The invention relates to a connection assembly, particularly a connector designed to connect electrical conductors in a right angle or ninety degree configuration.
Right angle electrical connectors are desirable in certain applications to minimize packaging space needed for connecting electrical conductors, especially compared to straight line connectors. This may be crucial for meeting packaging space requirements in electrical or hybrid electrical vehicles. Electrical connection assemblies having a high connection force typically require a mating assist device to meet ergonomic requires for assembly operators. For packaging space requirements, the space required around the connector must also be considered, so it is desirable to avoid connector systems that require additional space for an operator's hand to make the connection, e.g. lever based mating assist connectors.
When connectors are used in high voltage application, e.g. greater than 48 volts, it is desirable to prevent accidental contact with energized terminals. Prior art solutions have used interlock circuits that prevent terminals from being energized until after the interlock circuit is completed by the proper mating of the connector assembly. However, additional protective measures may be desired to prevent accidental contact with the energized terminals to provide a fail-safe system.
The subject matter discussed in the background section should not be assumed to be prior art merely as a result of its mention in the background section. Similarly, a problem mentioned in the background section or associated with the subject matter of the background section should not be assumed to have been previously recognized in the prior art. The subject matter in the background section merely represents different approaches, which in and of themselves may also be inventions.
In accordance with a first embodiment of the invention, an electrical connector assembly is provided. The electrical connector assembly includes a first connector having a first housing containing a first electrical terminal and a mating assist slider that is attached to the first housing. The mating assist slider is configured to slide along a first axis defined by the first connector. The electrical connector assembly includes a second connector having a second housing containing a second electrical terminal and an intermediate housing attached to the second housing. The intermediate housing is configured to slide along a second axis defined by the second connector. The intermediate housing is configured to receive the first housing along the first axis. The mating assist slider is configured to move the intermediate housing along the second axis from an initial position to a final position when the mating assist slider is moved along the first axis from a starting position to and ending position, thereby mating the first electrical terminal to the second electrical terminal. The first axis is substantially perpendicular to the second axis.
In accordance with a second embodiment of the invention, the electrical connector assembly further includes a terminal cover that is attached to the intermediate housing. The terminal cover is configured to enclose the second electrical terminal when the intermediate housing is in the initial position and at least partially expose the second electrical terminal when the intermediate housing is in the final position.
In accordance with a third embodiment of the invention, the electrical connector assembly further comprises a locking bar that is retained and slideably attached to the intermediate housing. The second housing defines a locking groove in which the locking bar may be engaged. The locking bar is configured to secure the intermediate housing in the initial position to the final position when the locking bar is engaged with the locking groove and allow movement of the intermediate housing from the initial position to the final position when the locking bar is disengaged from the locking groove.
In accordance with a fourth embodiment of the invention, the second housing defines a cam post. A least one of two side walls of the mating assist slider defines a cam slot that is configured to receive the cam post of the second connector. Upon moving the mating assist slider from the starting position to the ending position, the cam slot is moved relative to the cam post producing a force along the second axis which drives the intermediate housing from the initial position to the final position.
In accordance with a fifth embodiment of the invention, the electrical connector assembly further includes a connector position assurance device that is slideably attached to the mating assist slider and is configured to inhibit movement of the mating assist slider from the ending position when engaged.
In accordance with a sixth embodiment of the invention, the electrical connector assembly further contains an intermediate/first housing seal that is configured to provide an environmental seal between the intermediate housing and the first housing when the first housing is mated with the intermediate housing.
In accordance with a seventh embodiment of the invention, the electrical connector assembly further comprises an intermediate seal that is configured to provide an environmental seal between the intermediate housing and the second housing when the intermediate housing is in the final position.
In accordance with a eighth embodiment of the invention, the first connector includes an interlock shunt and the second connector includes a pair of interlock terminals. The interlock shunt is configured to electrically connect the pair of interlock terminals when the intermediate housing is in the final position.
The present invention will now be described, by way of example with reference to the accompanying drawings, in which:
Presented herein in a right angle electrical connector assembly. The connector assembly includes a first connector having a first housing that contains at least one female connector terminal terminating a wire cable. A mating assist slider is attached to the first connector. The connector assembly also includes a second connector having a second housing that contains at least one male connector terminal configured to mate with the female terminal and designed to terminate another wire cable. The second connector also has an intermediate housing attached and moveable relative to the second conductor housing. When the first housing is connected with the intermediate housing, the mating assist slider receives a post on the second connector body into a cam slot. As the mating assist slider is moved forward over the intermediate housing, the post and cam slot cooperate to drive the intermediate housing onto the second housing, thereby connecting the female terminals to the male terminals.
An exploded diagram of the first connector 100 is shown in
The female terminals 102 are formed of a conductive material, such as a copper-based material. The female terminals 102 have a mating portion 106 that is configured to mate, i.e. form a mechanical and electrical connection, with the male terminals 202. The mating portion 106 is generally U-shaped having a first terminal opening 108 that is generally perpendicular to the first axis X and a second terminal opening 110 that is generally parallel to the first axis X. The first terminal opening 108 allows the female terminal 102 to mate with the male connector in a ninety-degree connection.
The female terminal 102 also has a cable connection portion 112 that is configured to electrically and mechanically connect the female terminal 102 the inner conductor of the shielded wire cable (not shown). The cable connection portion 112 is configured to be sonically welded to the inner conductor of the shielded wire cable. Sonically welding the inner conductor to the female terminal 102 provides the benefit of a lower interface resistance between the inner conductor and the female terminal 102 and provides the benefit of a shorter overall terminal length compared to a terminal configured for a crimp connection to the wire cable. Alternative embodiments of the female terminal configured for crimp connection to a wire cable may be envisioned since a connector assembly with a crimp connection terminal may provide cost savings in applications that allow a larger terminal and/or higher interface resistance.
The outer shield conductor (not shown) of the shielded wire cable is terminated by a pair of conductive ferrules, an inner ferrule (not shown) disposed between the shield conductor (not shown) and an inner insulation layer (not shown) between the shield conductor and the inner conductor and an outer ferrule 114 that is attached over the shield conductor.
The female terminals 102 are secured within an inner housing 116 also formed of a dielectric material such as PBT, PP, NYLON. Once the female terminals 102 are snapped into place within the inner housing 116 by snap features 118 as shown in
A conductive first grounding shield 124 surrounds a rearward portion of the inner housing 116. The first shield 124 is electrically connected to the outer ferrule 114 by ridges formed in a tubular portion of the first shield 124 configured to receive the outer ferrule 114. The first shield 124 may be formed from a sheet of conductive material, such as plated copper or plated steel, by a deep draw stamping process. Other materials and manufacturing techniques well known to those skilled in the art may also be used to form the first shield 124. The first shield 124 is secured to the inner housing 116 by snap features 126 that engage rectangular holes 128 in the first shield 124, see
The first connector 100 also includes a complaint first seal 132 within the first housing 104 longitudinally surrounding the inner housing 116 as shown in
The first housing 104 defines a flexible primary locking tab 136 having a rectangular slot 138 that is configured to secure the first connector 100 to the second connector 200 by engaging a fixed primary locking nib 204 on the second connector 200.
The first connector 100 further includes a mating assist slider 140 that is slideably connected to the first housing 104. The mating assist slider 140 is formed of a dielectric material such as PBT, PP, or NYLON. The mating assist slider 140 defines a longitudinal channel having a top wall 142 and two side walls 144. Each of the inner side walls 144 defines a groove 146 that receives a rail 148 projecting from each side wall of the first housing 104. The grooves 146 slide longitudinally over the rails 148 along the first axis X. As shown in
The cam slot 152 defines a ramp 154 between a slot opening 156 and a slot end 158. The ramp 154 is configured to engage the cam post 206 of the second connector 200 in a manner effective to urge the second connector 200 from the initial position 208 to a final position 210 when the mating assist slider 140 is moved from the starting position 160 to an ending position 162.
A ramp angle may be varied along a length of the ramp 154 to reduce a peak value of an applied force F to advance the mating assist slider 140 from the starting position 160 to the ending position 162. The ramp angle may be varied in accordance with an engagement force generated by the first connector 100 and the second connector 200 when they are urged together.
The mating assist slider 140 also includes a secondary locking nib 164 defined by a flexible beam that is configured to engage a fixed secondary locking tab 212 on the second connector 200.
The mating assist slider 140 additionally includes a connector position assurance (CPA) device 166 slideably attached to the mating assist slider 140. A tongue 168 of the CPA device 166 is configured to slide under the secondary locking tab 212 when first and second connectors 100, 200 are mated, thus inhibiting release of the secondary locking nib 164 from the secondary locking tab 212 and preventing the mating assist slider 140 from inadvertently being moved and accidentally unmating the first and second connectors 100, 200.
The first conductor also includes a high voltage interlock (HVIL) shunt 170 that is designed to connect a pair of mating HVIL terminals 214 in the second connector 200 when the first and second connectors 100, 200 are fully mated. The HVIL terminals 214 are linked to a control circuit (not shown) that inhibits the male terminals 202 in the second connector 200 from being energized until the HVIL terminals 214 are shorted by the HVIL shunt 170, ensuring that the female and male terminals 102, 202 are properly connected before energizing the male terminals 202.
An exploded diagram of the second connector 200 is shown in
As shown in
The second housing 216 further comprises a second seal 228. The second seal 228 is designed to seal the second connector 200 to the conductive case. The second seal 228 may be formed of a compliant material such as silicone rubber. The second seal 228 provides protection for the male terminals 202 from water, dust, and other environmental contaminants.
Returning again to
The intermediate housing 230 slides relative to the second housing 216 from an initial position 208 to a final position 210 along longitudinal guide grooves 242 defined in each side wall of the intermediate housing 230 that receive longitudinal guide rails 244 defined by the side walls 220 of the shroud 218. Both the guide grooves 242 and the guide rails 244 are substantially parallel to the second axis Z. As used herein, substantially parallel is ±5° of absolutely parallel. The intermediate housing 230 is formed of a dielectric material such as PBT, PP, or NYLON.
The intermediate housing 230 is held in the initial position 208 by an intermediate locking bar 246 a locking bar that is retained and slideably attached to the intermediate housing 230 and is laterally slideable along the first axis X. The locking bar 246 holds the intermediate housing 230 in the initial position 208 by engaging a lateral locking groove 248 in the guide rails 244 on at least one side of the second housing 216 until the locking bar 246 is slid laterally aligning a notch 250 in the locking bar 246 with the guide rail 244, thereby disengaging the locking bar 246 from the locking groove 248 and allowing the intermediate housing 230 to slide from the initial position 208 to the final position 210.
The intermediate housing 230 includes a terminal cover 252 fixedly attached to the intermediate housing 230 within the second intermediate opening 236. The terminal cover 252 is configured to enclose the male terminals 202 when the intermediate housing 230 is in the initial position 208, thus preventing accidental contact by a finger of an assembly operator or a foreign conductive element, such as a screwdriver or wrench, with the male terminals 202 when the first connector 100 is not mated with the second connector 200. When the intermediate housing 230 is lowered to the final position 210, at least a portion of each of the male terminals 202 are exposed allowing contact and coupling with the female terminals 102 of the first connector 100. The terminal cover 252 also encloses the tower 222 of the second housing 216 and the HVIL terminals 214 within when the intermediate housing 230 is in the initial position 208, thus preventing accidental contact by a foreign conductive element with the HVIL terminals 214 that could short the HVIL terminals 214 together and inappropriately enable the HVIL circuit. When the intermediate housing 230 is lowered to the final position 210, the HVIL terminals 214 are exposed allowing contact with the HVIL shunt 170 of the first connector 100. The terminal cover 252 is formed of a dielectric material such as PBT, PP, or NYLON.
The intermediate housing 230 further comprises an intermediate seal 254. The intermediate seal 254 is designed to seal the intermediate housing 230 to the second housing 216. The intermediate seal 254 may be formed of a compliant material such as silicone rubber. The intermediate seal 254 provides protection for the male terminals 202 from water, dust, and other environmental contaminants.
The intermediate housing 230 also defines the secondary locking tab 212 that cooperates with the secondary locking nib 164 of the first connector 100 to inhibit movement of the mating assist slider 140 after the first and second connectors 100, 200 are fully mated.
The intermediate housing 230 also includes a conductive intermediate grounding shield 256. The intermediate shield 256 has a first intermediate shield 256A that longitudinally surrounds the female terminals 102 along the first axis X and a second intermediate shield 256B that longitudinally surrounds the male terminals 202 along the second axis Z. The first intermediate shield 256A defines a first shield opening along the first axis X that is coaxial with the first intermediate opening 234 and a second shield opening along the second axis Z that is coaxial with the second intermediate opening 236. The second intermediate shield 256B is received within the second shield opening of the first intermediate shield 256A.
When the first and second connectors 100, 200 are fully mated, the intermediate shield 256 is electrically connected to the first shield 124 within the first connector 100 and the second shield 226 within the second housing 216, thereby providing an electrical path for the grounding shields 124, 226, 256 of the first and second connectors 100, 200 and the shield conductors of the shielded wire cables 14 to the conductive case of the battery pack.
As shown in
As shown in
As shown in the cross section diagram of
As seen in
As seen in
Although the illustrated embodiment of the right angle connector assembly shown herein includes an HVIL shunt and HVIL connectors, other embodiments of the connector assembly may be envisioned without those elements in applications of the connector assembly where a high voltage interlock circuit is not required. Alternatively, other embodiments of the connector assembly may be envisioned without a terminal cover for use in applications of the connector assembly where finger intrusion protection is not required.
The examples presented herein are directed to electrical connector assemblies, however other embodiments of the connector assembly may be envisioned that are adapted for use with optical cables or hybrid connectors including both electrical and optical cable connections. Yet other embodiments of the connector system may be envisioned that are configured to interconnect pneumatic or hydraulic lines. The force generated by the mating assist slider 140 may beneficially provide a sealing force to seals interconnecting pneumatic or hydraulic lines.
Accordingly an electrical connector assembly is provided. The assembly allows insertion of the first connector 100 into the second connector 200 and activation of the mating assist lever along a single axis, reducing the packaging space required around the connector assembly and simplifying ergonomics for attaching the first and second connectors 100, 200 for assembly operators. The assembly also provides the benefit of covering the male terminals 202 and HVIL terminals 214 when the first connector 100 is not connected to the second connector 200, thus reducing the possibility of inadvertent contact of the male terminals 202 or HVIL terminals 214 by the hand of an operator or a conductive element, e.g. a tool.
While this invention has been described in terms of the preferred embodiments thereof, it is not intended to be so limited, but rather only to the extent set forth in the claims that follow. Moreover, the use of the terms first, second, etc. does not denote any order of importance, but rather the terms first, second, etc. are used to distinguish one element from another. Furthermore, the use of the terms a, an, etc. do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items.
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