Modular Electrical Connector Frame for Reconfigurable Terminal Bays

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Solution Overview

Problem

Traditional electrical connector designs require retooling of molds to modify input/output terminal configurations, limiting flexibility and adaptability to different applications.

Innovation Solution

An electrical connector assembly with modular terminal modules and a frame featuring module bays that allow for interchangeable terminal modules with varying configurations, secured by cantilevered locking arms and stop pads, enabling customizable input/output configurations without retooling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If traditional molded connector bodies with fixed terminal cavities are used, then manufacturing precision and structural stability are maintained, but adaptability to different applications deteriorates due to the inability to relocate or reconfigure terminals

Engineering Contradiction:

Improveterminal configuration adaptabilityVSAvoidconnector structure complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The connector body is segmented into modular terminal modules that can be independently configured and repositioned within the connector housing, allowing different terminal arrangements without redesigning the entire connector structure

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The connector body is designed with universal mounting features and standardized terminal modules that can accommodate multiple terminal configurations and applications through reconfiguration rather than requiring different connector designs

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Productivity

If hard changes to mold tools are required to modify terminal configuration, then manufacturing precision is maintained, but productivity and time to market deteriorate due to retooling requirements

Engineering Contradiction:

Improveconfiguration change speedVSAvoidtooling modification difficulty

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The terminal modules are designed to be dynamically reconfigurable within the connector body, allowing configuration changes during production or even in the field without requiring static mold retooling, thus improving productivity and response time to market requirements

Inventive Principle:

Principle #15Dynamics

3Adaptability or versatility

If terminal cavities are fixed in position and type, then ease of manufacture is improved through simplified molding processes, but adaptability to different vehicle trim levels and technological advancements deteriorates

Engineering Contradiction:

Improveapplication-specific customizationVSAvoidvehicle development phase time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

Multiple terminal modules are pre-configured with different terminal types and arrangements during connector manufacturing, allowing rapid selection and installation of appropriate configurations for different vehicle applications during the assembly process, thereby reducing vehicle development time

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS12431661B2Electrical connector with terminal modules and frame having module bays for customizable input/output configuration

Publication Date: 2025.09.30 APTIV TECHNOLOGIES AG

AI summary

A terminal module includes a housing defining a cavity configured to receive an electrical terminal within and a primary terminal lock configured to releasably retain the electrical terminal after it is fully inserted within the cavity. The terminal module further includes a secondary terminal lock attached to the housing defining a protrusion that enters into the cavity at a location rearward of the electrical terminal as the secondary terminal lock is moved from a pre-stage position to a staged position. A method of assembling an electrical connector including this terminal module is also provided.