Modular Connector Assembly With Integrated TPA for Terminal Insertion
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Solution Overview
Problem
Current electrical connectors lack modularity, leading to increased tooling and assembly costs, and are prone to assembly errors due to incorrect or insufficient terminal insertion, necessitating the use of separate terminal position assurance (TPA) devices.
Innovation Solution
A modular connector assembly with interconnected bodies featuring TPA elements that move between positions to ensure proper terminal insertion, reducing the need for separate TPA devices and allowing for customizable connections by standardizing terminal spaces and pitches.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional non-modular connector designs are used, then connector housing variety increases to accommodate different applications, but tooling and assembly costs increase
Solution Approach 1:
The connector is divided into separate modular components: a reusable base housing and interchangeable terminal assemblies. Each terminal assembly can be independently manufactured and then attached to the base housing, eliminating the need to create entirely new connector housings for different applications. This segmentation allows standardization of the base housing while maintaining versatility through different terminal configurations.
Solution Approach 2:
The base housing is designed as a universal component that can accommodate multiple types of terminals through standardized interfaces and terminal spaces. The housing includes generic features such as standardized cavity dimensions, attachment mechanisms, and mounting interfaces that work with various terminal types, thereby reducing the need for application-specific housing variations.
2Reliability
If traditional connector designs are used, then connector size is large, but terminal position assurance becomes more difficult
Solution Approach 1:
The TPA element is integrated within the terminal assembly structure itself, nested within the housing cavities and terminal positioning features. The TPA protrusions are incorporated as part of the terminal retention mechanism, eliminating the need for separate external TPA devices. This nesting approach ensures reliable terminal position verification while maintaining a compact connector overall size.
3Reliability
If separate TPA devices are used, then terminal placement errors can be detected, but device complexity increases
Solution Approach 1:
The TPA functionality is merged with the terminal assembly and base housing structures. The TPA protrusions are integrated into the terminal retention features, and the TPA detection mechanism is combined with the housing cavity design. This merging eliminates separate TPA components while maintaining error detection capability, thereby reducing overall device complexity.
Solution Approach 2:
The connector structures themselves provide the TPA function through their geometric features. The housing cavities and terminal retention mechanisms are designed to inherently verify terminal positioning through their physical geometry, eliminating the need for separate detection devices. The structure serves its own verification function.
Data Source
AI summary
A modular connector assembly comprises a plurality of interconnected bodies, including a first body and a second body. The first body defines at least a first portion of a first terminal space sized to receive a terminal of a first type in an insertion direction. A connecting element detachably connects the first body to the second body. The second body is movable relative to the first body between a first position and a second position via the connecting element. The connecting element may be embodied as a terminal position assurance (TPA) element. The TPA element is arranged outside of the first terminal space in the first position and arranged within the first terminal space in the second position for engaging with the terminal of the first type.