Modular Electric Plug Connector Laser Welding Precision
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Solution Overview
Problem
The increasing number of electrical lines in motor vehicle control units, requiring high precision and accuracy in connector assembly, poses challenges in positioning and manufacturing precision, especially with conventional injection molding methods which often result in insufficient positioning accuracy and increased complexity.
Innovation Solution
A modular electrical connector assembly method using a module carrier with laser-welded connector modules, where each module is manufactured with high precision and assembled with precise positioning, minimizing manufacturing tolerances and ensuring high accuracy, strength, and sealing requirements, utilizing different materials for flexible laser welding and minimizing space requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional injection molding methods are used to manufacture connector modules, then manufacturing simplicity is maintained, but positioning precision and manufacturing accuracy deteriorate
Solution Approach 1:
The connector assembly is divided into multiple independent connector modules that can be manufactured separately using injection molding, then precisely positioned and assembled on a module carrier. This segmentation allows each module to be manufactured with high precision independently, while the overall assembly complexity is managed through modular design.
Solution Approach 2:
A module carrier is introduced as an intermediary component that holds and precisely positions the individual connector modules. The module carrier serves as a mediator that enables accurate positioning of multiple modules relative to each other, resolving the positioning precision issue without requiring complex direct manufacturing of the entire assembly.
2Manufacturing precision
If connector modules are assembled with minimal manufacturing tolerances to achieve high precision, then positioning accuracy improves, but the risk of warping and damage during assembly increases
Solution Approach 1:
Conventional mechanical fastening methods are replaced with laser welding technology for joining connector modules to the module carrier. Laser welding provides precise, localized heating that minimizes thermal distortion and warping risk, while achieving strong, reliable bonds. This substitution of joining method enables minimal manufacturing tolerances to be maintained without increasing warping risk.
3Device complexity
If a large number of contact elements are integrated into a single connector unit, then device complexity is reduced, but positioning precision deteriorates
Solution Approach 1:
Instead of manufacturing one large connector unit with many contact elements, the system segments the connector into multiple smaller modules, each containing a subset of contact elements. Each module can be manufactured with high precision using standard injection molding techniques, and then assembled on the module carrier to achieve the required overall positioning accuracy.
4Ease of manufacture
If different materials are used for module carrier and connector modules to enable flexible laser welding, then welding flexibility improves, but material selection complexity increases
Solution Approach 1:
The laser welding process utilizes differences in optical absorption parameters between materials. By selecting materials with different laser absorption characteristics, the system enables flexible laser welding where the laser beam can selectively melt and join different material combinations. This parameter-based approach to material selection provides welding flexibility while managing complexity through established material properties.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method achieves high manufacturing precision, stability, and cost-effectiveness by allowing precise positioning and secure bonding of connector modules with minimal risk of warping or damage, meeting the stringent requirements for motor vehicle applications.
Implementation Method 1
the connector module is then laser-welded to the module carrier in a fastening area
Implementation Method 2
utilizing different materials for flexible laser welding
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The invention relates to a method for producing a modular electrical connector assembly (2) for a control unit in a motor vehicle. The connector assembly comprises a module mount (4) and at least two connector modules (6, 8) which are arranged next to each other on the module mount (4). Each connector module (6, 8) has a connector housing collar (12) and a plurality of contact elements (18) that are arranged in a contact region (19) within the connector housing collar (12). In order to produce the connector assembly (12), first one of the connector modules (6, 8) is arranged in a recess (5) in the module mount (4) and is arranged in a precise orientation relative to the module mount (4). The connector module is then pressed against the module mount (4), which is for example held in a holder (46), for example with the aid of a hold-down element (38). In this state, the connector module (6) is laser-welded to the module mount (4) in a fastening region (22) using a laser beam (40). The use of laser welding techniques allows a reliably stable and fluid-tight material connection between the components (4, 6) and an advantageous, space-saving arrangement of the fastening region (22) laterally inside the connector housing collar (12) with at the same time higher manufacturing precision and lower manufacturing tolerances.