Self-Aligning Terminal Module for Modular Connector Systems
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Solution Overview
Problem
Existing connector systems face challenges with misalignment and high coupling forces, leading to potential damage of electrical or optical contacts during connection, especially with complex devices and mate assist devices, where incorrect alignment may go unnoticed.
Innovation Solution
A connector arrangement with a terminal module that has pre-defined freedom of movement within the housing, allowing self-alignment during coupling, and guided by corresponding guide means to ensure precise alignment without excessive force, reducing the risk of damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the number of signal lines is increased to handle complex devices, then the connectivity capability is improved, but the coupling force required to close the connection increases excessively
Solution Approach 1:
The connector system is divided into a housing and a separate terminal module that can be independently assembled. The terminal module contains the electrical contacts and is inserted into the housing, allowing the housing to provide structural support and alignment features while the terminal module provides the electrical connection functionality. This segmentation reduces the overall coupling force requirement by distributing the mechanical load.
Solution Approach 2:
The terminal module is designed with freedom of movement in at least one axis perpendicular to the coupling direction, allowing it to dynamically adjust its position during the coupling process. This dynamic capability enables the terminal module to self-align with the mating connector, reducing the force required to achieve proper alignment and contact engagement.
2Reliability
If the coupling force is increased to ensure secure connection, then the connection reliability is improved, but the risk of contact damage due to misalignment increases
Solution Approach 1:
The terminal module is pre-positioned within the housing with guide means that provide preliminary alignment during the insertion process. The guide means, including guide ribs and guide grooves, establish the correct alignment path before the electrical contacts engage, ensuring that the contacts are properly aligned before full coupling force is applied.
Solution Approach 2:
The terminal module is designed with freedom of movement in at least one axis perpendicular to the coupling direction, allowing it to change its positional parameters during insertion. This parameter change enables the terminal module to adjust its alignment in real-time, compensating for manufacturing tolerances and preventing contact damage while maintaining connection reliability.
3Stability of the object's composition
If the terminal module is fixedly mounted in the housing, then the structural stability is improved, but the alignment precision during coupling deteriorates
Solution Approach 1:
The terminal module is mounted in the housing with controlled freedom of movement through guide means rather than being completely fixed. The guide ribs and guide grooves provide guidance and stability while allowing the terminal module to move slightly in the coupling direction and perpendicular axes to achieve precise alignment with the mating connector.
Solution Approach 2:
The mounting arrangement allows the terminal module to change its positional parameters within controlled limits. The freedom of movement in at least one axis perpendicular to the coupling direction enables the terminal module to adjust its position to compensate for manufacturing tolerances, achieving precise alignment while maintaining structural stability through the guide means.
4Ease of operation
If mate assist devices are added to facilitate coupling, then the ease of operation is improved, but the risk of undetected misalignment and contact damage increases
Solution Approach 1:
The guide means, including guide ribs and guide grooves, perform preliminary alignment of the terminal module with the housing and mating connector before the coupling force is fully applied. This preliminary alignment action ensures that the electrical contacts are properly positioned, preventing damage even when mate assist devices are used to facilitate the coupling process.
Solution Approach 2:
The terminal module has the capability to self-align through its freedom of movement in at least one axis perpendicular to the coupling direction. This self-alignment mechanism operates automatically during insertion, ensuring proper contact alignment without requiring external detection or correction, even when mate assist devices are used to apply coupling force.
Data Source
AI summary
The present invention relates to a connector arrangement, comprising a connector (20) having a connector housing (21) and at least one terminal module (10), adapted to be inserted into the connector housing (21). The terminal module (10) is mountable on the connector housing (21) with a freedom of movement in at least one axis, such that the terminal module is capable of self- alignment upon coupling of the connector (20) with a corresponding counter-connector (30).