Modular Contact Housing for Automotive Connectors
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Solution Overview
Problem
Existing electrical plug connectors and mating connectors require separate contact housings for different contact systems, leading to complex and costly production processes, especially when multiple planes are involved, and pose challenges in setting up secondary contact locks and quick, economical assembly.
Innovation Solution
A modular contact housing design with two interlocking modules that can accommodate different contact systems, allowing for production in a single casting process and easy assembly, featuring a flexible connecting element and contact-lock mechanisms for secure locking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate contact housings are used for different contact systems, then each contact system can be optimized independently, but the production process becomes complex and costly requiring multiple casting molds
Solution Approach 1:
The contact housing is divided into two separate contact-housing modules, each capable of accommodating a different contact system. This segmentation allows each module to be optimized for its specific contact system while maintaining the ability to produce both modules in a single casting process using a specially designed casting mold that can form both modules simultaneously.
2Adaptability or versatility
If contact means are arranged in multiple planes, then more contact systems can be integrated, but setting up secondary contact locks becomes awkward and complex
Solution Approach 1:
The patent addresses multi-plane contact integration by designing the contact-housing modules to accommodate contact means in different planes while maintaining simple contact lock mechanisms. The modules are designed with contact locks that can be easily set up regardless of the plane in which the contact means are arranged, avoiding the complexity that would normally arise from multi-plane configurations.
3Manufacturing precision
If separate contact housings are produced using injection-moulding, then each housing can be precisely manufactured, but two casting molds are required increasing production cost
Solution Approach 1:
The patent combines the production of two separate contact-housing modules into a single casting process. A specially designed casting mold can produce both modules simultaneously in one operation, maintaining the precision required for each module while eliminating the need for two separate casting molds, thereby reducing production costs.
4Productivity
If contact housings are designed for quick assembly, then assembly time is reduced, but the interface between plug connector and mating connector becomes more complex
Solution Approach 1:
The contact-housing modules are designed with pre-configured contact lock mechanisms and connection interfaces that enable quick assembly. The modules come pre-prepared with the necessary locking features and interface elements, allowing for rapid assembly without requiring complex interface designs or additional assembly steps.
Data Source
AI summary
The invention relates to a contact housing (1) for at least two electrical contact means, in particular for an electrical plug connector or mating connector for the automotive sector, with two contact-housing modules (10, 20), with a first electrical contact means being able to be set up in a first contact-housing module (10) and a second electrical contact means in a second contact-housing module (20), the contact-housing modules (10, 20) being provided to be able to be moved towards one another and being able to be fixed to one another, in particular being able to be mutually latched with each other. Further, the invention relates to an electrical plug connector or an electrical mating connector, in particular an electrical female connector, and to an assembled electrical line, the electrical plug connector or the electrical mating connector, or the assembled electrical line having a contact housing (1) according to the invention.