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The application refers to a modular connector housing, to a set for assembling a modular connector housing, to a modular connector, and to a process for manufacturing modular connector housings.
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During the assembly of modular connectors, the misplacement of modules can occur when positioning them within a modular connector housing. This is particularly problematic when the modules in question are visually similar. The misplacement of the modules in question directly disrupts the functionality of the entire connector. Consequently, an incorrectly assembled modular connector will not fit to its counterpart and may even damage it.
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In
DE 10 2022 107 678 A1 , a connector and a connector assembly are disclosed. The connector assembly includes first and second connectors adapted to mate. The first connector has a first housing and a plurality of first slots formed on the first housing. The second connector has a second housing and a plurality of second slots formed on the second housing. First coding keys are respectively arranged in one part of the first slots, and no coding key is arranged in the other part of the first slots; second coding keys are respectively arranged in one part of the second slots, and no coding key is arranged in the other part of the second slots; the first coding keys in one part of the first slots are respectively matched with the other part of the second slots, and the second coding keys in one part of the second slots are respectively matched with the other part of the first slots. According to the invention, the coding keys and the slots on the two connectors for realizing the same function connection correspond to each other uniquely, so that the connectors with different functions can be prevented from being plugged together by mistake, and the safety is improved.
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The connector parts are typically manufactured from plastic material formed in a moulding process. In the event of new coding features being added to modules or when a configuration of modular connectors is altered, it may be necessary to replace or modify the moulding tool. Such changes carry a risk of damaging the tool.
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An objective can be to propose a modular connector housing that facilitates a more efficient manufacturing process for modular connector housings.
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The objective is accomplished by a modular connector housing according to claim 1, by a set for assembling a modular connector housing according to claim 10, by a modular connector according to claim 13, and by a process for manufacturing modular connector housings according to claim 14.
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The modular connector housing comprises a frame forming an outer perimeter and at least one insert being inserted into the frame and forming receiving cavities for receiving modules with terminals. The insert being inserted into the frame can form the receiving cavities together with the frame. The at least one insert comprises module coding features for the receiving cavities to prevent incorrect insertion of the modules.
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An advantage of the modular connector housing is that in case of new coding features being added to modules or when a configuration of modular connectors is altered, the frame forming the outer perimeter does not have to be modified, as the coding features are arranged on the insert. A share of the module coding features can be arranged on the frame. According to an embodiment, the module coding features can be arranged on the at least one insert only. The moulding tool for producing the frame does not have to be altered or exchanged. The inserts can be produced with separate tools. The inserts can further be produced in a plurality of versions to provide different coding features for respective modular connector housing configurations.
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The modular connector housing is defined as a housing for receiving the modules in varying configurations. The frame forming the outer perimeter can be generally rectangular, comprising, for example, four side walls. The frame does not necessarily form the complete outer perimeter. The outer perimeter can partly or section-wise be formed by the insert. The insert can, for example, form part or parts of the side walls. The inserted modules are arranged inside of the perimeter formed by the walls. In an insertion direction, the modular connector housing can have a front opening and a rear opening defined by the side walls. The at least one insert can be inserted into the frame through the rear opening, as well as the modules can be inserted into the receiving cavities through the rear opening. The terminals arranged in the modules point towards the front opening through which a mating connector can be inserted. Wires attached to the terminals extend through the rear opening.
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The insert forms the receiving cavities in the sense of providing a geometrical shape and/or size. The module coding features on the receiving cavities can as well be provided as geometrical shapes and/or sizes fitting to corresponding shapes and/or sizes of the modules. For example, an aspect ratio of the cavity defined by the insert can be such a geometrical shape providing a simple module coding feature. The insert can also define a number of cavities provided for the modules. For example, the insert can provide a squared cavity for one square shaped module. In the same space, another insert can provide two rectangular cavities, instead, for two rectangularly shaped modules. However, the geometrical shapes providing the module coding features can also be physical features like protrusions and corresponding slots that ensure only compatible modules fit into the cavity.
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According to an embodiment, the module coding features comprise at least one type coding feature to prevent incorrect insertion of the modules regarding a type of the module. Advantageously, only the intended type of modules can be inserted in the respective receiving cavity.
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According to a further embodiment, the module coding features comprise at least one polarisation coding feature to prevent incorrect insertion of the modules regarding a polarisation of the module. Advantageously, the modules cannot be inserted with incorrect polarisation. Polarisation coding features can involve modules to fit in only one orientation, preventing reverse connections. Polarization coding features can be achieved through asymmetrical shapes or notches.
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According to a further embodiment, the at least one insert and/or the frame comprises mating coding features for a mating connector. The mating coding features ensure that only the mating connector matching the mating coding features can be mated with the modular connector housing through the front opening. Undesired mating with an incorrect mating connector is advantageously prevented.
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According to a further embodiment, the at least one insert and/or the frame comprises module locking features and module lock over-deflection features to protect the module locking feature from over-deflecting by providing an abutment. Further, the at least one insert can comprise a visual confirmation feature for a visible indication of a type of the insert. The frame can comprise insert locking features that connect the insert to the frame. According to a further embodiment, the frame comprises insert coding features to prevent incorrect insertion of the insert regarding a polarisation of the insert. The frame can further comprise module locking features for connecting the modules to the frame.
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A further aspect refers to the set for assembling the modular connector housing as described above. The set comprises the frame and at least two types of the insert insertable into the frame, wherein each of the at least two types of the insert comprises different module coding features. It is an advantage that at least two different kinds or types of modular connector housing can be built by providing the same frame and inserting one of the inserts.
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According to an embodiment, a material of the inserts has different material properties than a material of the frame. The material of the inserts can have a higher hardness than the material of the frame. The hardness can be a shore hardness, which can be measured on plastics according to ISO 868 or ASTM D2240. The inserts made of the harder material provide better mechanical performance. The frame made of less hardness material allows a longer service life of the tools for producing the frames.
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According to an embodiment, each of the at least two types of the insert form a different number of cavities. By changing the insert, the modular connector housing can, for example, form a six-module housing into a five-module housing, a four-module housing or a three module housing.
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A further aspect refers to the modular connector comprising the modular connector housing described above, with the at least one insert being inserted into the frame and forming receiving cavities, for example together with the frame. A plurality of modules for receiving the terminals is inserted into the receiving cavities, wherein each of the modules comprises counter coding features having a complementary form fitting to the module coding feature of the respective receiving cavity formed on the insert.
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According to an embodiment, the modular connector comprises a wire routing cover and a lever pivotally connected to the frame for locking the modular connector to a counterpart connector. Wires to which the terminals are attached, are routed by the wire routing cover, which covers the rear opening of the frame. The counterpart connector is inserted into the modular connector through the front opening.
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A further aspect refers to the process of manufacturing the modular connector housings described above. The process comprises the steps of producing a number of the frames, and producing the same number of inserts, wherein the produced inserts comprise at least two types of inserts with different module coding features. The inserts can be produced of a material of a higher hardness than a material of which the frames are produced.
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Various aspects will become apparent to those skilled in the art from the following detailed description of exemplary embodiments, when read in light of the accompanying drawings, wherein
- Figure 1 shows an embodiment of a modular connector in a perspective view;
- Figure 2 shows the modular connector of Figure 1 in a perspective exploded view;
- Figure 3 shows a further embodiment of a modular connector in a perspective view;
- Figure 4 shows the modular connector of Figure 3 in a perspective exploded view;
- Figure 5 shows an insert of the modular connector of Figure 1 in a perspective view;
- Figure 6 shows an insert of the modular connector of Figure 3 in a perspective view;
- Figure 7 shows an embodiment of a modular connector housing in a perspective exploded view;
- Figure 8 shows the modular connector housing of Figure 7 in a perspective view;
- Figure 9 shows a further embodiment of a modular connector housing in a perspective exploded view;
- Figure 10 shows the modular connector housing of Figure 9 in a perspective view;
- Figure 11 shows a variety of inserts for the modular connector housing of Figure 7 in a back view;
- Figure 12 shows a variety of inserts for the modular connector housing of Figure 9 in a back view;
- Figure 13 shows a variety of modules for the modular connector housing of Figures 7 and 9 in a top view and in a back view;
- Figure 14 shows an embodiment of a set for assembling a modular connector housing in a back view;
- Figure 15 shows a further embodiment of a modular connector in a front view;
- Figure 16 shows an insert of the modular connector of Figure 15 in a perspective view;
- Figure 17 shows the embodiment of the modular connector of Figure 15 with a different insert in a front view;
- Figure 18 shows the insert of the modular connector of Figure 17 in a perspective view.
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In Figure 1, a first embodiment of a modular connector 10 is depicted in a perspective view. In Figure 2 the modular connector of Figure 1 is shown in a perspective exploded view, without a wire routing cover 11. The Figures 1 and 2 will be described together.
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The modular connector 10 comprises a modular connector housing 1, a plurality of modules 5 for receiving terminals (not depicted), the modules 5 being inserted into receiving cavities 4 of the modular connector housing 1. The receiving cavities 4 without modules 5 installed are illustrated in Figure 8. The modular connector housing 1 comprises a frame 2 forming an outer perimeter and an insert 3 being inserted into the frame 2. The wire routing cover 11 is attached to a rear opening 20 of the frame 2. A front opening 19 is adapted to receive a mating connector (not depicted) when the modular connector is connected to the mating connector in the insertion direction D. A lever 12 is pivotally connected to the frame 2 for locking the modular connector 10 to the mating connector, which can also be referred to as counterpart connector. The insert 3 is inserted into the frame 2 through the rear opening 20 and the modules 5 with the terminals are inserted into the receiving cavities through the rear opening 20 as well. The insert 3 forms six receiving cavities 4 by separating the space inside the frame 2 into the six receiving cavities 4.
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The insert 3 comprises module coding features 6 for the receiving cavities 4 to prevent incorrect insertion of the modules 5. Each of the modules 5 comprises counter coding features 21 having a complementary form fitting to the module coding features 6 of the respective receiving cavities 4. The module coding features 6 are arranged only on the insert 3, not on the frame 2. The module coding feature 6 comprise in the depicted embodiment a type of coding feature 6 to prevent incorrect insertion of the modules 5 regarding a type of the module 5.
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In Figure 3, a second embodiment of the modular connector 10 is depicted in a perspective view. In Figure 4 the modular connector 10 of Figure 3 is shown in a perspective exploded view, without the wire routing cover 11. The Figures 3 and 4 will be described together.
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The modular connector 10 comprises a modular connector housing 1, a plurality of modules 5 for receiving terminals (not depicted), the modules 5 being inserted into the receiving cavities 4 of the modular connector housing 1. The receiving cavities 4 without modules 5 installed are illustrated in Figure 10. The modular connector housing 1 comprises a frame 2 forming an outer perimeter and an insert 3 being inserted into the frame 2. The wire routing cover 11 is attached to a rear opening 20 of the frame 2. A front opening 19 is adapted to receive a mating connector (not depicted) when the modular connector is connected to the mating connector in the insertion direction D. A lever 12 is pivotally connected to the frame 2 for locking the modular connector 10 to the mating connector, which can also be referred to as counterpart connector. The insert 3 is inserted into the frame 2 through the rear opening 20 and the modules 5 with the terminals are inserted into the receiving cavities 4 through the rear opening 20 as well. The insert 3 forms three receiving cavities 4, together with the frame 2, by separating the space inside the frame 2 into the three receiving cavities 4.
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The insert 3 comprises module coding features 6, 7 for the receiving cavities 4 to prevent incorrect insertion of the modules 5. Each of the modules 5 comprises counter coding features 21, which are not visible in the perspective view. Exemplary counter coding features 21 are comprehensible from Figure 13. The complementary counter coding features 21 have a complementary form fitting to the module coding features 6, 7 of the respective receiving cavities 4. The module coding features 6, 7 are arranged only on the insert 3, not on the frame 2. The module coding features 6, 7 comprise in the depicted embodiment a type of coding feature 6 to prevent incorrect insertion of the modules 5 regarding a type of the module 5. The module coding features 6, 7 further comprise polarisation coding features 7 to prevent incorrect insertion of the modules 5 regarding a polarisation of the module 5.
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In Figure 5, the insert 3 of the modular connector 10 of Figure 1 is shown in a perspective view. The insert 3 comprises a visual confirmation feature 9 for a visible indication of a type of the insert 3. The visual confirmation feature 9 is adapted to be visible when the insert 3 is installed. The visual confirmation feature 9 may carry a code in the form of colours, symbols or labels. The visual confirmation feature 9 of this embodiment also serves as a stabilisation rib 18. The module coding features 6 comprise the type coding features 6, which are different for all six cavities 4. The insert 3 further comprises insert locking features 14 with insert coding features 15, that connect the insert 3 to the frame 2, module guiding ribs 17, which may further serve as polarisation coding features 7, and further stabilisation ribs 18. The two wedge-formed upright stabilisation ribs 18 each have a polarisation coding feature 7 at their base portions in the form of a radius, which is only present on one of both sides of the two upright stabilisation ribs 18. The same polarisation coding feature 7 in the form of a radius is present at the base portion of one of the insert locking features 14.
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In Figure 6, the insert 3 of the modular connector 10 of Figure 3 is shown in a perspective view. The insert 3 comprises module lock over-deflection features 8 to protect a module locking feature 16, which in this embodiment is arranged on the frame 2, from becoming over-deflected, for example, when the module locking feature 16 is lifted for disassembly. The over-deflection features 8 protrude from the walls and form an abutment for the module respective module locking feature 16. The over-deflection feature 8 for the third cavity is not arranged on the depicted insert 3, but on the frame 2. The insert 3 further comprises insert locking features 14 that connect the insert 3 to the frame 2, module guiding ribs 17, which may further serve as polarisation coding features 7, and stabilisation ribs 18. Further, the insert 3 comprises insert coding features 15 to prevent incorrect insertion of the insert 3 regarding a polarisation of the insert 3.
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In Figure 7, the embodiment of the modular connector housing 1 of the modular connector 10 of Figure 1 is shown in a perspective exploded view. In Figure 8, the modular connector housing 1 of Figure 7 is shown in a perspective view with the insert 3 installed on the frame 2. The Figures 7 and 8 are described together. The frame 2 comprises insert coding features 15 to prevent incorrect insertion of the insert 3 regarding a polarisation of the insert 3 together with the corresponding insert coding features 15 on the insert 3. The frame 2 further comprises module locking features 16 for connecting the modules 5 to the frame 2. The frame 2 further comprises slots 22, into which the stabilisation ribs 18 are inserted in the installed position of Figure 8 to stabilise the connection between the insert 3 and the frame 2. The frame 2 further comprises slots 23 for the visual confirmation features 9, which allow the visual confirmation features 9 to be recognised in the installed position of Figure 8. The insert 3 comprises module coding features 6 for the receiving cavities 4 to prevent incorrect insertion of the modules 5 regarding a type of the module 5.
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In Figure 9, the embodiment of the modular connector housing 1 of the modular connector 10 of Figure 3 is shown in a perspective exploded view. In Figure 10, the modular connector housing 1 of Figure 9 is shown in a perspective view with the insert 3 installed on the frame 2. The Figures 9 and 10 are described together. The frame 2 comprises insert coding features 15 to prevent incorrect insertion of the insert 3 regarding a polarisation of the insert 3 together with the corresponding insert coding features 15 on the insert 3. The frame 2 further comprises module locking features 16 for connecting the modules 5 to the frame 2. The insert 3 comprises module coding features 6, 7 for the receiving cavities 4 to prevent incorrect insertion of the modules 5. The module coding features 6, 7 comprise in the depicted embodiment a type of coding feature 6 to prevent incorrect insertion of the modules 5 regarding the type of the module 5. The module coding features 6, 7 further comprise polarisation coding features 7 to prevent incorrect insertion of the modules 5 regarding the polarisation of the module 5. The insert 3 comprises module lock over-deflection features 8 to protect the module locking features 16 on the frame 2 from over-deflecting by providing an abutment. A further module lock over-deflection feature 8 of the far right cavity 4 is arranged on the frame 2.
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In Figure 11, a variety of inserts 3 for the modular connector housing 1 of Figure 7 are shown in a back view. The six different inserts 3, which are labelled A, B, C, D, E, and F, vary only in the geometrical forms of the module coding features 6, of which one is representatively labelled with the reference number 6. The six different inserts 3 allow six different configurations of the cavities 4. Compared to the specific coding features 6 of the inserts 3 labelled B, C, D, E, and F, the A-labelled insert 3 is a more general example that does not have different notches or ribs as coding features for the six cavities, the coding feature is realised by the size and form of the cavities 4 defined by the insert 3. The frame 2 and at least two of the types A, B, C, D, E, and F of the insert 3 insertable into the frame 2, comprising the different module coding features 6, form a set for assembling the modular connector housing 1 according to Figure 7. A material of the inserts 3 can have a higher hardness than a material of the frame 2. A process of manufacturing the modular connector housings 1 comprises the steps of producing a number of the frames 2, and producing the same number of inserts 3, wherein the produced inserts 3 comprise at least two of the types A, B, C, D, E, and F of the inserts 3 with different module coding features 6.
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In Figure 12, a variety of inserts 3 for the modular connector housing 1 of Figure 9 are shown in a back view. The three different inserts 3, which are labelled a, b, and c, vary only in the geometrical forms of the module coding features 6, 7, of which one each is representatively labelled with the reference numbers 6, 7. The three different inserts 3 allow three different configurations of the cavities 4. The frame 2 and at least two of the types a, b, and c of the insert 3 insertable into the frame 2, comprising the different module coding features 6, 7, form a set for assembling the modular connector housing 1 according to Figure 9. A material of the inserts 3 can have a higher hardness than a material of the frame 2. A process of manufacturing the modular connector housings 1 comprises the steps of producing a number of the frames 2, and producing the same number of inserts 3, wherein the produced inserts 3 comprise at least two of the types a, b, and c of the inserts 3 with different module coding features 6, 7.
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In Figure 13, a variety of modules 5 for the modular connector housing 1 of Figures 7 and 9 are shown in a top view and in a back view. The four different modules 5, which are labelled I., II., III., and IV., vary only in the geometrical forms of the counter coding features 21. They can, however, also vary in the form of the terminal pattern, as in Figure 1. The complementary counter coding features 21 have a complementary form fitting to the module coding features 6 of the respective receiving cavities 4.
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The aspects, features and advantages of the embodiments described above refer to the modular connector housing 1, to the set for assembling the modular connector housing 1, to the modular connector 10, and to the process for manufacturing the modular connector housings 1 and can be transferred between these as applicable.
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A proposal regarding coding has been described for securing unique arrangements of the modules 5 in the modular connectors 10 during connector assembly. It eliminates the need for changes on the tool producing the frame 2 when adding new arrangements of the modules 5 or new codings. The module cavities 4 are formed by the frame 2 and the insert 2, which results in unique module 5 configurations. Advantages are simpler moulding tools, visual confirmation features 9, the option of using different materials to combine different mechanical properties, and potentially reduced production costs. Different new module cavities 4 can be added without any impact on the moulding tool for producing the frame 2.
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In Figure 14, an embodiment of a set for assembling a modular connector housing is depicted in a back view. The set comprises the frame 2 and at least two different types of the insert 3 insertable into the frame 2, wherein each of the at least two types of the insert 3 comprises different module coding features 6. The frame 2 comprises insert coding features 15 to prevent incorrect insertion of the inserts 3 regarding a polarisation of the inserts 3 together with the corresponding insert coding features 15 on the inserts 3. In the depicted embodiment, each of the at least two types of the insert 3 form a different number of cavities 4, i.e. the insert 3 depicted in the upper part of Figure 14 has five cavities 4, whereas the insert 3 depicted below has six cavities 4. The upper insert 3 has one enlarged cavity 4, which takes the space of two of the other cavities 4. The enlarged cavity 4 may have a module locking feature 16 that deviates from the module locking features 16 of the other cavities 4. An additional module lock over-deflection feature 8 is provided on the upper insert 3 to prevent an over-deflection of the deviating module locking feature 16 of the enlarged cavity 4. Additionally, the set may comprise further inserts 3 with different numbers of cavities 4, which inserts 3 fit into the frame 2. For example, an additional insert 3 with two enlarged cavities 4 could comprise four cavities 4, and a further additional insert 3 could comprise three of enlarged cavities 4 without any of the smaller cavities 4.
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In Figure 15, a further embodiment of the modular connector housing 1 is shown in a front view. In Figure 16, the insert 3 of Figure 15 is shown alone in a perspective view. The Figures 15 and 16 are described together. The insert 3 comprises mating coding features 24 for a mating connector (not depicted). The mating coding features 24 ensure that only the mating connector matching the mating coding features 24 can be mated with the modular connector housing 2 through the front opening. The insert 3 comprises six cavities in which six modules 5 are inserted.
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In Figure 17, another modular connector housing 1 of the embodiment according to Figure 15 is shown in a front view. In Figure 18, the insert 3 of Figure 17 is shown alone in a perspective view. The Figures 17 and 18 are described together. The frame 2 is identical to the frame 2 of Figure 15. The insert 3 comprises different mating coding features 24 than the insert 3 of Figure 15. Further, the insert 3 depicted in Figure 17 has five cavities 4 with five modules 5, whereas the insert 3 depicted in Figure 15 has six cavities 4. Accordingly, the frame 4 and the two different types of the insert 3 of this embodiment also form a further embodiment of the set for assembling a modular connector housing. Further coding features on the inserts 3 have been described in detail before, which will not be repeated.
Reference Numerals
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- 1
- Modular connector housing
- 2
- Frame
- 3
- Insert
- 4
- Cavity
- 5
- Module
- 6
- Module coding feature, type coding feature
- 7
- Module coding feature, polarisation coding feature
- 8
- Module lock over-deflection feature
- 9
- Visual confirmation feature
- 10
- Modular connector
- 11
- Wire routing cover
- 12
- Lever
- 14
- Insert locking feature
- 15
- Insert coding feature
- 16
- Module locking feature
- 17
- Module guiding ribs
- 18
- Stabilisation ribs
- 19
- Front opening
- 20
- Rear opening
- 21
- Counter coding features
- 22
- Slot for stabilisation ribs
- 23
- Slot for visual confirmation feature
- 24
- Mating coding feature
- D
- Direction of insertion
- A, B, C, D, E, F
- Types of the insert
- a, b, c
- Types of the insert
- I., II., III., IV.
- Types of the module