Electrical Connector Assembly With Segmented Contacts
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Solution Overview
Problem
Electrical connectors in automotive applications face challenges such as degradation due to vibration and exposure to inclement weather, and the fragility of terminals makes them susceptible to damage during assembly and mating, particularly as connectors become smaller and more densely packed.
Innovation Solution
The design of an electrical connector assembly featuring a header with separated receptacles and contacts that include first and second pins, allowing for secure mating and sealing through independent secondary locks and peripheral seals, which also includes a two-piece housing with latches and wire seals to prevent moisture ingress, enabling robust and reliable connections between wire harnesses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If terminals are made smaller to increase density, then connector size decreases and terminal density increases, but terminal robustness deteriorates and fragility increases
Solution Approach 1:
The patent combines the pin and receptacle functions into a single contact element. The contact includes both a pin portion extending into the first receptacle and a receptacle portion extending into the second receptacle, eliminating the need for separate pin and receptacle terminals. This merging allows for more robust single-piece contacts while maintaining high density.
Solution Approach 2:
The contact is segmented into distinct functional portions: a pin portion for mating with the first plug and a receptacle portion for mating with the second plug. The midwall separates these portions while providing structural support. This segmentation allows each portion to be optimized for its specific function while maintaining overall robustness.
2Reliability
If connectors are sealed to protect against environmental factors, then protection against water and contaminants improves, but manufacturing complexity increases
Solution Approach 1:
The header body integrates multiple functions: it provides structural support, holds the contacts, defines the receptacles, and incorporates the seal. The seal is integrated into the header body structure itself rather than being a separate component, simplifying manufacturing while maintaining effective sealing.
Solution Approach 2:
The seal is implemented as a flexible sealing member that can deform to accommodate assembly variations and provide reliable sealing. The sealing member is positioned within the header body to prevent water and contaminant ingress while maintaining a relatively simple overall structure.
3Reliability
If multiple separate components are used for secure mating, then connection reliability improves, but assembly complexity increases
Solution Approach 1:
The contact is manufactured as a single integrated piece combining both pin and receptacle portions. The midwall provides structural support while holding both portions. This reduces the number of parts from multiple separate components to a single integrated contact element, simplifying assembly while maintaining reliable electrical and mechanical connections.
Data Source
AI summary
An electrical connector assembly includes a header having a body having a first receptacle and a second receptacle separated by a midwall and a plurality of contacts held by the midwall. The contacts have first pins located within the first receptacle and second pins located within the second receptacle. A first plug is received in the first receptacle. The first plug includes a housing holding a plurality of terminals terminated to corresponding wires having sockets mated with corresponding first pins in the first receptacle. The sockets are configured to be electrically connected to sockets of a second plug received in the second receptacle by the contacts held by the header.