Modular Electrical Connector Assembly for Automotive FAKRA Applications
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Solution Overview
Problem
The complexity of FAKRA standard connectors for automotive applications leads to inefficient assembly processes and increased production costs due to the need for multiple connector types and molds, causing manufacturing and management burdens.
Innovation Solution
An electrical connector assembly with integrated terminal sets in plug and receptacle connectors, compliant with SMB RF connector specifications, allowing for simplified assembly and reduced production costs through modularization and one-step docking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple connector types with different keys or colors are provided for different applications, then the adaptability to different functions is improved, but the device complexity and manufacturing burden increase
Solution Approach 1:
The patent applies universality by designing a single connector body structure that can accommodate multiple terminal types (SMB, SMA, MCX, etc.) through modular terminal assemblies. The connector body includes a standardized key slot and docking interface, while different terminal configurations can be installed in the terminal receiving space, allowing one connector body to serve multiple functions and applications.
Solution Approach 2:
The patent segments the connector into distinct modular components: a standardized connector body and separate terminal assemblies. The terminal assemblies can be independently configured with different terminal types and arrangements, allowing customization without changing the base connector structure. This segmentation enables flexible configuration while maintaining a unified docking interface.
2Adaptability or versatility
If multiple connector types are provided for different applications, then the adaptability is improved, but the manufacturing cost and production management burden increase
Solution Approach 1:
The connector body is designed as a universal platform that can produce multiple connector variants. By maintaining a standardized connector body design with consistent manufacturing processes and then configuring different terminal assemblies, the manufacturer can produce various connector types from a single base design, reducing the need for separate molds and tooling for each connector variant.
Solution Approach 2:
The patent merges the common structural elements (connector body, key slot, docking interface) into a single standardized component that serves all connector types. Only the terminal assemblies differ, allowing the manufacturing process to be consolidated around the universal connector body while accommodating different terminal configurations through modular assembly.
3Adaptability or versatility
If multiple connector types are provided for different applications, then the adaptability is improved, but the assembly time and production efficiency decrease
Solution Approach 1:
The connector is segmented into a pre-manufactured standardized body and modular terminal assemblies. This segmentation allows the connector body to be produced once and reused for different applications, while only the terminal assemblies need to be changed. The modular terminal assemblies can be pre-configured and then quickly installed into the standardized body, significantly reducing assembly time compared to manufacturing complete connectors from scratch for each application.
Solution Approach 2:
The connector body is prepared in advance with standardized features (key slot, terminal receiving space, docking interface) that are compatible with multiple terminal types. This preliminary preparation of the universal body allows for rapid configuration of different connector variants by simply installing different terminal assemblies, eliminating the need to perform full manufacturing procedures for each connector type.
4Adaptability or versatility
If multiple connector types are provided for different applications, then the adaptability is improved, but the inventory management complexity and production costs increase
Solution Approach 1:
The standardized connector body serves as a universal platform that can accommodate multiple terminal configurations. Instead of maintaining separate inventories for completely different connector types, the manufacturer and assembler can maintain inventory of a single connector body design and different terminal assemblies, reducing the total variety of items that need to be managed in the supply chain.
Solution Approach 2:
By segmenting the connector into a universal body and interchangeable terminal assemblies, the inventory system can be simplified. The standardized body can be produced in large quantities and stored as a common component, while terminal assemblies can be configured as needed. This reduces the number of unique SKUs that need to be tracked and managed compared to maintaining complete assemblies for each connector variant.
Data Source
AI summary
An electrical connector assembly including a plug electrical connector and a receptacle electrical connector is provided. The plug electrical connector includes a first structural member and a plurality of first terminals, and the first terminals are disposed in the first structural member. The receptacle electrical connector includes a second structural member and a plurality of second terminals, and the second terminals are disposed in the second structural member. The first structural member is adapted for docking with the second structural member such that the first terminals are correspondingly inserted and electrically connected to the second terminals.