Modular Plug Connector System with Universal Adapters
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Solution Overview
Problem
The automotive industry faces challenges in integrating different types of plug connectors into a common module housing due to varying assembly requirements, leading to high design, production, and assembly costs, and a need for enhanced security and robustness, especially in autonomous vehicles.
Innovation Solution
A modular plug connector system with a module housing featuring uniform plug places and adapters with uniform interfaces for different types of plug connectors, utilizing a primary and secondary securing means to ensure secure and adaptable connections, allowing for the integration of various plug connector types into a single housing system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If different types of plug connectors are integrated in a common module housing with varying assembly configurations, then the system can accommodate diverse connector types, but the design, production and assembly complexity and costs increase significantly
Solution Approach 1:
The patent implements a universal module housing design with standardized plug places that can accommodate multiple types of plug connectors through interchangeable adapters. The housing structure, plug places, and securing mechanisms are designed as universal components that work with various adapter types, eliminating the need for different housing designs for each connector type. This multi-functional approach allows a single housing to serve multiple purposes across different vehicle applications.
Solution Approach 2:
The system is segmented into independent modular components: the module housing, plug places, adapters, and securing means are all separate, interchangeable units. This segmentation allows the adapters to be customized for different connector types while the housing and plug places remain standardized. The primary and secondary securing means are also separate components that can be applied universally, reducing design complexity while maintaining versatility.
2Adaptability or versatility
If different types of plug connectors are integrated in a common module housing with varying assembly configurations, then the system can accommodate diverse connector types, but the production and assembly costs increase
Solution Approach 1:
The module housing, plug places, and securing mechanisms are designed as universal components that can be mass-produced through standardized manufacturing processes. The standardized interfaces and dimensions allow for efficient production using the same tooling and assembly methods regardless of which specific adapter type is being produced, significantly reducing production costs compared to custom manufacturing for each connector type.
Solution Approach 2:
The adapters are pre-configured with specific internal geometries and securing mechanisms appropriate for different connector types before assembly into the housing. The primary and secondary securing means are designed to be pre-installed or easily attached to the standardized plug places. This preliminary preparation simplifies the final assembly process, reducing labor costs and assembly time.
3Reliability
If a plug connection is designed to withstand high mechanical loading and remain securely closed, then the connection security is improved, but the design and assembly complexity increases
Solution Approach 1:
The securing function is segmented into two independent mechanisms: primary securing means that provide the main mechanical retention and secondary securing means that provide additional safety and locking. This segmentation allows each mechanism to be optimized for its specific function while using standardized components that interface with the universal plug place design, managing complexity through functional separation.
Solution Approach 2:
The secondary securing means acts as a pre-prepared safety mechanism that engages automatically or through simple action to provide additional security. The design incorporates built-in safety features such as detent mechanisms, locking elements, and force distribution structures that are already in place before high mechanical loads are applied, ensuring connection security without requiring complex real-time adjustment mechanisms.
Data Source
AI summary
Embodiments of a modular plug connector system for vehicles may include a module housing having a first housing part with a plurality of uniform first plug places having interfaces for receiving a respective first adapter from a first adapter group, wherein the first adapter group has a plurality of first adapters of different types which have, on their outer sides, uniform interfaces for positioning in the first plug places of the first housing part, wherein the adapters have a different internal geometry for accommodating differently designed plug connectors. The module housing also has a second housing part with a plurality of uniform second plug places having interfaces for receiving a respective second adapter from a second adapter group, wherein the second adapter group has a plurality of second adapters of different types which have, on their outer sides, uniform interfaces for positioning in the second plug places of the second housing part, wherein the adapters have a different internal geometry for accommodating differently designed mating connectors. The outer sides of the first adapter and the second adapter and their corresponding plug places are may form a primary safety device for securing the adapters in their respective plug places when the corresponding adapter is inserted into an end position in the plug places.