Plug Insert Positioning Element for Automotive Connectors
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Solution Overview
Problem
Existing plug inserts for automotive connectors face challenges in maintaining narrow positioning tolerances for soldering or press-fitting, especially when combining shielded and unshielded connectors, due to the nested design of FAKRA and HSD connectors.
Innovation Solution
A plug insert design featuring a base body with a receptacle and a positioning element extending through it, where the positioning element is accessible from both sides and positions the contact pin, using modular electromagnetic shielding with interlocking shielding elements to maintain precise alignment and shielding of connectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If connectors are nested in a compact arrangement to reduce space, then the device complexity is reduced and space is saved, but the positioning precision of contact pins deteriorates
Solution Approach 1:
A positioning element is introduced as an intermediary component between the receptacle and the connector. This positioning element, which may be integrated into or separate from the shielding, provides reference surfaces that guide the connector into correct alignment during insertion, ensuring precise contact pin positioning despite the compact nested arrangement.
Solution Approach 2:
The shielding and positioning elements are pre-configured with specific geometries and reference surfaces before connector insertion. These pre-configured elements establish the correct positioning pathways and alignment references in advance, enabling precise contact pin alignment without requiring complex adjustment mechanisms during assembly.
2Object-affected harmful factors
If shielding is added to protect against electromagnetic interference, then the protection against harmful factors is improved, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The shielding elements are merged with the positioning functionality. The shielding serves dual purposes: providing electromagnetic protection and acting as a positioning reference structure. This integration eliminates the need for separate positioning components, reducing overall device complexity while maintaining both shielding and positioning functions.
Solution Approach 2:
The shielding elements are designed to perform multiple functions simultaneously: electromagnetic shielding, mechanical positioning, and structural support. This multi-functionality reduces the total number of components needed in the plug insert, simplifying the overall device complexity while maintaining effective EMI protection.
3Adaptability or versatility
If different types of connectors are combined in a single plug insert to increase versatility, then the adaptability is improved, but the manufacturing precision and positioning difficulty worsen
Solution Approach 1:
Different regions of the plug insert are designed with locally optimized characteristics. Each receptacle area has customized shielding geometry and positioning element configurations tailored to the specific connector type it accommodates. This localized customization allows precise positioning for each connector type while maintaining overall system versatility.
Solution Approach 2:
The plug insert is segmented into multiple independent receptacle areas, each with its own shielding and positioning elements. This segmentation allows each connector type to be positioned and shielded independently according to its specific requirements, maintaining high positioning precision across different connector types without interfering with other receptacles.
Data Source
AI summary
A plug insert comprises a base body, a receptacle extending through the base body, and a positioning element at least partially received in the receptacle. The base body has a plug side and an opposite contact side. The receptacle extends through the base body from the plug side to the contact side and at least partially receives a connector. The positioning element is accessible from both the plug side and the contact side and positions a contact pin of the connector.