Patent Grant
11264747
This application claims priority to Chinese Application No, 201910559024.3, filed on Jun. 26, 2019, which is incorporated herein by reference in its entirety.
The present disclosure relates to field of electrical connectors, in particular, electrical connectors used in a vehicle harness and having a mate assist mechanism.
A typical lever-type electrical connector assembly includes a first actuator connector which has an actuating or mating assist lever rotatably mounted thereon for connecting and disconnecting the actuator connector with a complementary second mating connector. The actuating lever and the mating connector typically have cam groove/cam follower arrangement for drawing the mating connector into mating condition with the actuator connector in response to rotation of the lever.
A common structure for a lever-type electrical connector of the character described above is to provide a generally U-shaped lever having a pair of arms which are disposed on opposite sides of the actuator connector. The arms may have cam grooves for engaging cam follower projections or posts on opposite sides of the mating connector.
Such lever-type electrical connectors often are used where large forces are required to mate and unmate a pair of connectors. For instance, terminal and housing frictional forces encountered during connecting and disconnecting the connectors may make the process difficult to perform by hand. Some lever-type electrical connectors use slide members which are slidably mounted on the housing of the actuator connector for movement in a direction generally perpendicular to the mating direction of the connectors. First cam groove and cam follower means are provided between the lever and the slide members, whereby pivotal movement of the lever effects linear movement of the slide members relative to the actuator connector. Second cam groove and cam follower means are provided between the slide members and the second connector, whereby the connectors are mated and unmated in response to the lever and resulting translation of the slide members.
In an embodiment, an actuator connector has a housing configured to mate with a housing of a mating connector, a pair of slide members movably mounted on the housing, and a lever pivotably attached to the housing and slidably coupled to the slide members. Each slide member has a cam groove in a side surface which provides an angled lead-in surface into the cam groove and cam surfaces engageable with a cam follower post of the second housing. A blocking shoulder partially blocking an opening of the cam groove to prevent entry of the cam follower post unless the cam follower post is in a correct position. When the cam follower post engages the angled lead-in surface, this provides a visual and tactile indication to a user that the connector is ready to be mated with the second housing.
In another embodiment, a lever-type electrical connector assembly is provided. The connector assembly includes a mating connector having a housing with a cam post extending outwardly therefrom. The cam post having a main body and a projection extending from the main body. In some embodiments, the projection is crescent-shaped. The connector system further includes an actuator connector configured to mate with the mating connector. The actuator connector includes a housing, a pair of slide members movably mounted on the housing, and a lever pivotably attached to the housing and slidably coupled to the slide members. Each slide member has a cam groove in a side surface which provides an angled lead-in surface into the cam groove and cam surfaces engageable with the cam follower post. A blocking shoulder partially blocking an opening of the cam groove to prevent entry of the cam follower post unless the cam follower post is in a correct position. When the cam follower post engages the angled lead-in surface, this provides a visual and tactile indication to a user that the actuator connector is ready to be mated with the mating connector.
In some embodiments, the actuator connector includes a terminal retention portion mounted in a cavity of the connector housing such that a space is provided therebetween, the terminal retention portion having first and second locks that engage with terminals that pass therethrough. The terminal retention portion includes a terminal housing, a first seal attached to the terminal housing, a second seal mounted on the terminal housing and extending into the space, and an independent secondary lock movably seated in the terminal housing. The independent secondary lock can be moved to a first position relative to the terminal housing and into the space to allow terminals to pass through terminal retention portion. The independent secondary lock is movable to a second position relative to the terminal housing to engage the terminals. The independent secondary lock includes an elongated slot in communication with the space which can be engaged by a pry tool to move the independent secondary lock relative to the terminal housing.
The present disclosure is illustrated by way of example, and not limited, in the accompanying figures in which like reference numerals indicate similar elements and in which:
As required, the appended figures illustrate embodiments of the present disclosure and it is to be understood that the disclosed embodiments are merely exemplary of the disclosure, which may be embodied in various forms. Therefore, specific details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present disclosure.
Referring to the drawings in greater detail, and first to
The lever-type electrical connector assembly 20 provides a sealed system which is typically used in an automobile or other vehicle. Although depicted as a sealed system, the electrical connector assembly may also be used in an unsealed application. The mating connector 24 is a header connector which may be mounted on an electronics module chassis or frame in an automobile, for instance. Therefore, the lever-type electrical connector assembly 20 is applicable for use in high vibration and impact environments, although the lever-type electrical connector assembly 20 can be used in other applications. In actual practice, the lever-type electrical connector assembly 20 has been used directly on the motor chassis of a vehicle where vibrations and impacts are quite severe. This the lever-type electrical connector assembly 20 are primarily used on connectors having a high number of circuits, whereby the force required to mate the connectors 22, 24 together is increasingly high. Therefore, the lever-type electrical connector assembly 20 provides an assist to the operator for mating the connectors 22, 24 together.
The mating connector 24 includes an insulative plug housing 26 into which the actuator connector 22 is insertable in the direction of arrow “M” as shown in
A pair of reinforcing ribs 42 extend outwardly from each side wall 34, 36 in a direction perpendicular to the longitudinal axis 40, and a cam follower post 44 projects outwardly from each reinforcing rib 42 in a direction perpendicular to the longitudinal axis 40. Each cam follower post 44 has a circular main body 46 which projects outwardly from the respective reinforcing rib 42 and has a perimeter surface 47 which defines a diameter of the cam follower post 44, and a pair of crescent shaped projections 48a, 48b extending outwardly from an outer surface 49 of the main body 46. Each crescent shaped projection 48a, 48b has a length from a curved point 50 at an outer end to an inner end thereof which is generally parallel to the longitudinal axis 40. The curved point 50 aligns with and falls along the same radius as the main body 46. A convex surface 52 of each crescent shaped projection 48a, 48b faces the top end of the plug housing 26 and a concave surface 54 of each crescent shaped projection 48a, 48b faces a bottom end of the plug housing 26. While two crescent shaped projection 48a, 48b on each cam follower post 44, only one of the crescent shaped projection 48a, 48b is used during a particular mating process. Two crescent shaped projections 48a, 48b are provided so that the mating connector 24 can be used in either direction relative to the actuator connector 22. In addition, while two separate crescent shaped projections 48a, 48b are provided on each post, the crescent shaped projections 48a, 48b can be joined together at their inner ends.
A pair of reinforcing ribs 56 extend outwardly from each side wall 34, 36 in a direction perpendicular to the longitudinal axis 40 and are positioned between the reinforcing ribs 42. A projection 58 extends outwardly from each reinforcing rib 42 in a direction perpendicular to the longitudinal axis 40.
The plug housing 26 is a unitary structure which may be molded of plastic material. A lip 60 projects outwardly from the base wall 28 and forms an interference surface which faces upward toward actuator connector 22. The plug housing 26 mounts a plurality of conductive terminals (not shown).
As best shown in
The main body portion 76 is generally rectangular and has a base wall 82 at a top end thereof having front, rear and side walls 84, 86, 88, 90 extending downward from the outer perimeter of the base wall 82, such that an open-bottomed cavity 92 is formed. A longitudinal axis 94 of the connector housing 62 extends parallel to the side walls 88, 90 from the front wall 84 to the rear wall 86.
A plurality of passageways 96 through which terminals (not shown) pass are provided through the base wall 82 and extend perpendicular to the longitudinal axis 94. A rectangularly shaped retaining lip 98 extends downwardly from the base wall 82 and is spaced from the front, rear and side walls 84, 86, 88, 90 such that a space 100, see
Each side wall 88, 90 has a pair of spaced apart vertically extending cam follower post receiving slots 102 extending upward from a bottom end thereof. The cam follower post receiving slots 102 receive the reinforcing ribs 42 therein from the mating connector 24 and the cam follower posts 44 project outwardly from each side wall 88, 90 as described herein. Each side wall 88, 90 further has a pair of vertically extending projection receiving slots 104 extending upward from the bottom end thereof. The projection receiving slots 104 are between the cam follower post receiving slots 102 and receive the reinforcing ribs 56 therein from the mating connector 24 and the projections 58 project outwardly from each side wall 88, 90 as described herein. The side walls 88, 90 are planar with the exception of slide members retaining projections 106 which extend outwardly therefrom. In an embodiment, the slide members retaining projections 106 extend outwardly from the side walls 88, 90 above the cam follower post receiving slots 102.
Each retaining portion 78, 80 has a bottom wall 108 which extends outwardly from the side walls 88, 90, a side wall 110 extending upward from the outer end of the bottom wall 108, and a pair of top walls 112, 114 at front and rear ends of the side wall 110 which connect the side wall 110 to the respective side wall 88, 90 of the main body portion 76. An open-topped pocket 116 is formed by each retaining portion 78, 80 and the side walls 88, 90 of the main body portion 76. A pivot hole 118 is provided through each side wall 110 at approximately the midpoint of each side wall 110. Slide member 70 and a portion of the lever 66 seat within the pocket 116 of the retaining portion 78, and slide member 72 and a portion of the lever 66 seat within the pocket 116 of the retaining portion 80 as described herein.
The wire dress cover 64, see
The lever 66 is pivotally mounted on the connector housing 62 and sandwiches the respective slide member 70, 72 between the lever 66 and the side walls 90 of the main body portion 76 of the connector housing 62. The lever 66 preferably is fabricated of molded plastic material. The lever 66 is rotatable in a pivotal operating stroke in the direction of arrow “C”,
The connector position assurance device 74 is engageable with the cross portion 128 of the lever 66 to lock the lever 66 to the wire dress cover 64 when the actuator connector 22 is in its fully mated position with the mating connector 24 as shown in
As best shown in
Each cam groove 146 is formed by a base wall 150 which is parallel to the inner side surface 136 and is recessed therefrom, a front wall 152 extending perpendicularly outwardly from the base wall 150 to the inner side surface 136, and a rear wall 154 extending perpendicularly outwardly from the base wall 150 to the inner side surface 136. An end wall 156 is provided at the rear ends of the walls 150, 152, 154. An opening 158 is provided at the bottom ends of the front and rear walls 152, 154 in a bottom end 134c of the plate 134. The opening 158 is formed by front and rear walls 160, 162 which angle inwardly toward each other to form lead-in surfaces to the respective front and rear walls 152, 154. The rear wall 162 is angled relative to the angle A relative to the longitudinal axis 140.
Each front wall 152 has a first lower wall portion 163 which extends vertically upward from the front wall 160 of the opening 158, a second lower wall portion 164 which extends forwardly and upwardly at an angle B relative to the longitudinal axis 140 and extends from the upper end of the first lower wall portion 163, and an upper wall portion 166 which extends forwardly and upwardly from the upper forward end of the lower wall portion 164 and at an angle C relative to the longitudinal axis 140. The angle B is greater than the angle C.
Each rear wall 154 has a lower wall portion 168 which is curved along a radius line which is equal to the radius of the main body 46, which extends forwardly and upwardly, and which extends from the upper end of the rear wall 162 of the opening 158, and an upper wall portion 170 which extends forwardly and upwardly from the upper forward end of the lower wall portion 168 along a tangent line thereof. In each cam groove 146, the upper wall portion 170 of the rear wall 154 is parallel to the upper wall portion 166 of the front wall 152 and the space formed between the upper wall portions 166, 170 is approximately equal to the diameter of the main body 46. The rear wall 162 is rearward of the first lower wall portion 163. The lower wall portion 168 is rearward of the second lower wall portion 164 and the upper wall portion 166. In each cam groove 146, the space formed between the first lower wall portion 163 and the junction of the rear wall 162 and the lower wall portion 168 is approximately equal to the diameter of the main body 46.
In each cam groove 146, a blocking shoulder 172 extends rearwardly from the front wall 152, and outwardly from the base wall 150, such that a secondary opening 174 is formed in the bottom end 134c of the plate 134 between the bottom end of the blocking shoulder 172 and the rear wall 162. Each blocking shoulder 172 has a side wall 176 which extends rearwardly from the front wall 160 and the wall portions 163, 164 and is parallel to the base wall 150 and the inner side surface 136, a bottom wall 178 which extends from the bottom end 134c of the plate 134 and is planar, and a rear wall 180 which extends outwardly from the base wall 150 to the side wall 176. The side wall 176 is spaced from the base wall 150 at a distance which is equal to the distance the crescent shaped projections 48a project outwardly from the main body 46 of the respective cam follower post 44. The rear wall 180 has a lower wall portion 182 which extends forwardly and upwardly from the bottom end 134c of the plate 134 at an angle C relative to the longitudinal axis 140, and an upper wall portion 184 which extends forwardly and upwardly from the upper forward end of the lower wall portion 182 and at the angle C. The forward end of the upper wall portion 184 merges with the upper wall portion 166. The angle D is greater than angles A and B. In each cam groove 146, the space formed between the lower wall portion 182 and the lower wall portion 168 is approximately equal to the diameter of the main body 46.
The lever projection receiving groove 148 in the outer side surface 138 of each slide member 70, 72 extends vertically downward from a top surface 134d of the plate 134. The lever projection receiving groove 148 is longitudinally rearward of the front cam groove 146 and is longitudinally forward of the rear cam groove 146.
As shown for example in in
The terminal retention portion 68 seats within the cavity 92 of the main body portion 76 as described herein.
To assemble the lever-type electrical connector assembly 20, the actuator connector 22 is moved in the direction shown by arrow “M” as shown in
The reinforcing ribs 42 slide into the cam follower post receiving slots 102, and the reinforcing ribs 56 slide into the projection receiving slots 104. The cam follower posts 44 and the projections 58 extend outwardly from the side walls 88, 90 and into the pockets 116 of the respective retaining portions 78, 80. This initially connects the mating connector 24 and the actuator connector 22 together. The projections 58 engage with the inner side surfaces 136 of the respective slide member 70, 72, and the cam follower posts 44 on the opposite side walls 34, 36 engage with the bottom ends 134c of the plates 134 of each slide member 70, 72.
To enter into the cam grooves 146, the perimeter surfaces 47 of the main bodies 46 of the cam follower posts 44 must first engage with the rear walls 162 of the slide members 70, 72 as shown in
If the plug housing 26 is inserted such that the main bodies 46 of the cam follower posts 44 are offset rearwardly from the rear walls 162, the crescent shaped projections 48a engage with the blocking shoulders 172. The convex surfaces 52 of the crescent shaped projections 48a may engage with the bottom walls 178 of the blocking shoulders 172 and the outer surfaces 49 of the main bodies 46 engage against the side walls 176 of the blocking shoulders 172, or the curved points 50 of the crescent shaped projections 48a may engage the junction between the bottom wall 178 and the lower wall portion 182 of the respective blocking shoulder 172. In this position, the cam follower posts 44 are blocked by the blocking shoulders 172 from entering into the cam grooves 146; the cam follower posts 44 can only enter into the cam grooves 146 when the cam follower posts 44 are in the correct position. To remove the block formed by the blocking shoulders 172, the lever 66 is rotated in the direction of arrow “C” such that the lever 66 is rotated toward the rear wall 86 of the connector housing 62. When the lever 66 is so rotated, the slide members 70, 72 are moved longitudinally since the slide member engaging projections 132 pivot within the lever projection receiving groove 148 of the slide member 70 and bear against the rear wall of the lever projection receiving groove 148. As the crescent shaped projections 48a clear the engagement with the blocking shoulders 172, the lever 66 rotates in a direction opposite to direction shown by arrow “C” to provide a visual indication to the user that the crescent shaped projections 48a have cleared the engagement with the blocking shoulders 172, and that the mating connector 24 is in the ready-to-mate position. This causes the perimeter surfaces 47 of the main bodies 46 of the cam follower posts 44 to engage with the rear walls 162.
After the position of
The lever 66 is locked to the wire dress cover 64 using the connector position assurance device 74 in its fully mated position with the mating connector 24 as shown in
When the actuator connector 22 is in its fully mated position with the mating connector 24, the upper ends of the walls 30, 32, 34, 36 of the plug housing 26 seat within the space 100 of the main body portion 76 as shown in
The mating connector 24 can be decoupled from the actuator connector 22 by rotating the lever 66 in a direction opposite to the direction shown by arrow “C” after the connector position assurance device 74 is decoupled from the lever 66 and the wire dress cover 64. When the lever 66 is rotated in the direction opposite to the direction shown by arrow “C” such that the cross portion 128 is moved from proximate to the rear wall 86 of the connector housing 62 to proximate to the front wall 84 of the connector housing 62. When the lever 66 is rotated, this causes the cam follower posts 44 to travel along the cam grooves 146 and causes the slide member engaging projections 132 to travel vertically along the lever projection receiving grooves 148. The perimeter surfaces 47 of the main bodies 46 and the curved points 50 of the cam follower posts 44 engage with, and travel along, the upper wall portions 166, 170. As the lever 66 is further rotated, the perimeter surfaces 47 of the main bodies 46 of the cam follower posts 44 engage with the curved lower wall portions 168. The outer surfaces 49 of the main bodies 46 may engage against, and slide over, the side walls 176. The concave surfaces 54 of the crescent shaped projections 48a engage with the lower wall portions 182, and slide along the angled lower wall portions 182. The crescent shaped projections 48a then pass through the secondary openings 174 and the main bodies 46 pass through the openings 158. As a result, the slide members 70, 72 move longitudinally forward as the lever 66 rotates.
As shown in
As best shown in
The mat seal 194 seats within the upper cavity 212 and proximate to an upper surface of the base wall 202, see
The lower terminal housing 192 seats within the lower cavity 214 below the slots 218, 226, see
The lower cover 200 seats within the lower cavity 214 below the lower terminal housing 192, see
A stop surface is formed in the lower terminal housing 192 or in the lower cover 200 that includes a forward located shoulder portion that engages a cooperating surface formed on a nose portion of the terminal. The shoulder portion creates a front stop to limit the insertion of each terminal within the terminal retention portion 68.
The apertures 216, 230, 232, 236 align with each other such that a terminal can be inserted through the mat seal 194, the base wall 202, the lower terminal housing 192 and the lower cover 200.
The perimeter seal 196 extends around the walls 204, 206, 208, 210 of the upper terminal housing 190 and sits on the shoulder 228 and above the shoulder 228, see
When the terminal retention portion 68 is assembled with the connector housing 62, the mat seal 194 is proximate to base wall 82 of the connector housing 62, and the passageways 96 through the base wall 82 and the apertures 216, 230, 232, 236 align with each other. The walls 204, 206, 208, 210 of the upper terminal housing 190 are spaced from the walls 84, 86, 88, 90 of the connector housing 62 such that a space 238, see
The independent secondary lock 198 is mounted in the lower cavity 214 and in the slots 218, 226, and is between a lower surface of the base wall 202 and an upper surface of the lower terminal housing 192, see
To assemble the independent secondary lock 198 with the remainder of the terminal retention portion 68, the independent secondary lock 198 is inserted through the slot 218 of the upper terminal housing 190 and into the lower cavity 214 and into a first position. The base wall 202 of the upper terminal housing 190 seats within the three-sided cavity 247 of the independent secondary lock 198, and an inner surface of the side wall 246 of the independent secondary lock 198 engages against a side surface of the base wall 202 of the upper terminal housing 190. The latch arms 220, 222 flex outwardly from the slot 219 when the barbed ends 224 engage with the protrusions 258, but the latch arms 220, 222 snap back into place once the protrusions 258 pass the barbed ends 224. In this first position, a terminal cannot be passed through the terminal retention portion 68; a wall forming the apertures 256 in the independent secondary lock 198 block the aligned apertures 216, 230, 232, 236 in the mat seal 194, the upper terminal housing 190, the lower terminal housing 192 and the lower cover 200.
Once the terminal retention portion 68 is assembled, the terminal retention portion 68 is inserted into the cavity 92 of the connector housing 62 to form the actuator connector 22 and the space 238 is formed. A lower opening 260, see
In order to permit the passage of terminals through the actuator connector 22, the independent secondary lock 198 must be shifted relative to the upper terminal housing 190 to a second position, such that the walls forming the apertures 256 in the independent secondary lock 198 are misaligned with the aligned apertures 216, 230, 232, 236 in the mat seal 194, the upper terminal housing 190, the lower terminal housing 192 and the lower cover 200, such that the apertures 256 in the independent secondary lock 198 aligned with the aligned apertures 216, 230, 232, 236. To affect this, a pry tool (not shown) is inserted through the lower opening 260 and into the space 238. The pry tool can have a hooked end and engages within the slot 254 and with the wall portion 252 of the independent secondary lock 198. In the view shown in
Upon complete insertion of the terminals, the independent secondary lock 198 is moved from the second position back to the first position by use of the pry tool. The pry tool is again inserted through the lower opening 260 and into the space 238, and is engaged within the slot 254 and with the wall portion 248 of the independent secondary lock 198. In the view shown in
On occasions, terminals may need to be serviced, and in such cases, the terminals need to be removed from the actuator connector 22. The terminals can be removed from the actuator connector 22 by removing the wire dress cover 64, releasing the locking fingers 234 in the lower terminal housing 192 from the terminals, shifting the independent secondary lock 198 to the second position as described herein, and pulling the terminals out of the aligned apertures 216, 230, 256, 232, 236 in the mat seal 194, the upper terminal housing 190, the independent secondary lock 198, the lower terminal housing 192 and the lower cover 200. A new terminal can then be reinserted into the actuator connector 22 in the manner described herein.
When the mating connector 24 is inserted into the actuator connector 22, the walls 30, 32, 34, 36 of the plug housing 26 pass through the opening 260 and into the space 238. The walls 30, 32, 34, 36 sealingly engages with the perimeter seal 196, thereby providing a completely sealed system.
It will be understood that there are numerous modifications of the illustrated embodiments described above which will be readily apparent to one skilled in the art, such as many variations and modifications of the lever-type electrical connector assembly 20 and/or its components including combinations of features disclosed herein that are individually disclosed or claimed herein, explicitly including additional combinations of such features, or alternatively other types of contact array connectors. Also, there are many possible variations in the materials and configurations.
The disclosure provided herein describes features in terms of preferred and exemplary embodiments thereof. Numerous other embodiments, modifications and variations within the scope and spirit of the appended claims will occur to persons of ordinary skill in the art from a review of this disclosure.
| Number | Date | Country | Kind |
|---|---|---|---|
| 201910559024.3 | Jun 2019 | CN | national |
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| 10566728 | Sundarakrishnamachari | Feb 2020 | B1 |
| 20060040536 | Putnam | Feb 2006 | A1 |
| 20070099461 | Pittenger | May 2007 | A1 |
| 20090305536 | Martin | Dec 2009 | A1 |
| Number | Date | Country |
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| 101044658 | Sep 2007 | CN |
| 101044659 | Sep 2007 | CN |
| 101199087 | Jun 2008 | CN |
| 101218716 | Jul 2008 | CN |
| 101299500 | Nov 2008 | CN |
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| Entry |
|---|
| JP office action received for Application No. 2020-102799, dated Jul. 6, 2021, 8 pages (4 pages of English Translation and 4 pages of original documents). |
| Number | Date | Country | |
|---|---|---|---|
| 20200412040 A1 | Dec 2020 | US |
