Connector Module Assembly With Integrated Secondary Locking Beams

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Solution Overview

Problem

Existing modular electrical connector systems face deficiencies in design complexity, requiring additional parts for secondary locking and lacking flexibility in accommodating terminals of varying sizes within a single housing.

Innovation Solution

An electrical connector system with integrated elongate beams in the housing that serve as secondary locks, allowing terminals of different sizes to be used in one row, and a snap-fit mechanism for secure fastening without additional parts.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If additional parts are provided to fasten connector modules in the housing, then the connector modules are securely fastened, but the device complexity increases

Engineering Contradiction:

Improvesecure fastening of connector modulesVSAvoidnumber of additional parts

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the secondary locking function with the housing structure by integrating elongate locking beams directly into the housing body. This merging eliminates the need for separate fastening parts, as the housing itself provides both structural support and locking functionality through the integrated beams that engage with connector modules.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The housing structure is designed to serve multiple functions: it provides structural support, guides connector module insertion, and simultaneously provides secondary locking through the integrated elongate beams. This multi-functionality reduces the need for dedicated fastening components while maintaining secure connector module attachment.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Device complexity

If the housing structure is simplified, then the device complexity is reduced, but the ability to accommodate terminals of different sizes is limited

Engineering Contradiction:

Improvehousing structure designVSAvoidaccommodation of different terminal sizes

Core Design Contradiction:

Device complexityVSAdaptability or versatility

Solution Approach 1:

The housing is segmented into multiple regions defined by transverse walls and longitudinal walls, creating distinct compartments that can accommodate connector modules of varying sizes. The elongate locking beams are positioned to engage with different sections of connector modules, allowing the same simplified housing structure to securely hold modules with different terminal configurations.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The housing structure incorporates local variations in wall positions and locking beam placements to accommodate different terminal sizes. Specifically, the transverse walls and longitudinal walls create localized regions with different dimensional characteristics, while the elongate beams provide localized locking at critical points, enabling versatility without overall structural complexity.

Inventive Principle:

Principle #3Local quality

3Device complexity

If elongate locking beams are integrated with the housing, then the number of additional parts is reduced, but the manufacturing complexity increases

Engineering Contradiction:

Improvenumber of partsVSAvoidintegration process

Core Design Contradiction:

Device complexityVSEase of manufacture

Solution Approach 1:

The elongate locking beams are merged with the housing structure, forming a single integrated component. This combining reduces the total part count and simplifies assembly, as the locking beams are already positioned and secured within the housing during its formation, eliminating separate installation steps.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Inventive Principle:

Principle #6Universality (Multi-functionality)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The system provides a simplified design with reduced installation space, enabling secure fastening of terminals of varying sizes within a single housing, enhancing flexibility and stability.

Implementation Method 1

The secondary lock is integrated with the housing and comprises an elongate beam having a snap-fit profile adapted for snapping into a corresponding groove in the connector module

Methodology Applied

Scientific EffectSnap-fit: Mechanical Fastener

Data Source

PatentEP4614736A1Method of assembling connector modules using secondary lock

Publication Date: 2025.09.10 APTIV TECHNOLOGIES AG

Figure 1A~1B
Figure 2A~2B
Figure 2C~2D

AI summary

The present disclosure relates to an electrical connector system. An electrical connector system (200) is provided. The electrical connector system (200) comprises a housing (202) and at least one connector module (204A, 204B, 204C, 204D) adapted for holding a plurality of terminals. Each terminal comprises a primary lock adapted for primary locking the terminal in the connector module (204A, 204B, 204C, 204D). The connector module (204A, 204B, 204C, 204D) is associated with a secondary lock. The secondary lock is adapted for secondary locking the terminals in the connector module. The secondary lock is integrated with the housing (202) and comprises an elongate locking beam (214A, 214B, 214C, 214D) having a snap-fit profile adapted for snapping into a corresponding groove (216A, 216B, 216C, 216D) of the connector module (204A, 204B, 204C, 204D) for fastening the connector module to the housing (202).