Caged Modular Female Connector Inserts for Secure Terminal Locking
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Solution Overview
Problem
Automotive electrical connectors face challenges in high-bandwidth data transmission due to heat, vibration, electromagnetic interference, space constraints, dirt, and dust, requiring a robust, reliable, and serviceable connector system for high-speed data applications.
Innovation Solution
A female electrical connector with a shiftable modular insert and cage inner housing design that allows easy assembly, secure locking, and disassembly, along with a latching mechanism and elastic seal for protection and encoding, ensuring reliable and adaptable connectivity for high-speed data transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a robust connector design is used to withstand automotive environments (heat, vibration, EMI), then reliability is improved, but assembly complexity increases
Solution Approach 1:
The connector is divided into modular components: outer housing, cage inner housing, inserts, and electrical terminals. Each component serves a specific function and can be assembled independently, reducing overall assembly complexity while maintaining robustness through modular design
Solution Approach 2:
The cage inner housing is nested within the outer housing, and the inserts are nested within the cage inner housing. This nested structure provides multiple protective layers against environmental factors while maintaining a compact design that doesn't significantly increase assembly complexity
2Reliability
If a secure locking mechanism is implemented to prevent accidental disconnection, then reliability is improved, but ease of operation deteriorates
Solution Approach 1:
The insert is designed to be dynamically shiftable between assembly position and locking position. This dynamic mechanism allows the connector to transition from an open assembly state to a secure locked state, providing both ease of assembly and secure connection through a single movable component
Solution Approach 2:
The shiftable insert automatically performs both assembly and locking functions through its movement. When the insert shifts from assembly position to locking position, it simultaneously secures the electrical terminal and prevents accidental disconnection, eliminating the need for separate locking operations
3Reliability
If a protective cage structure is added to shield inserts, then reliability is improved, but device complexity increases
Solution Approach 1:
The cage inner housing combines multiple functions into a single structural element: it provides mechanical protection for the inserts, defines the mating direction, guides the shiftable insert movement, and structurally connects to both the outer housing and inserts. This merging reduces the need for separate protective components
4Adaptability or versatility
If modular inserts are used to allow individual terminal assembly, then adaptability is improved, but manufacturing precision requirements increase
Solution Approach 1:
The connector uses individually shiftable inserts for each electrical terminal, allowing selective assembly and configuration. Each insert can be independently positioned and locked, enabling adaptability for different terminal configurations while maintaining precise alignment through the standardized insert design
Solution Approach 2:
The insert acts as an intermediary component between the electrical terminal and the cage inner housing. It provides a standardized interface that simplifies the assembly process and maintains precise positioning, reducing the overall manufacturing precision requirements for the complete connector assembly
Data Source
Figure 1
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AI summary
Female electrical connector 1 comprising an outer housing to defining a mating direction X of the female electrical connector 1; at least one female electrical terminal 20, 21; at least one insert 30, 31, individually surrounding the at least one female electrical terminal 20, 21; a cage inner housing 40, connected to the inside of the outer housing 10, extending in mating direction X out of the outer housing 10, and surrounding the at least one insert 30, 31 in mating direction X; wherein the insert 30, 31 is shiftable in mating direction X between an assembly position 32 in which the female electrical terminal 20, 21 is insertable into the female electrical connector 1 and a locking position 33 in which the female electrical terminal 20, 21 is locked within the female electrical connector 1.