feature improves the adaptability and reliability of the modular connector assembly by enabling a more flexible and robust connection between modules. By incorporating these specific fasteners, the split module can achieve a more secure and stable connection, which is particularly advantageous in applications where the modular connector assembly may be subject to mechanical stress or vibration.

[0019] In a further embodiment of the split module according to the first aspect, the split module can comprise between 1 and 20 connection cavities, preferably a total of 1, 2, 3, 6, 8 or 12 connection cavities.

[0020] The design specifies a particular range and preferred quantities for the connection cavities within the split module. The split module comprises between one and twenty connection cavities, with a preferred total of one, two, three, six, eight, or twelve connection cavities. This feature provides flexibility and adaptability to the split module, enabling it to accommodate varying numbers of electrical connections based on the specific requirements of the modular connector arrangement. The ability to accommodate different numbers of connection cavities enhances the versatility of the split module, making it suitable for a wide range of applications. By specifying preferred quantities, the design also highlights common configurations that may be particularly useful or efficient in certain contexts.For example, a 1-way split module with a single connection cavity could be used for simple connections, while a 12-way split module with twelve connection cavities could be used in more complex arrangements requiring multiple connections. This range, along with the preference for specific numbers of connection cavities, provides a clear framework for designing and manufacturing split modules that can meet various electrical and mechanical requirements. Incorporating these details into the design adds a layer of specificity that can guide the development and implementation of the split module in various modular connector arrangements.

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

[0022] In a further embodiment of the split module according to the first aspect, the spacing between two connection 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] The design introduces a specific feature relating to the pitch between two connection cavities within the split module. This pitch is defined to be within a range of 0.1 mm to 5 mm, with preferred values ​​specified as 0.5 mm, 0.63 mm, 1.2 mm, 2.8 mm, or 4.8 mm. The pitch is a critical parameter that affects the module's ability to accommodate electrical connections and influences the overall density and compactness of the modular connector assembly. By specifying a range for the pitch, the design provides flexibility in the design and manufacture of the split module, enabling it to be tailored to different application requirements and standards.The preferred values ​​offer specific options that can be adapted to industry standards or particular use cases, thereby improving the adaptability and functionality of the module. This feature brings several advantages to the split module design. First, it allows precise control over the spacing of electrical terminals, which can be crucial for ensuring reliable electrical connections and minimizing interference between adjacent terminals. A smaller pitch spacing can result in a more compact design, which is advantageous in applications where space is limited. Conversely, a larger pitch spacing may be preferred in scenarios where ease of handling and installation are prioritized or where there is a need to accommodate larger terminals.Additionally, the specified split distances can facilitate compatibility with existing systems and components, making the Split Module a versatile option for various modular connector layouts. The inclusion of preferred values ​​provides guidance for optimal configurations, potentially simplifying the design process and reducing the need for extensive customization.

[0024] The pitch can also be such that the split module corresponds to known connector configurations, such as High Speed ​​Cable Arrangement (HSCA), High Speed ​​Data (HSD), High Frequency Miniature (HFM) or Modular High Speed ​​Twisted Pair Data (HMTD).

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

[0026] The described item comprises a mixed module that includes at least one first split module and one second split module. These split modules are connected to each other using their fastening elements.

[0027] In this context, a mixed module refers to a modular component that can combine different or identical types of split modules. Split modules are individual segments of the mixed module and can be implemented as described above. Fasteners are the parts of the split modules that allow them to be securely attached to one another.

[0028] The advantage of this configuration is that it allows for greater flexibility and customization when creating modular connectors. Using split modules enables different combinations without requiring new tools or designs each time a new configuration is needed. This reduces overall tooling investment and facilitates easier assembly for various wiring harness manufacturers. Additionally, it minimizes unused cavity space and can reduce the overall connector size, making it more efficient and adaptable to different applications.

[0029] In a first version of the mixed module according to the second aspect, the fastening elements can prevent a relative movement of the split modules to each other along the longitudinal axis by means of positive locking.

[0030] The design introduces a specific feature regarding the fastening elements of the split modules that form the combined module. These fastening elements are designed to prevent relative movement of the split modules along their longitudinal axis by means of positive locking. This feature adds a significant advantage to the structural integrity and operational reliability of the combined module. The positive locking can be achieved through the interaction between a rail and a slide, in particular a dovetail rail and a dovetail slide. The positive locking ensures that once the split modules are connected, they remain securely in place without the risk of displacement or loosening along their longitudinal axis. This is particularly advantageous in applications where the modules may be subject to vibrations, external forces, or any conditions that could otherwise 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 connections. In automated processes where precision and reliability are paramount, the positive locking feature ensures that the modules are correctly aligned and remain in position during operation. This reduces the risk of unintentional separation or misalignment, which could lead to operational downtime or the need for frequent maintenance. Additionally, the positive locking provides a mechanical interlock that enhances the overall stability of the mixed module array. By preventing movement along the longitudinal axis, the positive locking contributes to the durability and longevity of the mixed module by minimizing wear that could result from relative movement between the split modules.This feature is particularly advantageous in environments where the mixed module may be subjected to dynamic loads or where precise positioning is critical to the module's function. Overall, the positive locking of the fasteners improves the mixed module's performance by ensuring a secure and stable connection between the split modules, thereby enhancing the reliability and efficiency of the system in which the mixed module is used.

[0031] In a further embodiment of the mixed module according to the second aspect, the split modules together can comprise a total number of connection cavities between 2 and 40.

[0032] The specification defines that the combined total number of connection cavities within the split modules ranges from 2 to 40, with a preference for specific numbers such as 2, 3, 4, 5, 14, 18, or 26. This feature introduces a degree of flexibility and adaptability to the mixed module, allowing it to be tailored to specific applications or requirements by varying the number of connection cavities. The specification of a range and preferred numbers for the connection cavities implies that the mixed module can accommodate different configurations and functionalities depending on the user or application requirements.This flexibility is significant because it allows for the creation of a hybrid module that can be used in various contexts, potentially reducing the need for multiple different modules and thereby streamlining inventory and manufacturing processes. By specifying a range and preferred numerical values, the implementation ensures that the hybrid module can meet a wide variety of requirements while maintaining a level of standardization that facilitates ease of use and integration. This feature enhances the versatility and adaptability of the hybrid module, making it a more attractive option for users who need a reliable and customizable solution for their specific needs.

[0033] In a further embodiment of the mixed module according to the second aspect, the total number of connection cavities of the first split module can be the same or different from the total number of connection cavities of the second split module.

[0034] The design introduces a specific feature regarding the total number of connection cavities in the first and second split modules. Specifically, the total number of connection cavities in the first split module can differ from the total number of connection cavities in the second split module. This feature adds a new dimension to the mixed module by allowing variation in the number of connection cavities between the two split modules. This variation can provide flexibility in the design and functionality of the mixed module, enabling it to accommodate different types of connections or electrical components that may require a different number of connection cavities.This differentiation in the number of connection cavities can also facilitate the adaptation of the mixed module for specific applications, where connection requirements may vary. Additionally, this feature can improve the modularity of the mixed module, making it easier to adapt and reconfigure the module for different uses without requiring significant modifications. The ability to have split modules with varying numbers of connection cavities can also improve the efficiency of the mixed module by optimizing the use of space and resources, ensuring that each split module is tailored to its specific function within the overall system.This can lead to improved performance and reliability of the mixed module, as each split module can be designed to meet the exact requirements of its intended application.

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

[0036] A third aspect of the invention provides a modular connector arrangement for automotive applications, comprising: a connector housing with at least one module slot; wherein the at least one module slot accommodates a mixed 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 mixed module constructed according to the second aspect, which includes the combination of split modules according to the first aspect.

[0038] A modular connector assembly is a system that enables the connection of various electrical components within a vehicle. The connector housing serves as a protective outer shell that securely holds the internal components. The module slot is a specific space within the connector housing designed to accommodate a module, which is a unit containing electrical connections within connection cavities.

[0039] The advantage of using split modules in a modular connector arrangement is the increased flexibility and scalability it offers. It allows for easier adaptation and customization to different configurations without requiring new tools or designs. For example, it enables the combination of different connection types, such as power and signal connections, within a single (mixed) module.

[0040] This can lead to reduced connector size, less unused space, and lower tooling investment. Additionally, it supports the next level of automation for wiring harness manufacturers, enabling more efficient and versatile electrical systems in vehicles.

[0041] In a first embodiment of the modular connector arrangement according to the third aspect, the connector housing can include several module slots, preferably four module slots.

[0042] This design introduces a modular connector assembly for automotive applications, expanding its functionality by specifying the presence of multiple module slots, with a preference for four. This enhancement allows for greater versatility and scalability in the design and application of the connector assembly. By integrating multiple module slots, the assembly can support a variety of standard (monoblock) and mixed modules, thereby increasing its potential for customization and adaptability to diverse automotive systems and requirements. The feature of multiple module slots, particularly the preference for four, offers several advantages. It enables the integration of multiple mixed modules within a single connector housing, which can improve the functionality and performance of the automotive system.This configuration can support complex electrical and electronic systems by facilitating the connection and communication of various components through the mixed modules. Additionally, the presence of multiple module slots can improve the ease of maintenance and upgradeability of the system. With multiple slots, individual modules can be replaced or upgraded without replacing the entire connector assembly, thus reducing downtime and maintenance costs. The preference for four module slots suggests an optimal balance between size, functionality, and cost, providing sufficient capacity for most automotive applications while maintaining a compact and efficient design. This feature is also adaptable, allowing manufacturers to tailor the connector arrangement to specific applications and customer requirements.

[0043] In a further embodiment of the modular connector arrangement according to the third aspect, the at least one module slot can have a length of between 20 mm and 30 mm and a height of between 5 mm and 10 mm.

[0044] This design introduces specific dimensional characteristics into the module slot of the modular connector assembly. It further refines this by specifying that the module slot has a length in the range of 20 mm to 30 mm and a height in the range of 5 mm to 10 mm, with a preference for a length of 25.3 mm and a height of 8.3 mm. This refinement introduces precise dimensional constraints that are critical to ensuring compatibility and proper fit with the mixed module that the slot is intended to accommodate. The specific dimensions facilitate the design and manufacturing process by providing clear guidelines for the module slot size, which can help maintain consistency across different units of the modular connector assembly.The communication mechanism between the module slot and the mixed module is inherently mechanical, as the slot dimensions define the physical space available for the module to be inserted and secured. By defining these dimensions, the implementation ensures that the module slot can reliably accommodate the mixed module without issues related to misfit or mechanical instability. Introducing these dimensions also potentially influences the thermal and electrical performance of the connector assembly, as the slot size can affect heat dissipation characteristics and the spatial arrangement of electrical contacts within the housing. Furthermore, specifying preferred dimensions allows for optimization of the connector assembly's performance in specific automotive applications where space constraints and precise alignment are often critical.Dimensional restrictions can ensure compliance with industry standards or regulations that govern the design and use of automotive connectors.

[0045] In a further embodiment of the modular connector arrangement according to the third aspect, the modular connector arrangement can comprise a variety of mixed modules, each housed in a module slot of the connector housing and each comprising a different total number of connection cavities.

[0046] The introduction of multiple mixed modules, each with a different number of connection cavities, brings several new features and benefits to the modular connector arrangement. First, it improves the flexibility of the connector arrangement by allowing customization based on specific application requirements. Different automotive systems may require different numbers of connection points, and the ability to accommodate mixed modules with varying numbers of connection cavities allows the arrangement to be tailored to meet these diverse needs. This feature is particularly advantageous in complex automotive systems where different components may have varying connectivity requirements.Additionally, the use of multiple mixed modules with different connection cavity configurations can improve the scalability of the connector array. As automotive systems evolve and expand, the connector array can be easily adapted to accommodate additional connections by simply introducing mixed modules with different or more connection cavities. This scalability is crucial in modern automotive applications, where technological advancements and increased system complexity demand more sophisticated connectivity solutions. Furthermore, the modular nature of the array allows for easier maintenance and replacement of individual modules without requiring a complete connector replacement. This can lead to cost savings and reduced downtime in automotive systems, as faulty or obsolete modules can be replaced with minimal disruption.

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

[0048] The subject matter describes a method for manufacturing a modular connector assembly. This method comprises forming a mixed module by joining a first split module and a second split module. The mixed module is then inserted into a module slot of the connector housing along the longitudinal axis of the split modules.

[0049] The advantages of this method include increased flexibility and scalability for wiring harness manufacturers, reduced connector size due to fewer unused cavities, the ability to assemble split modules from different wiring harness manufacturers, and low tooling investment since no new tools are required for different hybrid connector configurations. This method enables the creation of various module combinations using a standard connector shell, thus supporting future applications with intelligently designed modular connections. BRIEF DESCRIPTION OF THE FIGURES Fig. Figure 1 shows a state-of-the-art connector arrangement. Fig. 2: illustrates the combination of split modules to form mixed modules. Fig. Figure 3 shows a mixed module formed by combining a first split module and a second split module. Fig. Figure 4 shows an embodiment of a split module. Fig. Figure 5 shows an embodiment of a modular connector arrangement. DETAILED DESCRIPTION OF PREFERRED EXECUTION FORMS

[0050] Fig. Figure 1 illustrates a connector arrangement 1 that is representative of the state of the art in the field of electrical connectors. This arrangement incorporates a module with a monoblock structure, meaning that it is constructed as a single, unified piece rather than comprising several detachable components. The arrangement integrates connection cavities 2 of different types, enabling the accommodation of various electrical connections within a single housing 3.

[0051] The modular connector assembly 1 is shown with a housing 3 that encapsulates the terminal cavities 2. The housing 3 serves as the structural frame that holds the terminal cavities 2 in place and provides protection from environmental factors such as dust and moisture. The housing is typically made of a durable material, often some type of plastic or composite, which ensures the integrity and longevity of the connector assembly in various applications, including automotive and industrial environments.

[0052] The connection cavities 2 within the housing 3 are arranged in a grid-like pattern, enabling the efficient organization and connection of multiple electrical connections. These cavities are designed to securely hold the connections in place, ensuring reliable electrical connections. The configuration of the connection cavities can vary to accommodate different sizes and types of connections, which is essential for the versatility of the modular connector arrangement when connecting to various electrical systems.

[0053] The monoblock structure of the module may limit the flexibility of connector arrangement 1 in terms of adaptation and scalability, as the entire module must be replaced or modified if changes to the configuration of connector arrangement 1 are required.

[0054] Fig. Figure 2 illustrates the possible exchange of prior art modules 10 and 20 with split modules 100, 200, 300, 400, which can be combined to form mixed modules. The figure shows two examples of this exchange.

[0055] In the first example, module 10, which is a known prior art module, is shown on the left side of the figure. Module 10 comprises a module housing 11 and connection cavities 12 arranged in two rows. This module 10 can be replaced by combining two split modules, in particular split module 100 and split module 200. Split module 100 comprises a module housing 101 and connection cavities 102 arranged in two rows. It also includes a fastening element 104 for connecting to another split module. Split module 200 comprises a module housing 201, connection cavities 202 arranged in a row, and a fastening element 204. When split module 100 and split module 200 are connected via their respective fastening elements 104 and 204, they form a combined module that can replace module 10 according to the prior art.

[0056] In the second example, module 20, another known module from the prior art, is shown on the left side of the figure. Module 20 comprises a module housing 21 and connection cavities 22. This module 20 can be replaced by combining two split modules, in particular split module 300 and split module 400. Split module 300 comprises a module housing 301 and connection cavities 302. It also includes a fastening element 304 for connecting to another split module. Split module 400 comprises a module housing 401, connection cavities 402, and a fastening element 404. When split module 300 and split module 400 are connected via their respective fastening elements 304 and 404, they form a mixed module that can replace module 20 according to the prior art.

[0057] The figure illustrates the modularity and flexibility of the Split Modules, enabling the creation of mixed modules that can replace existing standard modules in a modular connector arrangement. This approach offers the advantage of adaptable configurations, allowing the arrangement to accommodate various electrical connection requirements by combining different Split Modules. The fasteners ensure a secure connection between the Split Modules, maintaining the structural integrity and functionality of the mixed module.

[0058] Fig. Figure 3 illustrates the assembly process of a mixed module 500, which comprises a first split module 100 and a second split module 400. The figure provides a visual representation of the components and their interaction during the assembly process.

[0059] The connection cavities 102 are designed to accommodate electrical connections and are aligned along the longitudinal axis 40 of the module housing 101. The module housing 101 is equipped with a fastening element 104, which is integral to the process of connecting the first split module 100 to the split module 400.

[0060] The second Split Module 400 is similarly structured. This module also includes a fastener 404, which is designed to engage with the fastener 104 of the first Split Module 100. Fasteners 104 and 404 are crucial for securely fastening the two modules, ensuring a stable and reliable connection. Fastener 104 is a dovetail rail, while fastener 404 is a dovetail slide.

[0061] The assembly process is illustrated in a sequence of steps. First, the first split module 100 and the second split module 400 are positioned so that their respective fastening elements 104 and 404 are aligned. The guide axis 30, which is perpendicular to the longitudinal axis 40, facilitates the alignment and connection of the modules. The modules are then joined along the guide axis 30, as indicated by the directional arrows in the figure.

[0062] After successful alignment and engagement of the fastening elements 104 and 404, the modules are securely connected, forming the mixed module 500. The figure indicates this successful connection with a "click" sound, symbolizing the completion of the assembly process. The mixed module 500 then incorporates the combined connection cavities 102 and 402, enabling a versatile configuration of electrical connections.

[0063] The design of the fastening elements 104 and 404 is such that they prevent relative movement of the split modules 100 and 400 along the longitudinal axis 40, thereby ensuring a positive fit. This secure connection is essential to maintain the integrity and functionality of the mixed module 500 in various applications.

[0064] Fig. Figure 4 illustrates an embodiment of a split module 300 for a modular connector arrangement. The split module 300 comprises a module housing 301 and connection cavities 302 formed along a longitudinal axis 40 of the module housing 301. The module housing 301 includes fastening elements 304 on the top and bottom surfaces, designed to attach the module housing 301 to a second module housing of a second split module.

[0065] The fastening elements 304 in this embodiment are shown as a dovetail rail (on the top) and a dovetail slide (on the bottom) extending along the guide axis 30. The guide axis 30 is perpendicular to the longitudinal axis 40 of the module housing 301, as shown in Fig. Figure 3 shows. The fastening element 304 on the top side further comprises a snap hook 305 and the fastening element 304 on the bottom side comprises a locking shoulder 306, which facilitate the secure fastening of the module housing 301 to the second module housing.

[0066] The Split Module 300 also features a terminal position indicator (TPA) 701, which ensures the correct positioning of the electrical connections within the terminal cavities 302. The TPA 701 is an essential component for maintaining the reliability and integrity of the electrical connections within the Split Module 300.

[0067] The connection cavities 302 are arranged with a specific pitch 70 between them, which can range from 0.1 mm to 5 mm. This pitch is crucial for accommodating various electrical connections and ensuring correct alignment and spacing within the module housing 301.

[0068] The in Fig. The embodiment shown in Figure 4 depicts a split module 300 that can be easily connected to another split module using the fasteners 304, the snap hook 305, and the locking shoulder 306. This modular design allows flexibility in configuring the connector arrangement to meet specific requirements, such as the number of connection cavities and the pitch between them.

[0069] Fig. Figure 5 illustrates a modular connector arrangement 600 designed for automotive applications. The arrangement comprises a connector housing 602 and is shown with a mixed module 500 inserted into one of the module slots 601. The connector housing 602 is structured to accommodate multiple module slots, with the illustrated embodiment having four module slots 601. These module slots are configured to accommodate both mixed modules 500, as described in the invention, and standard monoblock modules 603, demonstrating the versatility of the arrangement in accommodating different types of modules.

[0070] The mixed module 500, which consists of split modules, is inserted along the longitudinal axis 40 of the module slots 601. The design ensures that the split modules forming the mixed module 500 are securely held in place after complete insertion. This is achieved because the connector housing 602 prevents any relative movement of the split modules along the guide axis 30, thus ensuring a stable connection.

[0071] The split modules that form the mixed module 500 have a different number of connection cavities, highlighting the modularity of the modular connector arrangement 600.

[0072] The figure also highlights the presence of a standard monoblock module 603 within the arrangement, indicating that the modular connector arrangement 600 is capable of accommodating both the mixed modules according to the invention and conventional monoblock modules simultaneously. This capability underscores the flexibility and adaptability of the arrangement in various applications, thereby enabling the combination of different module types to meet specific electrical or mechanical requirements.

[0073] The assembly is equipped with a mating support lever 604, which interacts with mating support means 605. This interaction facilitates easier connection of the modular connector assembly 600 to mating connections, thus improving the user experience by simplifying the process of creating a secure connection. The mating support lever 604 is strategically positioned to provide leverage, thereby reducing the effort required during the mating process.

[0074] Additionally, the module slots 601 feature a coding groove 606. This groove is designed to interact with a coding rib on a module housing, thereby ensuring the correct insertion of the module into the slot. The coding groove 606 acts as a guide, preventing misalignment and incorrect insertion of the modules, which could otherwise lead to connection errors or damage to the assembly. In the illustrated example, the mixed module 500 does not provide a coding rib for interaction with the coding groove; however, in another embodiment, one of the split modules forming the mixed module 500 may include a coding rib on its module housing.

[0075] Fig. 3 and Fig. Figure 5 together show a method for manufacturing the modular connector arrangement 600. According to Fig. 3. Two split modules, 100 and 400, are connected to form a mixed module, 500. According to Fig. 5. The mixed module 500 is then inserted into the module slot 601 of the connector housing 602 along the longitudinal axis 40. The longitudinal axis 40 in Fig. 5 is the same as the longitudinal axis 40 in Fig. 3, i.e. the longitudinal axis 40 of the split modules 100 and 400 of the split module 500.

Claims

[1] Split module (100, 300) for a modular connector arrangement (600), comprising: a module housing (101, 301); and at least one connection cavity (102, 302) adapted to accommodate an electrical connection and formed along a longitudinal axis (40) of the module housing (101, 301); wherein the module housing (101, 301) comprises a fastening element (104, 304) for fastening the module housing (101, 301) to a second module housing (201, 401) of a second split module (200, 400). [2] Split module (100, 300) according to claim 1, wherein the fastening element (104) is a slide or a rail extending along a guide axis (30) and is preferably dovetail-shaped, L-shaped or T-shaped. [3] Split module (100) according to claim 2, wherein the guide axis (30) is perpendicular or parallel to the longitudinal axis (40) of the module housing (101, 301). [4] Split module (100, 300) according to any one of claims 1 to 3, wherein the fastening element (104, 304) comprises a snap hook (305) and / or a locking shoulder (306). [5] Split module (100) according to any one of claims 1 to 4, wherein the split module (100) comprises between 1 and 20 connection cavities (102, 302), preferably a total number of 1, 2, 3, 6, 8 or 12 connection cavities (102, 302). [6] Split module (100) according to any one of claims 1 to 5, wherein a pitch distance (70) between two connection 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] Mixed module (500), comprising at least one first split module (100, 300) and one second split module (200, 400) according to one of claims 1 to 6; wherein the first and second split modules (100, 200, 300, 400) are connected to each other by means of their fastening element (104, 204, 304, 404). [8] Mixed module (500) according to claim 7, wherein the fastening elements (104, 204, 304, 404) prevent a relative movement of the split modules (100, 200, 300, 400) to each other along the longitudinal axis (40) by means of positive locking. [9] Mixed module (500) according to one of claims 7 or 8, wherein the split modules (100, 200, 300, 400) together comprise a total number of connection cavities (102, 202, 302, 402) between 2 and 40, preferably 2, 3, 4, 5, 14, 18 or 26. [10] Mixed module (500) according to any one of claims 7 to 9, wherein the total number of connection cavities (102, 302) of the first split module (100, 300) is equal to or different from the total number of connection cavities (202, 402) of the second split module (200, 400). [11] Modular connector arrangement (600) for automotive applications, comprising: a connector housing (602) with at least one module slot (601); wherein the at least one module slot (601) accommodates a mixed module (500) according to one of claims 7 to 9. [12] Modular connector arrangement (600) according to claim 11, wherein the connector housing (692) comprises several module slots (601), preferably four module slots (601). [13] Modular connector arrangement (600) according to one of claims 11 or 12, wherein the at least one module slot (601) has a length of between 20 mm and 30 mm and a height of between 5 mm and 10 mm, preferably a length of 25.3 mm and a height of 8.3 mm. [14] Modular connector arrangement (600) according to any one of claims 11 to 13, further comprising: a plurality of mixed modules (400) each housed in a module slot (601) of the connector housing (601) and each comprising a different total number of connection cavities (102, 202, 302, 402). [15] Modular connector arrangement (600) obtainable by a method comprising the following steps: Forming a mixed module (500) according to any one of claims 7 to 9 by connecting a first split module (100, 300) and a second split module (200, 400) according to any one of claims 1 to 6; and Inserting the mixed module (500) into a module slot (601) of the connector housing (601) along the longitudinal axis (40) of the split modules (100, 200, 300, 400) of the mixed module (500).

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