Modular Connector Fastening for Precision Alignment
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Solution Overview
Problem
Current control units in motor vehicles face challenges with precise positioning and increased complexity due to a large number of contact elements, requiring a modular electrical plug connector arrangement that maintains precision, strength, and moisture tightness while minimizing space and assembly difficulties.
Innovation Solution
A modular electrical plug connector arrangement featuring a module carrier with laterally attached plug modules, where each module is secured in a fastening area between the connector housing collar and contact area, using a material bond such as laser welding, and optionally featuring partial contact areas and a conical gap to manage moisture and mechanical forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a large number of contact elements are provided on the control unit for up to 200 or more electrical lines, then the control unit can handle increased functions and data exchange requirements, but positioning the contact elements with sufficient accuracy becomes difficult
Solution Approach 1:
The plug connector is divided into multiple plug modules (first plug module, second plug module, etc.), each containing a subset of contact elements. This segmentation allows each module to be manufactured separately with high precision using injection molding, avoiding the positioning difficulties that would arise with a single large connector containing 200+ contact elements.
2Area of stationary object
If multiple plug modules are arranged side by side on the module carrier, then space usage is optimized and assembly efficiency is improved, but ensuring sufficient mechanical strength and moisture tightness becomes more challenging
Solution Approach 1:
The plug modules are nested within the module carrier structure, with each module positioned in a dedicated receptacle. The module carrier provides a protective outer structure that maintains mechanical strength and moisture tightness while accommodating multiple smaller plug modules inside, similar to nested dolls.
3Manufacturing precision
If plug modules are attached to the module carrier in an attachment area laterally between the connector housing collar and contact area, then precise contact alignment is achieved, but the attachment structure becomes more complex
Solution Approach 1:
The module carrier acts as an intermediary structure between the plug modules and the final assembly. It provides standardized attachment areas and positioning features that simplify the connection process, mediating between the individual plug modules and ensuring precise contact alignment without requiring complex direct attachment mechanisms.
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
This design achieves high mechanical strength, fluid tightness, and precise contact alignment, ensuring reliable electrical connections under varying environmental conditions while optimizing space usage and assembly efficiency.
Implementation Method 1
using a material bond such as laser welding
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
The invention relates to a modular electrical connector assembly (2) for a control unit in a motor vehicle. The connector assembly (2) comprises a module mount (4) and a first and second connector module (6, 8). Each connector module (6, 8) has a connector housing collar (12, 14) which juts out in a direction away from the module mount (4) and which is formed to receive one electrical connector each. The first and the second connector module (6, 8) each has a plurality of for example pin-type contact elements (18) that are arranged in a contact region (19) within the respective connector housing collar (12, 14) and that are formed to cooperate with complementary mating contact elements of the respective electrical connector. The connector modules (6, 8) are fastened to the module mount (4) in a fastening region (22) which is arranged between the respective connector housing collar (12, 14) and the respective contact region (19), i.e., in the top view, the fastening region is arranged within the outer contour of the connector module (6, 8) defined by the connector housing collar (12). Owing to this inner fastening connection between the module mount and the connector module, the individual connector modules can be arranged in very close lateral adjacency to each other. A connection in the fastening region (22) can for example be a material connection by laser welding.