Modular Electrical Connector Assembly With Interchangeable Covers
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Solution Overview
Problem
Existing electrical connectors require soldering for terminal splicing and resin potting, which can fail during manufacturing or installation, and are not modular with interchangeable parts, necessitating different models for various applications.
Innovation Solution
A modular electrical connector assembly with a base and interchangeable covers, where the base terminals and cover terminals are designed with tabs and receptacles for secure engagement, allowing alternate covers to be mounted without solder or resin potting, and latches for secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldering is used for terminal splicing, then electrical connection reliability is improved, but manufacturing complexity and failure risk increase
Solution Approach 1:
The patent replaces the soldering process (thermal/chemical joining) with a mechanical tab-and-receptacle engagement system. The cover terminal tabs insert into base terminal receptacles, creating a reliable electrical connection through purely mechanical means, thereby eliminating soldering complexity and associated failure modes.
Solution Approach 2:
The connector is divided into separate modular components (base with base terminals, cover with cover terminals) that can be assembled independently. The base terminals include receptacles and the cover terminals include tabs, allowing the electrical connection to be established through simple insertion without requiring complex soldering operations.
2Object-affected harmful factors
If resin potting is used for terminal sealing, then environmental protection is improved, but manufacturing time and complexity increase
Solution Approach 1:
The patent replaces resin potting (chemical sealing process requiring curing time) with a mechanical latch system. The latches engage with the cover to provide environmental sealing through purely mechanical means, eliminating the time required for resin application and curing while maintaining protective functionality.
Solution Approach 2:
The latch mechanism is pre-configured on the base to engage with the cover, providing immediate environmental protection upon assembly. This eliminates the need for subsequent resin potting and curing steps, as the sealing action is accomplished during the initial assembly operation.
3Reliability
If connector design is application-specific, then connection reliability for particular equipment is improved, but adaptability to different equipment decreases
Solution Approach 1:
The patent designs the base terminals with standardized receptacles that can accommodate tabs from different cover configurations. This universal receptacle design allows a single base model to work with multiple cover types, enabling adaptability to different equipment while maintaining reliable electrical connections through the consistent tab-and-receptacle engagement mechanism.
Solution Approach 2:
The connector system allows dynamic reconfiguration by enabling the base to mate with different cover types as needed. The standardized receptacle design permits flexible assembly of appropriate covers for different applications, providing adaptability without compromising the reliability of the electrical connection mechanism.
4Adaptability or versatility
If modular design with interchangeable parts is implemented, then adaptability is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent applies local quality by providing precise dimensional specifications and tolerances specifically for the tab-and-receptacle engagement features, while other portions of the connector components can be manufactured with standard tolerances. This focused approach to precision manufacturing ensures reliable interchangeability without requiring high precision across all components.
Solution Approach 2:
The patent employs partial action by concentrating manufacturing precision requirements only on the critical tab and receptacle interfaces that enable interchangeability, rather than requiring high precision throughout the entire component. This selective precision approach achieves the necessary adaptability while controlling manufacturing complexity and cost.
Data Source
AI summary
A connector assembly has a base and a cover. The base has first base terminals and second base terminals for engaging an equipment member. The first and second base terminals include tabs at a first end thereof. The cover has cover terminals, with each cover terminal comprising a tab at first end and at least one receptacle at a second end thereof. The tabs of the cover terminals are configured to releasably engage a first mating electrical connector and the receptacles are configured to releasably engage the tabs of the first base terminals or the tabs of the second base terminals. The configuration of the first base terminals and the second base terminals allows alternate covers to be releasably mounted on the base as required.