Patent Application
20240364054
The present disclosure relates to connectors. In particular, aspects relate to electrical connectors having keying systems to ensure correct mating between a keyed female housing and a corresponding keyed male housing.
Electrical connectors can be used in various wiring systems. Electrical connectors can include a locking mechanism to maintain coupling between a female housing and a male housing. The female housing can support one or more terminals for mating with one or more male pins supported by the male housing. Electrical connectors can also include mechanisms, such as color coding, to single that a matching pair of female housing and male housing are correctly mated.
Some aspects are directed to a connector having a male housing and a female housing. The male housing has a first keying pattern on a left side and a second keying pattern on a right side, and the first keying pattern and the second keying pattern each comprises a rib and a groove. The female housing has a third keying pattern on a left side and a fourth keying pattern on a right side, and the third keying pattern and the fourth keying pattern each comprises a rib and a groove. The rib of the first keying pattern is configured to be inserted to the groove of the third keying pattern, and the rib of the third keying pattern is configured to be inserted to the groove of the first keying pattern, thereby allowing the female housing to mate with the male housing. The rib of the second keying pattern is configured to be inserted to the groove of the fourth keying pattern, and the rib of the fourth keying pattern is configured to be inserted to the groove of the second keying pattern, thereby allowing the female housing to mate with the male housing.
In some aspects, the rib of the first pattern has a cross-sectional area in a rod shape, and the groove of the third pattern has a cross-sectional area in a rod shape.
In some aspects, the rib of the first pattern has a cross-sectional area in an inverted-T shape extending from the top side of the male housing, and the groove of the third pattern has a cross-sectional area in an inverted-T shape.
In some aspects, the groove of the first pattern has a cross-sectional area in a T shape, and the rib of the third pattern has a cross-sectional area in a T shape extending from the top side of the female housing.
In some aspects, the rib of the second pattern has a cross-sectional area in a rod shape, and the groove of the fourth pattern has a cross-sectional area in a rod shape.
In some aspects, the rib of the second pattern has a cross-sectional area in an inverted-T shape extending from the top side of the male housing, and the groove of the fourth pattern has a cross-sectional area in an inverted-T shape.
In some aspects, the groove of the second pattern has a cross-sectional area in a T shape, and the rib of the fourth pattern has a cross-sectional area in a T shape extending from the top side of the female housing.
In some aspects, the rib of the first pattern and the rib of the second pattern extend from a front side of the male housing to a point between the front side and a rear side of the male housing.
In some aspects, the rib of the third pattern and the rib of the fourth pattern extend from a rear side of the female housing to a point between the rear side and a front side of the female housing.
In some aspects, the rib of the male housing extends downwardly from a top side of the male housing.
In some aspects, the rib of the female housing extends upwardly from a top side of the female housing.
Some aspects are directed to a method of connecting a connector having the steps of selecting a first housing comprising a first keying pattern comprising a rib and a groove, selecting a second housing comprising a second keying pattern comprising a rib and a groove, and mating the male housing with the female housing with a first force. The second keying pattern corresponds to the first keying pattern. The rib of the first keying pattern is configured to be inserted to the groove of the second keying pattern, and the rib of the second keying pattern is configured to be inserted to the groove of the first keying pattern.
In some aspects, if a third housing comprising a third keying pattern comprising a rib and a groove different from the second keying pattern is used to mate the third housing with the first housing with a second force, the second force is at least three times larger than the first force.
In some aspects, the rib of the first keying pattern and the rib of the third keying pattern are deformed if the first housing and the third housing are mated.
Some aspects are directed to a connector having a first housing and a second housing.
The first housing has a first keying system selected from a rod shape formed by a rib, an inverted-T shape formed by a rib, or a T shape formed by a groove. The second housing has a second keying system selected from a rod shape formed by a groove, an inverted-T shape formed by a groove, or a T shape formed by a rib. The second keying system is configured to mate with the first keying system such that the second keying system is selected to correspond to the first keying system.
In some aspects, the first keying system is disposed on a left side of the first housing, and the second keying system is disposed on a left side of the second housing.
In some aspects, the first keying system is disposed on a right side of the first housing, and the second keying system is disposed on a right side of the second housing.
In some aspects, the first keying system extends from a top of the first housing, and the second keying system extends from a top of the second housing.
In some aspects, the first keying system is disposed on a front of the first housing, and the second keying system is disposed on a rear of the second housing.
In some aspects, the first keying system is disposed along a longitudinal direction of the first housing, and the second keying system is disposed along a longitudinal direction of the second housing.
The accompanying drawings, which are incorporated herein and form part of the specification, illustrate aspects and, together with the description, further serve to explain the principles of the aspects and to enable a person skilled in the relevant art(s) to make and use the aspects.
The features and advantages of the aspects will become more apparent from the detail description set forth below when taken in conjunction with the drawings, in which like reference characters identify corresponding elements throughout. In the drawings like reference numbers generally indicate identical, functionally similar, and/or structurally similar elements.
The present invention(s) will now be described in detail with reference to aspects thereof as illustrated in the accompanying drawings. References to “one aspect,” “an aspect,” “an exemplary aspect,” etc., indicate that the aspect described may include a particular feature, structure, or characteristic, but every aspect may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same aspect. Further, when a particular feature, structure, or characteristic is described in connection with an aspect, it is submitted that it is within the knowledge of one skilled in the art to affect such feature, structure, or characteristic in connection with other aspects whether or not explicitly described.
The following examples are illustrative, but not limiting, of the present aspects. Other suitable modifications and adaptations of the variety of conditions and parameters normally encountered in the field, and which would be apparent to those skilled in the art, are within the spirit and scope of the disclosure.
As used herein, the term “approximately” is inclusive of the number to which it refers and includes numbers that bound and are within a range of 5%, 10%, 15%, or 20% except where such number would exceed 100% of a possible value.
Aspects provide an electrical connector for wiring systems, such as a vehicle wiring system. The electrical connector described herein can be a single or dual row, low profile, high voltage connector. In some aspects, the connector can have a low profile. The connector can secure to a printed circuit board (PCB), or can be a wire to wire connector, for example.
The electrical connector can include a female housing, a male housing, a connector position assurance member (“CPA member”), and a terminal position assurance member (“TPA member”). The female housing, the CPA member, and the TPA member can form an assembly that can be coupled to the male housing. In some embodiments, each of the female housing and the male housing includes a keying system to ensure correct mating between the female housing and the corresponding male housing.
The CPA member can ensure position assurance. Position assurance is important in wiring systems to ensure and maintain terminal mating and resist disconnection. To ensure coupling, a higher force can be required to couple the assembly with the male housing. The coupling can be intentionally released for maintenance by overcoming the resistance to disconnection. The CPA member can be released to allow decoupling of the female housing and male housing. Advantageously, feedback (e.g., a visual, tactile, and/or auditory feedback) can be provided to signal that the connector housings are coupled with position assurance. The coupling with connector position assurance between the assembly and the male housing can move the electrical connector from a pre-mate position to a fully mated position. The assembly including the female housing and the CPA member can be pre-installed. Accordingly, a user does not have to couple the CPA member to the female housing. In addition, the pre-installed assembly can help to prevent components from being detached and/or misplaced.
The TPA member can maintain proper terminal positioning within the housings. Terminal segments containing wire terminals can include a primary lock to maintain their position in a housing, ensuring proper mating. In an aspect, a portion of the TPA member can extend outside the female housing. In an aspect, the TPA member can reinforce the primary lock. In another aspect, a TPA member can be a secondary lock. Advantageously, feedback (e.g., visual, tactile, and/or audible feedback) can be provided to signal that the TPA member is in a final lock position so that a terminal can be installed with terminal position assurance. In the final lock position, the TPA member can be fully within the female housing. Once the terminal segments are installed, the TPA member can be in a final lock position in which the TPA member can be in blocking engagement with the terminal segments to prevent the terminal segments from being unintentionally removed from the female housing. The TPA member can also be pre-installed in the assembly of female housing and the CPA member. Accordingly, a user does not have to couple the TPA member to the female housing.
The male housing can include a front, a rear, a top, a bottom, a first side, and a second side. An aperture for receiving the female housing and TPA member assembly can extend from the front to a portion between the front and the rear. The female housing can include a front, a rear, a bottom, a top, a first side, and a second side. A keying system can be disposed, for example, on the top of the male housing and the top of the female housing. The keying system can have keying ribs forming different patterns, and the patterns on the male housing can correspond to patterns on the corresponding female housing, so that the matching pair of male housing and female housing can be correctly mated together. If a wrong pair of male housing and female housing are mismated, it can require at least three times of insertion force greater than mating a correct pair of male housing and female housing, thus signaling to the user that it is an incorrect match and potentially reduce damage or mismating in the first place.
The keying systems described herein generally relate to three patterns: rod shape, T shape, and inverted-T shape. The keying system can have one complimentary/corresponding pattern on the first side of the male housing and the female housing, and another complimentary/corresponding pattern one the second side of the male housing and the female housing. The patterns on the first side and the on the second side can be the same or different. Accordingly, within the limited space on the top of the male housing and the female housing, the combination of the patterns on the first side and the second side can provide nine different keying options, accommodating situations where up to nine different connectors are used. Thus, the keying systems described herein provides a more efficient alternative to color coding a matching pair of male housing and female housing. For example, nine different colors would have been required to signal nine matching pair of male housing and female housing, but with the keying systems, all housings can be manufactured with one color. Additionally, the keying systems can be combined with color coding to greatly expand the number of connectors that can be accommodated in a single situation. For example, using two different color codings with the keying systems accommodates 18 connectors, etc.
One or more terminal apertures can extend intermediate to a first side and a second side opposing the first side of the female housing. The terminal apertures can extend from the front to the rear of the female housing to receive one or more terminal segments. Another aperture can extend from the bottom to a portion between the bottom and the top of the female housing to receive the TPA member.
The terminal apertures can be arranged in one or more rows. In some aspects, the terminal apertures can be arranged in two rows. As described herein, a first row and a second row of terminal apertures can be provided, the second row being below the first row. In some aspects, the rows of terminal apertures can be aligned such that terminal apertures are arranged in parallel. In some aspects, the rows of terminal apertures can be offset.
The rear of the male housing can include a plurality of openings through which a plurality of pins are disposed. Accordingly, the pins extend into the aperture that receives the female housing. The pins can correspond to the terminal apertures in the female housing. In this way, when the female housing and male housing are coupled, the pins of the male housing can be aligned with the terminal apertures of the female housing. Terminals supported by the terminal aperture can therefore mate with the pins as the female housing and the male housing are mated.
In some aspects, the connector can be a single or dual row, low profile, connector. Accordingly, the arrangement of the male pins can support forming a single or dual row of solder pads. In some aspects, the connector can be a high voltage connector that supports 18 or 21 pins, for example. In some aspects, the overall size of the electrical connector can be reduced such that the connector has a low profile. For example, generally parallel rows of terminals can allow for a reduced female housing size to limit the connector profile. In addition, orienting the terminals such that they are generally parallel to the top end and the bottom end of the female housing can support the electrical connector having a low profile. The arrangement of the terminals can also support a larger clearance or creepage. For example, a clearance or creepage for an electrical path extending from a first terminal of the plurality of terminals to a second terminal of the plurality of terminals can be approximately 0.6 millimeters.
A connector 10 is shown in
With reference to
As shown in
In some aspects, keying ribs 502 forms keying patterns 504 with a rib shape 506 of ribs 502 and a groove shape 508 of the space around ribs 502. In some aspects, keying patterns 504 on female housing 100 correspond to and are compatible with keying patterns 504 on male housing 200 such that the connectors mate. For example, when keying patterns 504 are matching, rib shape 506 on female housing 100 corresponds with groove shape 508 on male housing 200, so that keying ribs 502 of female housing 100 can be inserted to groove shape 508 on male housing 200. Similarly, when keying patterns 504 are matching, groove shape 508 on female housing 100 corresponds with rib shape 506 on male housing 200, so that keying ribs 502 of male housing 200 can be inserted to groove shape 508 on female housing 100.
In some aspects, matching keying patterns 504 on female housing 100 and male housing 200 allow rear 102 of female housing 100 to mate with male housing 200 through aperture 222. In some aspects, if keying patterns 504 of female housing 100 do not match with keying patterns 504 of male housing 200, the insertion force required to insert rear 102 of female housing 100 to aperture 222 of male housing 200 can be at least three times greater. In some aspects, if keying patterns 504 of female housing 100 do not match with keying patterns 504 of male housing 200, the insertion force required to insert rear 102 of female housing 100 to aperture 222 of male housing 200 can be at least 1.5 times greater. In some aspects, if keying patterns 504 of female housing 100 do not match with keying patterns 504 of male housing 200, the insertion force required to insert rear 102 of female housing 100 to aperture 222 of male housing 200 can be at least two times greater. The increased insertion force can signal to a user that a wrong pair of female housing 100 and male housing 200 are mated. In some aspects, if keying patterns 504 of female housing 100 do not match with keying patterns 504 of male housing 200, female housing 100 and male housing 200 cannot be mated until keying ribs 502 deform or break.
Connector 10 in fully mated position 40 is shown in
In some aspects, terminal apertures 120 can be disposed between first side 110 and second side 112 of female housing 100 along front 102. In some aspects, female housing 100 can include a plurality of terminal apertures 120. The plurality of terminal apertures 120 can be arranged in one or more rows. As shown in
Aperture 222 of male housing 200 can receive the pre-installed assembly of female housing 100, TPA member 300 (
As shown in
In some aspects, second openings 218 can be positioned below first openings 214. Accordingly, second row 220 of second openings 218 can be positioned below first row 216 of first openings 214. In some aspects, first openings 214 can be positioned above a central lateral axis 3 of rear 204 of male housing 200. Accordingly, first row 216 of first openings 214 can be positioned above central lateral axis 3. In some aspects, second openings 218 can be positioned below central lateral axis 3. Accordingly, second row 220 of second openings 218 can be positioned below central lateral axis 3.
In some aspects, second row 220 of second openings 218 can be aligned with first row 216 of first openings 214. In some aspects, second row 220 of second openings 218 can be offset from first row 216 of first openings 214. First row 216 of first openings 214 and second row 220 of second openings 218 can be formed in rear 204.
In some aspects, first row 216 of first openings 214 and second row 220 of second openings 218 can receive pins 230. Pins 230 can include one or more first pins 232 and one or more second pins 234. First pins 232 can be disposed in first openings 214 and second pins 234 can be disposed in second openings 218. Accordingly, first pins 232 can be arranged in a first row 236 that can coincide with first row 216 of first openings 214. Similarly, second pins 234 can be arranged in a second row 238 that can coincide with second row 220 of second openings 218. Pins 230 can be disposed in male housing 200 to mate with terminals 130.
Keying systems 500 with various keying patterns 504 are shown in
Rear 104 of female housing 100 according an aspect with rod pattern is shown in
With reference to
Rear 104 of female housing 100 according an aspect with inverted-T pattern is shown in
With reference to
Rear 104 of female housing 100 according an aspect with T pattern is shown in
The aspects described in
In key option A, keying patterns 504 include rod pattern 510 on first side 110/210 and rod pattern 510 on second side 110/210. In key option B, keying patterns 504 include inverted-T pattern 520 on first side 110/210 and inverted-T pattern 520 on second side 110/210. In key option C, keying patterns 504 include T pattern 503 on first side 110/210 and T pattern 503 on second side 110/210. In key option D, keying patterns 504 include rod pattern 510 on first side 110/210 and inverted-T pattern 520 on second side 110/210. In key option E, keying patterns 504 include rod pattern 510 on first side 110/210 and T pattern 503 on second side 110/210. In key option F, keying patterns 504 include inverted-T pattern 520 on first side 110/210 and rod pattern 510 on second side 110/210. In key option G, keying patterns 504 include inverted-T pattern 520 on first side 110/210 and T pattern 503 on second side 110/210. In key option H, keying patterns 504 include T pattern 503 on first side 110/210 and rod pattern 510 on second side 110/210. In key option K, keying patterns 504 include T pattern 503 on first side 110/210 and inverted-T pattern 520 on second side 110/210. When male housing 200 and female housing 100 have the same key option can they be fully mated.
In some aspects, when male housing 200 and female housing 100 having mismatch keying patterns 504 are mated together, the interference between mismatch keying patterns 504 can result in an insertion force at least three times greater than the insertion force when keying patterns 504 are matching. In some aspects, the insertion force between mismatch keying patterns 504 is the force enough to cause keying ribs 502 to deform or to break.
In some aspects, the insertion force between mismatch keying patterns 504 is at least approximately 150 N, while the insertion force between matched keying patterns 504 is less than approximately 50 N. In some aspects, when female key option B is mismated with male key option D, the insertion force is approximately 278.55 N. In some aspects, when female key option B is mismated with male key option K, the insertion force is approximately 236.83 N. In some aspects, when female key option C is mismated with male key option E, the insertion force is approximately 250.12 N. In some aspects, when female key option C is mismated with male key option G, the insertion force is approximately 343.92 N. In some aspects, when female key option D is mismated with male key option B, the insertion force is approximately 243.26 N. In some aspects, when female key option D is mismated with male key option K, the insertion force is approximately 276.09 N. In some aspects, when female key option E is mismated with male key option C, the insertion force is approximately 287.13 N. In some aspects, when female key option E is mismated with male key option G, the insertion force is approximately 254.80 N. In some aspects, when female key option F is mismated with male key option H, the insertion force is approximately 166.87 N. In some aspects, when female key option G is mismated with male key option C, the insertion force is approximately 165.29 N. In some aspects, when female key option G is mismated with male key option E, the insertion force is approximately 400.04 N. In some aspects, when female key option His mismated with male key option F, the insertion force is approximately 303.97 N. In some aspects, when female key option K is mismated with male key option D, the insertion force is approximately 255.95 N. In some aspects, when female key option K is mismated with male key option F, the insertion force is approximately 230.16 N.
The present invention(s) have been described above with the aid of functional building blocks illustrating the implementation of specified functions and relationships thereof. The boundaries of these functional building blocks have been arbitrarily defined herein for the convenience of the description. Alternate boundaries can be defined so long as the specified functions and relationships thereof are appropriately performed.
The foregoing description of the specific aspects will so fully reveal the general nature of the invention that others can, by applying knowledge within the skill of the art, readily modify and/or adapt for various applications such specific aspects, without undue experimentation, without departing from the general concept of the present invention. Therefore, such adaptations and modifications are intended to be within the meaning and range of equivalents of the disclosed aspects, based on the teaching and guidance presented herein. It is to be understood that the phraseology or terminology herein is for the purpose of description and not of limitation, such that the terminology or phraseology of the present specification is to be interpreted by the skilled artisan in light of the teachings and guidance.
The breadth and scope of the present invention should not be limited by any of the above-described exemplary aspects, but should be defined only in accordance with the following claims and their equivalents.
