Modular Connector Carrier Alignment
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Solution Overview
Problem
In vehicle systems, modular electrical connectors face challenges with improper alignment and connection due to increased electrical content and larger connectors, leading to potential electrical failures.
Innovation Solution
A connector system with a frame and carrier structure, where the carrier is insert molded within the frame to provide stiffness and precise alignment of connector modules, using a metal carrier to prevent bowing and ensure true positioning, and ultrasonic welding for secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If modular connectors are used with increased electrical content and larger connectors, then the electrical connection capacity is improved, but the alignment precision and connection reliability deteriorate
Solution Approach 1:
The connector is divided into modular receiving bays that can be independently positioned and secured. Each bay is a separate module that can be precisely aligned and attached to the frame, allowing the overall connector to maintain high alignment precision even as the total number of electrical connections increases.
Solution Approach 2:
A carrier component is introduced as an intermediary between the frame and the connector modules. The carrier provides precise positioning features and structural support that ensure accurate alignment of multiple modules within the frame, solving the alignment precision problem in large-scale modular connectors.
2Quantity of substance
If the number of connector modules is increased, then the electrical content and connection density are improved, but the structural stability and true position maintenance deteriorate
Solution Approach 1:
Multiple connector modules are merged into a single integrated assembly within the frame structure. The frame and carrier combine to form a unified structural system that provides overall stability while accommodating multiple individual modules, maintaining true position across the entire assembly even as module quantity increases.
Solution Approach 2:
The frame structure serves multiple functions simultaneously: it provides structural support, maintains alignment, secures modules in place, and ensures true position. This multi-functional design allows the structure to maintain stability while accommodating increased numbers of connector modules.
3Quantity of substance
If larger connectors are used to accommodate more circuits, then the electrical connection capacity is improved, but the risk of electrical failures due to improper alignment increases
Solution Approach 1:
Alignment features and positioning mechanisms are built into the frame and carrier structures before the connector modules are assembled. This preliminary preparation of alignment references ensures that when modules are installed, they automatically achieve precise alignment, reducing the risk of electrical failures even in large-scale connectors with many circuits.
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 solution enhances precision and stability of connector alignment, reducing electrical failures by maintaining precise module positioning and providing greater dimensional stability, allowing for easier production and adaptability of smaller modules with varied terminal arrangements.
Implementation Method 1
the carrier is insert molded within the frame to provide stiffness and precise alignment of connector modules
Implementation Method 2
and ultrasonic welding for secure attachment
Data Source
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AI summary
A connector assembly is provided that includes a carrier embedded within a molded frame. The carrier further includes an aperture positioned within an opening formed in the carrier configured to receive a boss formed on a connector housing. A connector module having a plurality of electrical terminals retained in the housing and secured to the frame. The connector module aligned to the frame by the carrier by the boss formed in the housing engaging the aperture. The carrier adding rigidity to the frame and providing a precise alignment of the connector modules to the frame.