Modular Electrical Connector Inserts for Secure Terminal Assembly
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Solution Overview
Problem
Existing electrical connectors for high-speed data applications in automotive environments lack ease of assembly, reliability, and robustness, particularly in harsh conditions such as heat, vibration, and electromagnetic interference.
Innovation Solution
The electrical connector features a modular design with caged inserts that include a terminal locking mechanism, allowing for easy assembly and secure locking of electrical terminals. The terminal locking mechanism is integral to the insert, switchable between assembly and locking positions, and provides reliable locking without the need for additional parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional electrical connectors are used for high-speed data applications, then electromagnetic interference protection is provided, but assembly complexity increases and serviceability deteriorates
Solution Approach 1:
The connector is divided into modular components: an outer housing, multiple removable inserts (each containing a terminal locking means), and electrical terminals. This segmentation allows each insert to be independently assembled and serviced, reducing overall assembly complexity while maintaining shielding effectiveness through the structured modular architecture.
Solution Approach 2:
The insert serves multiple functions: it houses the terminal locking means, provides structural support for the electrical terminal, and contributes to the overall shielding structure. This multi-functionality reduces the number of separate components needed, simplifying assembly while maintaining reliability.
2Reliability
If traditional electrical connectors are used for high-speed data applications, then electromagnetic interference protection is provided, but ease of assembly and serviceability worsen
Solution Approach 1:
The connector is divided into modular components: an outer housing, multiple removable inserts (each containing a terminal locking means), and electrical terminals. This segmentation allows each insert to be independently assembled and serviced, reducing overall assembly complexity while maintaining shielding effectiveness through the structured modular architecture.
Solution Approach 2:
The terminal locking means incorporates a movable locking element that can transition between locked and unlocked states. This dynamic mechanism enables easy assembly and disassembly of terminals while ensuring secure connection during operation, improving ease of serviceability without compromising connection reliability.
3Ease of operation
If modular inserts with integral locking means are used, then ease of assembly and serviceability improve, but device complexity increases
Solution Approach 1:
The terminal locking means is integrated as an integral part of the insert, combining the locking mechanism with the insert structure itself. This merging eliminates the need for separate locking components, reducing the overall number of parts while maintaining ease of assembly and serviceability through the unified modular design.
Data Source
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AI summary
Electrical connector 1 comprising an outer housing to defining a mating direction X of the female electrical connector 1; at least one electrical terminal 20; at least one insert 30, individually surrounding the at least one electrical terminal 20; wherein the insert 30 comprises a terminal locking means 40 for selectively locking the electrical terminal 20 within the insert 30; wherein the terminal locking means 40 is an integral part of the insert 30 and is switchable between an assembly position 41 in which the electrical terminal 20 is insertable into the electrical connector 1 and a locking position 42 in which the electrical terminal 20 is locked within the electrical connector 1 by the terminal locking means 40. The application further comprises a method for an assembly of an electrical connector 1.