Modular Plug Connector Assembly Using Fixed Functional Units
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Solution Overview
Problem
Existing modular industrial connectors face limitations in modularity and flexibility due to a limited number of connector module slots, which also increases assembly effort.
Innovation Solution
The connector module is composed of at least two independent functional units that can operate independently and combine synergistically, featuring a cavity filled with a fixative for secure attachment, allowing for increased modularity without additional assembly complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the number of connector module slots in a mounting frame is increased to enhance modularity and flexibility, then the adaptability of the industrial connector is improved, but the device complexity and assembly effort increase
Solution Approach 1:
The patent combines multiple functional units (contact carrier unit, terminal unit, housing unit) into a single integrated connector module that is pre-assembled as one component. This merging approach allows the module to be installed as a single unit in the mounting frame, thereby enhancing modularity and flexibility without increasing assembly effort, since the complex internal assembly is already completed during manufacturing.
2Adaptability or versatility
If connector modules are made highly modular with multiple independent functional units to improve adaptability, then the versatility is enhanced, but the device complexity increases due to more components
Solution Approach 1:
The connector module is segmented into distinct functional units (contact carrier unit with contacts, terminal unit with terminals, housing unit with housing) that are independently designed and manufactured. These segmented units are then assembled into a complete module during manufacturing, allowing for high modularity and adaptability while keeping the complexity managed through standardized interfaces and pre-assembly processes.
Solution Approach 2:
Multiple independent functional units are merged into a single integrated connector module that functions as one cohesive component. This merging eliminates the need for end-users to assemble multiple separate components, thereby achieving high modularity without increasing the perceived device complexity for the user.
3Ease of repair
If functional units are designed to be independently replaceable to enhance ease of repair and reuse, then the ease of repair is improved, but the device complexity increases due to additional connection and fixation mechanisms
Solution Approach 1:
The connector module is segmented into independently replaceable functional units with standardized interfaces. Each unit (contact carrier, terminal, housing) can be independently removed and replaced through simple insertion and extraction actions, enabling easy repair and reuse without requiring complex disassembly procedures or additional connection mechanisms.
Data Source
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AI summary
The invention relates to a plug connector module (1, 1', 1") for a modular industrial plug connector, wherein the plug connector module (1, 1', 1") is formed from at least two independent functional units (2, 2'), wherein the functional units (2, 2') enclose a cavity (6) when in the assembled state together. The invention also relates to a method for producing a plug connector module (1, 1', 1'') for a modular industrial plug connector, comprising the following method steps: initially assembling at least two independent functional units (2, 2'), wherein the functional units (2, 2') enclose a cavity (6) when in the assembled state together; and subsequently at least partially filling the cavity (6) with a fixing material (7), whereby the functional units (2, 2') are fixed to one another.