This invention relates to electrical connection systems utilizing a connector position assurance (CPA) component.
It is known to use a connector position assurance (CPA) component in an electrical connection device to ensure that one connector remains fully mated with a corresponding connector when the electrical connection device is disposed in an electrical application.
In many such connection device configurations, a CPA component is used to ensure two halves of an electrical connection device remain mated so as to keep the two halves from inadvertently unmating from each other during normal use of the electrical connection device. Often, the two halves of the connection device contain more than one termination that also correspondingly mate together when the two connector halves are mated. As electrical connection devices continue to be a mainstay in many electrical applications and circuits, and the need to ensure these electrical connection devices remain robustly mated during normal operation also persists, it remains desirable to utilize CPA components. Some electrical applications, however, may require the mating of numerous electrical connectors in a single electrical connection system configuration while also ensuring that these numerous electrical connectors remain mated during routine, or normal use of the electrical connection system.
Thus, what is needed is an electrical connection system that includes a CPA member that robustly, consistently, and repeatedly ensures connector devices remain mated regardless of the number of connector devices used in a configuration.
In accordance with one aspect of the invention, a ganged electrical connection system includes a plurality of first connectors, a plurality of second connectors and a connector position assurance (CPA) member. The plurality of first connectors are matable to the plurality of second connectors along mating axes. The CPA member includes a plurality of tabs and a plurality of release fingers. The plurality of first connectors include a plurality of lock arms and the plurality of second connectors include a plurality of inclined ramps. When the plurality of tabs receive the plurality of lock arms and the plurality of inclined ramps deflectingly engage the plurality of release fingers, the CPA member is moveable to a position, that when disposed in the position, keeps the plurality of second connectors from unmating from the plurality of coupled first connectors.
Methods to fabricate the electrical connection system and the ganged electrical connection system that include the CPA member are also presented.
These and other advantageous features as disclosed in the embodiments of the present invention will be become apparent from the following brief description of the drawings, detailed description, appended claims and drawings.
This invention will be further described with reference to the accompanying drawings in which:
A connector position assurance (CPA) member ensures that fully mated connectors in an electrical connection system remain mated so that an undesirable inadvertent disconnect event that may unmate these connectors does not occur. Should an undesirable unmating event occur, electrical components electrically connected with the electrical connection system may be rendered electrically inoperative. For example, an inadvertent unmating of the connectors may occur if undue applied force due to a stress or strain in the electrical application urges the connectors apart when it is otherwise desired that this unmating not occur. When an electrical connection system has an increased number of connectors this may only increase the importance of keeping these plurality of connectors connected and the electrical components or systems in connection with the plurality of connectors operative. Each of these connectors contained in the electrical connection system may include one or more electrical terminals.
Referring to
Referring to
Referring to
Female connector 220d is fixedly attached to support frame 214 and preferably integrally molded to support frame 214 that may provide an alignment feature for the mating of the remaining connectors in system 210 if system 210 is mated to a single electrical device. CPA member 284 includes a groove (not shown) that is fitted to one or more rails 276 disposed on support frame 214 so CPA member 284 is movingly attached to support frame 214. CPA member 284 is disposed on support frame 214 adjacent receptacles 216 that are formed in support frame 214 in row 218. CPA member 284 communicates with mated connectors 220, 222 that enables CPA member to be moved to a position on support frame 214 and ensure mated connectors 220, 222 do not prematurely unmate. For example, a premature unmating may occur if an undesired force is applied along the mating axis that may accidentally unmate at least one of the plurality of second connectors from at least one of the plurality of first connectors when it is desired that unmating not occur. A premature unmating of the connectors in the electrical connection system may cause the electrical devices connected to the electrical connection system to become undesirably inoperative. CPA member 284 may be constructed of a durable material being formed of a metal material or a dielectric material similar to that of support frame 214, as previously discussed herein.
In contrast, connectors 220, 222 are fully, or completely mated together when the terminals of the connectors 220, 222 are mated together so that electrical connections are realized within electrical connection system 210. Additionally, connectors 220, 222 are fully engaged when ramp (not shown) of male connectors 222 are engaged with lock arms 203 of coupled female connectors 220. Connectors 220, 222 are further fully mated when CPA member 284 is positioned on support frame 214 to ensure fully mated connectors 220, 222 do not unmate.
Coupled female connectors 220a-c are additionally attached and secured to support frame 214 using retainer pin 286. Wire conductor retainer 287 further secures wire conductors 236 that communicate with female connectors 220 while also assisting to limit undesired rocking movement motion of support frame 214 when electrical connection system 210 is assembled together in an electrical application. Rocking motion of the electrical connection system during assembly in the electrical circuit application may cause undesired damage to the electrical connection system. Referring to
Referring to
Retainer pin 286 is used to further secure female connectors 220a-c to support frame 214. Retainer pin 286 has a length L3 and includes an index rib 289, a pin retention feature 290, and a crush rib 291. Retainer pin 286 is insertable in a cavity 292 formed in support frame 214 that communicates with retention feet 293 on each of plurality of coupled female connectors 220a-c. Index rib 289 is disposed along a length L3 of retainer pin 286 and is used to ensure retainer pin 286 is inserted in support frame 214 in a single orientation. Retainer pin 286 fits along length L1 of support frame 214 to communicate with receptacles 218a-c. Length L1 of support frame 214 is greater than length L3 of retainer pin 286. Crush rib 291 is useful to force retainer pin 286 after insertion in cavity 292 in an opposing direction away from crush rib 291 against a portion of support frame 214 in cavity 292 to ensure a tight retention fit for female connectors 220a-c and eliminate the potential for female connectors 220a-c to have undesirable rattle noise when employed in the electrical configuration. For instance, this feature may be very important to prevent rattle when the electrical connection system is employed in a vehicle electrical circuit application.
Referring to
Referring to
When arrangement 212 is ready for assembly in an electrical circuit application retaining pin 286 is inserted in cavity 292 after female connectors 220 are received in slots 207 of support frame 214. Wire conductor retainer 287 is also installed preferably have connectors 220, 222 have been mated and wire conductors 236 dressed.
Turning our attention more particularly to the CPA member 284, referring to
CPA member 284 is a staged, bi-directional staged CPA member 284. CPA member 284 may be disposed in a pre-stage position 217 or a final stage position 226 remotely distanced along a length L1 of support member 214 from pre-stage position 217. Base 201 further defines a pair of notches, or cutouts 231a, 231b along a raised wall 265 of support frame 214. Raised wall 265 generally extends along the length L1 of support frame. Cutout 231a is spaced apart from cutout 231b along support frame 234 in a direction perpendicular to mating axes A1, A2, A3. CPA member 284 contains a detent 235 that fits in cutout 231a when CPA member 284 is disposed in pre-stage position 217. Detent 235 also fits in cutout 231b when CPA member 284 is disposed in final stage position 226b. After initial assembly of CPA member 284 atop support frame 214, CPA member 284 is disposed in pre-stage position 217 where detent 235 is disposed in cutout 231a. CPA member 284 is prevented from further movement past pre-stage position 217 to final stage position 226 after initial assembly of CPA member 234 to support frame 234 as resilient release fingers 253 of CPA member 234 are disposed in elongate holes 241 of respective lock arms 203 of female connectors 220.
After initial assembly of CPA member 284 on support frame 214, CPA member 284 is configured for movement between pre-stage position 217 and final stage position 226 in respective directions s1, s2 in relation to the fully mated connectors 220, 222. The direction of s1 is opposite of the direction of s2. CPA member 284 is configured for movement from pre-stage position 217 to final stage position 226 along first direction s1. Once in final stage position 226, raised wall 265 prevents further movement of detent 235 along first direction s1 past final stage position 226 as detent 235 will engage raised wall 265. CPA member 284 is also further configured for movement from final stage position 226 back to pre-stage position 226 in second direction s2 opposite first direction s1. Consequently, directions s1, s2 are bi-directional movement directions for CPA member 284 and these movement directions are generally perpendicular to mating axes A1, A2, A3 when CPA member 284 is assembled on support frame 214. However, CPA member 284 is not freely moveable between pre-stage position 217 and final stage position 226. The conditions for movement of CPA member 284 between stages 217, 226 will be further described below. Only if CPA member 284 is disposed in final stage position 226, under normal operation, will CPA member 284 be properly positioned on support frame 214 to prevent male connectors 222 from freely unmating from female connectors 220 in an unrestricted fashion. Only if CPA member 284 is disposed in pre-stage position 217 and male connectors 222 are fully mated with female connectors 220, will CPA member 284 be positioned and configured to potentially allow male connectors 222 to unmate from coupled female connectors 220. Even when CPA member 284 is positioned in pre-stage position 217 and the male connectors 222 are fully mated, a tool 237 is required to engage CPA member 284 through an aperture 239 in CPA member that receives an end of tool 237 so that tool 237 may be used as a lever to apply a sufficient force to deflect CPA member 284, which subsequently deflects lock arms 203 of female connectors 220 in a manner that allows inclined ramps 230 disposed in elongate holes 241 to be removed, or untrapped from elongate holes 241 allowing mated male connectors 222 to be unmatable from coupled female connectors 220 in support frame 214. For example, tool 237 may be a flat-bladed screwdriver. Alternately, the tool may be any tool that fits the aperture to be used as a lever to engage the CPA member. Alternately, any tool that fits the aperture to allow a sufficient force to be applied against the tool to deflect the CPA member may be used.
Each of the coupled female connectors 220 and mated male connectors 222 communicate with CPA member 234, respectively, in a manner that enables CPA member 234 to move into final stage position 219 from pre-stage position 217, relative to the mated connectors 220, 222, such that when disposed in final stage position 219, CPA member 234 prevents connectors 220, 222 from unmating. CPA member 234 communicates respectively with connectors 220, 222 through plurality of extended sections 215. When CPA member is disposed in pre-stage position 217, an extended member 215 for each receptacle 216 generally overlies each receptacle 216.
To better simplify the discussion of the plurality of extended sections 215, a single extended section 215 will now be described. Referring to
Initial assembly of CPA member 284 to support frame 214 occurs by sliding CPA member 284 on rails 276 disposed on support frame 214 until detent 235 engages and is moved past a portion of raised wall 265 and disposed in cutout 231a disposing CPA member 234 in pre-stage position 217. CPA member 234 may be moved along support frame 214 in direction s1 by applying pressure against CPA member 234, such as may occur by using an appendage of the human hand of a human operator. Female connectors 220 are then received in receptacles 216 so that release fingers 253 of CPA member 234 are received in elongate holes 241 of coupled first connectors 220 to further secure CPA member 284 in pre-stage position 217 and prevent further lateral movement of CPA member 284. Being locked in pre-stage position 217 keeps CPA member 234 from inadvertently being moved out of and away from pre-stage position 217 to final stage position 219 or being removed off from support frame 214. Each extended section 215 is similarly constructed and the plurality of extended members 215 is best illustrated in
CPA member 284 is not in use if female connectors 220 are not coupled in any of the available receptacles 216 of support frame 214. Thus, receptacles 216 are void of female connectors 220. When female connectors 220 are coupled in the available receptacles 216 in support frame 214, and male connectors 222 have been fully mated to at least one, but not all of coupled female connectors 220, CPA member 284 is also not in use. When this scenario occurs, and the at least one female connector 220 has not received male connector 222, CPA member 284 is not moveable along support frame 214 as release finger 253 is disposed in aperture 239 of lock arm 203 of at least one of female connector 220. Consequently, it is important that the individual lock arms 203 are engaged by the respective male connectors 220 and release fingers 253 deflect as a result of engagement with inclined ramps 230 of the received male connectors 222. After this occurs, CPA member 284 is movable to final stage position 219 where CPA member 284 ensures all of the male connectors 222 mated with the coupled female connectors 220 remain mated.
CPA member 284 is operatively in use when all female connectors 220 are coupled in all available receptacles 216 of support frame 214 and male connectors 222 are fully mated to these coupled female connectors 220. Faces 204 of first connectors 220 do not face protrusion walls 255, 257 of CPA member 284, rather faces 204 of CPA member 234 face towards aperture 239 that includes release fingers 253. When male connector 222 is mated with coupled female connector 220, inclined ramp 230 of male connector 222 engages release finger 253 so as to deflect release finger 253 an amount as determined by a height of inclined ramp 230, as best illustrated in
CPA member 234 of electrical connection system 210 is configured to advantageously allow a collective umating of male connectors 222 from coupled first connectors 220 at about a same period in time. In other words, the plurality of male connectors 222 may be unmatable as though the plurality of male connectors were a single male connector being unmated, as further discussed below. When male connectors 222 need to be unmated from coupled first connectors 220, CPA member 234 is manually moved by a human operator, such as a service technician or assembler, in direction s2 back to pre-stage position 217. Once in pre-stage position 217, connecting tabs 259 again underlie U-shaped lock arms 203 of coupled female connectors 220. A sloped surface 261 along a portion of release finger 253 engages a sloped surface 263 along a portion of male connector 222 so that release finger 253 is urged to be positioned atop male connector 222 to again be disposed to overlie incline ramp 230 of male connector 222. When the frictional forces against the engaging sloped surfaces 261, 263 are overcome by the applied force to move the CPA member from final stage potion 219 to pre-stage position 217, sloped surfaces 261, 263 ensure release finger 253 moves in direction s2 to overlie male connector 222 and come to rest to overlie inclined ramp 230 of male connector 222. Once in pre-stage position 217, referring to
Alternately, instead of the CPA member being engaged with a tool to allow the plurality of second connectors to be unmatable with coupled female connectors as previously described herein, the CPA member may employ a pump handle. When a force is applied generally perpendicular to the pump handle the CPA member deflectingly engages the lock arms of the coupled female connectors when disposed in the pre-stage position.
In one particular alternate embodiment, the CPA member employs a pump handle 231 along a rear area of the CPA member opposite the extended portions. The plurality of rails disposed on the support frame are further cylindrical in shape in contrast to the anvil shape of rails 276 as illustrated in
In another alternate embodiment, a stop may be added to the retainer between the support frame and the CPA member or the wire retainer and the CPA member to eliminate activation of the CPA member when the CPA member is disposed in the final stage position. This would inhibit movement of the CPA member when the CPA member is disposed in the final stage position. Still yet alternately, this stop feature may be used in combination with other features of the CPA member's pump handle feature to further ensure that the CPA member is not movably activated in the final stage position.
Still yet alternately, if the number of coupled female connectors used in particular electrical configuration is less than the amount of receptacles, and the additional unused receptacles are left empty, or void of coupled female connectors, the movement operation and the function of the CPA member remains in use as described herein.
In yet another alternate embodiment, if any of the receptacles are populated with a coupled female connector, but any of the coupled female connectors are not mated with a corresponding male connector, the CPA member will not function.
Alternately, the rails of the CPA member may have any shape such that a corresponding shape of the groove of the CPA member allows the CPA member to be received by the rail and allow movement of CPA member along the support frame thereon between the pre-stage and the final stage position as described herein.
Alternately, the male connectors may be electrically connected to a plurality of battery cells that form a battery stack. The battery stack then is mated to the electrical connection system in a single, unimpeded movement. In another alternate embodiment, the battery cells may be associated with an electric vehicle, a hybrid electric vehicle, or a plug-in electric vehicle. Regardless of the intended application, the CPA member performs as described herein to keep the male connectors of battery stack from unmating from the coupled first connectors in the electrical connection system. Still yet alternately, the plurality of male connectors may be associated with a single electronic component or assembly that mates with the electrical connection system and the CPA member still performs in a manner as described herein.
Similar elements in the embodiment of
Thus, an electrical connection system includes a CPA member that robustly, consistently, and repeatedly ensures connector devices remain mated regardless of the number of connector devices used in a configuration has been presented. The CPA member is conveniently secured to a support frame that may be constructed to include one or more receptacles to receive a plurality of electrical connectors. The CPA member is a staged CPA that has bi-directional movement in a direction perpendicular to the mating axes of male connectors mated to coupled female connectors. The CPA member is movable between a pre-stage and a final stage position laterally along the support frame perpendicular to the mating axes of the connectors. The pre-stage position allows the male connectors to be mated to the coupled female connectors and also allows unmating of the connectors when the CPA member is further engaged in an opening of the CPA member with a tool. The tool is used a lever by a human operator apply a force to the CPA member so that connecting tabs of the CPA member deflect and thus engage the lock arms of the coupled first connectors so that the lock arms decouple from the inclined ramps of the male connectors allowing the male connectors to be unmatable from the coupled female connectors. When disposed in the final stage position, the CPA member prevents multiple male connectors from being unmated from the corresponding coupled female connectors. The inclined ramps of the male connectors remain disposed in the elongate holes of the lock arms of the coupled first connectors to ensure the male connectors remain fully mated to the coupled female connectors. The plurality of receptacles are constructed in the support frame to form a row perpendicular to the mating axes of the connectors and the CPA member is advantageously disposed along a length of the support frame adjacent the row to conveniently keep the fully mated connectors mated. A detent of the CPA member is engagable in cutouts in the support frame to properly position the CPA member in the respective pre-stage and final stage positions.
While this invention has been described in terms of the preferred embodiment thereof, it is not intended to be so limited, but rather only to the extent set forth in the claims that follow.
It will be readily understood by those persons skilled in the art that the present invention is susceptible of broad utility and application. Many embodiments and adaptations of the present invention other than those described above, as well as many variations, modifications and equivalent arrangements, will be apparent from or reasonably suggested by the present invention and the foregoing description, without departing from the substance or scope of the present invention. Accordingly, while the present invention has been described herein in detail in relation to its preferred embodiment, it is to be understood that this disclosure is only illustrative and exemplary of the present invention and is made merely for purposes of providing a full and enabling disclosure of the invention. The foregoing disclosure is not intended or to be construed to limit the present invention or otherwise to exclude any such other embodiments, adaptations, variations, modifications and equivalent arrangements, the present invention being limited only by the following claims and the equivalents thereof.
This application is related to U.S. non-provisional application Delphi Docket Number DP-319443 entitled “ELECTRICAL CONNECTION SYSTEM THAT ABSORBS MULTI-CONNECTOR POSITIONAL MATING TOLERANCE VARIATION,” and non-provisional application Delphi Docket No. DP-319552 entitled “ELECTRICAL CONNECTION SYSTEM HAVING DIELECTRIC SPRING TO ABSORB AXIAL POSITIONAL MATING TOLERANCE VARIATION FOR MULTIPLE CONNECTORS,” that are each co-owned by the assignee of this application and are incorporated by reference herein. The instant U.S. non-provisional application and the abovementioned non-provisional applications have been harmoniously filed on the same day of XX April 2011.