Electrical connector with electrical terminal service feature

Abstract

The present application relates to electrical connectors having electrical terminal service features. An electrical connector includes a housing having an interior space and a retention finger extending into the interior space. An electrical terminal and a terminal position assurance member are each disposed within the interior space of the housing. The terminal position assurance member is movable relative to the housing between: (1) a pre-lock position in which the retention finger prevents the electrical terminal from being withdrawn from the interior space of the housing and the terminal position assurance member does not prevent the retention finger from moving relative to the housing; (2) a service position in which the retention finger does not prevent the electrical terminal from being withdrawn from the interior space of the housing; and (3) a lock position in which the retention finger prevents the electrical terminal from being withdrawn from the interior space of the housing and the terminal position assurance member prevents the retention finger from moving relative to the housing.

Description

BACKGROUND

[0001] The present invention relates generally to an electrical distribution system that supplies electrical power from an electrical power source to one or more electrically operated devices. In particular, the present invention relates to an improved construction for an electrical connector used to releasably connect an electrical power source to one of the electrically operated devices in such an electrical distribution system.

[0002] In a conventional electrical distribution system, an electrical power source (e.g., a generator or a battery) is connected to supply electrical power through one or more electrical conductors (e.g., wires or bus bars) to respective electrically operated devices. To facilitate assembly and maintenance of the electrical distribution system, it is generally desirable to releasably connect some or all of the electrically operated devices to their respective electrical conductors. This can be accomplished by providing mating electrical connectors on the electrical conductors and the electrically operated devices. These mating electrical connectors are designed to selectively mechanically and electrically connect the electrical conductors to, and disconnect the electrical conductors from, their respective electrically operated devices.

[0003] Conventional electrical connectors include a non-conductive housing that supports a conductive terminal therein. Typically, the electrical terminal is protectively enclosed within the interior of the housing to prevent accidental contact with the electrical terminal during installation and use. The housing typically includes one or more retainers adapted to cooperate with corresponding retainers provided on a mating electrical connector to provide a releasable mechanical connection therebetween. Many conventional electrical connectors also include a terminal position assurance that ensures that the electrical terminal is properly positioned within the interior of the housing and is positively retained thereto.

[0004] A wide variety of electrical connector constructions are known in the art and have functioned satisfactorily. However, it is also known that in some instances it can be necessary to remove the electrical terminal from the housing for repair. In most known electrical connectors, a repair tool is required to disconnect the electrical terminal from the housing for disassembly and repair. Accordingly, it is desirable to provide an improved electrical connector that allows the electrical terminal to be disconnected from the housing and disassembled without the need for a repair tool. SUMMARY

[0005] This invention relates to an improved structure for an electrical connector that allows electrical terminals to be disconnected and removed from a housing without the need for service tools. The electrical connector includes a housing having an internal space and retaining fingers extending into the internal space. Electrical terminals and terminal position guarantees are each disposed within the internal space of the housing. The terminal position guarantees are movable relative to the housing between: (1) a pre-locked position, wherein the retaining fingers prevent the electrical terminals from being withdrawn from the internal space of the housing, and the terminal position guarantees do not prevent the retaining fingers from moving relative to the housing; (2) a service position, wherein the retaining fingers do not prevent the electrical terminals from being withdrawn from the internal space of the housing; and (3) a locked position, wherein the retaining fingers prevent the electrical terminals from being withdrawn from the internal space of the housing, and the terminal position guarantees prevent the retaining fingers from moving relative to the housing.

[0006] Various aspects of the invention will become apparent to those skilled in the art when read in conjunction with the accompanying drawings, based on the following detailed description of preferred embodiments. Brief description of the attached diagram

[0007] Figure 1 This is a perspective view of an improved structure for an electrical connector according to the present invention.

[0008] Figure 2 yes Figure 1 A perspective view of a partial cross-section of the housing of the electrical connector shown.

[0009] Figure 3 yes Figure 1 A perspective view of the terminal position guarantee of the electrical connector shown.

[0010] Figure 4 It is a side perspective view of a partial cross-section of the housing and the terminal position guarantee shown in the pre-locked position.

[0011] Figure 5 It is the casing and is shown in Figure 4 The diagram shows a bottom perspective view of a partial cross-section of the terminal position guarantee member in the pre-locked position.

[0012] Figure 6 It is a side perspective view of a partial cross-section of the housing and the terminal position guarantee shown in the service position.

[0013] Figure 7 It is the casing and is shown in Figure 6 The diagram shows a bottom perspective view of a portion of the cross-section of the terminal position guarantee component at the maintenance location.

[0014] Figure 8 It is the casing and is shown in Figure 6 and Figure 7The illustrated partial cross-sectional side view of the terminal position assurance member in the repair position, and also shows the electrical terminal mounted in the housing.

[0015] Figure 9 is a partial cross-sectional side perspective view of the housing and terminal position assurance member shown in the locked position.

[0016] Figure 10 is a partial cross-sectional side perspective view of the housing and terminal position assurance member shown in the Figure 9 The illustrated partial cross-sectional side view of the terminal position assurance member in the repair position, and also shows the electrical terminal mounted in the housing.

[0017] Figure 11 is a partial cross-sectional side perspective view of the housing and terminal position assurance member shown in the Figure 9 and Figure 10 The illustrated partial cross-sectional side view of the terminal position assurance member in the repair position, and also shows the electrical terminal mounted in the housing.

[0018] Figure 12 is a schematic side view showing the relative orientation of portions of the housing, terminal position assurance member and electrical terminal when the terminal position assurance member is in the pre-locked position.

[0019] Figure 13 is a schematic side view showing the relative orientation of portions of the housing, terminal position assurance member and electrical terminal when the terminal position assurance member is in the repair position.

[0020] Figure 14 is a schematic side view showing the relative orientation of portions of the housing, terminal position assurance member and electrical terminal when the terminal position assurance member is in the locked position.

[0021] Detailed description of the preferred embodiments

[0022] Referring now to the drawings, and initially to Figure 1 , an improved structure for an electrical connector, generally indicated at 10, in accordance with the present application is illustrated. It is known that the electrical connector 10 can be used to selectively connect first and second components in an electrical distribution system (not shown). However, the electrical connector 10 of the present application can be used in any desired electrical circuit or other environment for any desired purpose.

[0023] The electrical connector 10 includes an outer housing, generally indicated at 20. The structure of the housing 20 is described in detail in Figure 2 , Figure 4 and Figure 5The interior of the housing 20 is clearly shown. As shown therein, the illustrated housing 20 is generally shaped in the form of a hollow rectangular parallelepiped that defines a longitudinally extending interior space 21. However, the housing 20 can be shaped in any desired shape. Although the housing 20 can be formed in any desired manner and from any desired material, the housing 20 is preferably molded from a single piece of electrically non-conductive material.

[0024] The housing 20 of the electrical connector 10 includes a retention finger 22 that extends within the interior space 21. In the illustrated embodiment, the retention finger 22 is a cantilevered member that extends generally longitudinally through a portion of the interior space 21. The illustrated retention finger 22 terminates at an actuation surface 23 that is oriented at an angle relative to the longitudinally extending interior space 21 of the housing 20. An upstanding terminal locking member 24 is disposed on the retention finger 22 adjacent the actuation surface 23. As will be explained in greater detail below, the retention finger 22, the actuation surface 23 and the terminal locking member 24 are used to retain a terminal 12 within the electrical connector 10. Figure 2 As best shown, the housing 20, the retention finger 22 and the terminal locking member 24 are all integrally molded from a single piece of electrically non-conductive material. However, the housing 20, the retention finger 22 and the terminal locking member 24 can be formed in any desired manner and from any desired material or combination of materials. The use of the retention finger 22, the actuation surface 23 and the terminal locking member 24 will be explained in greater detail below.

[0025] As Figure 5 As best shown, the housing 20 of the electrical connector 10 also includes a pair of first retention recesses, generally indicated at 25, and a pair of second retention recesses, generally indicated at 26. In the illustrated embodiment, each of the pair of first retention recesses 25 is disposed longitudinally adjacent to a respective one of the pair of second retention recesses 26. However, any desired number of such first retention recesses 25 and second retention recesses 26 can be disposed at any desired location within the interior space 21 of the housing 20. Moreover, either or both of the first retention recesses 25 and the second retention recesses 26 can be implemented as any other desired positioning mechanism in the housing 20.

[0026] Each first retention recess 25 disposed in housing 20 includes a stop surface 25a and a ramp surface 25b. Similarly, each second retention recess 26 disposed in housing 20 also includes a stop surface 26a and a ramp surface 26b. The illustrated stop surfaces 25a and 26a each extend generally perpendicularly from the longitudinally extending interior space 21 of housing 20, while the illustrated ramp surfaces 25b and 26b each extend at a non-right angle relative to the longitudinally extending interior space 21 of housing 20. However, first retention recesses 25 and second retention recesses 26 can have any desired shape or combination of shapes. The purpose of first retention recesses 25 and second retention recesses 26 will be explained hereinafter.

[0027] Electrical connector 10 also includes a terminal position assurance member, generally designated 30. The structure of terminal position assurance member 30 is illustrated most clearly in Figure 3 、 Figure 4 and Figure 5 . As shown in the figures, the illustrated terminal position assurance member 30 includes a body 31 having a locking portion 31a extending generally longitudinally therefrom. The purpose of locking portion 31a of body 31 will be explained hereinafter. In addition, a pair of opposing actuation arms 32 extend generally longitudinally from body 31 of terminal position assurance member 30. As Figure 3 best shown, actuation arms 32 terminate in respective actuators 33 which extend inwardly toward one another. Each actuator 33 has an angled actuation surface 33a disposed thereon. In the illustrated embodiment, actuation arms 32 and actuators 33 are integrally molded from a single piece of electrically non-conductive material. However, any desired number of such actuation arms 32 and actuators 33 can be formed in any desired manner and from any desired material or combination of materials. The purpose of actuation arms 32, actuators 33 and actuation surfaces 33a will also be explained hereinafter.

[0028] As Figure 5 best shown, terminal position assurance member 30 also includes a pair of retainers, generally designated 34, which also extend generally longitudally from body 31. As Figure 7 best shown, retainers 34 terminate in respective protrusions 35 which extend inwardly toward one another. In the illustrated embodiment, each protrusion 35 includes a first surface 35a and a second surface 35b. The illustrated first surfaces 35a each extend generally perpendicularly from protrusions 35, while the illustrated second surfaces 35b each extend at a non-right angle relative to protrusions 35. However, first surfaces 35a and second surfaces 35b can have any desired shape or combination of shapes. The purpose of first surfaces 35a and second surfaces 35b will be explained hereinafter.

[0029] Electrical connector 10 also includes an electrical terminal and wire assembly, generally designated 40. The structure of electrical terminal and wire assembly 40 is illustrated most clearly inFigure 8 and Figure 11 are clearly shown therein. As shown therein, the illustrated electrical terminal and wire assembly 40 includes an electrical terminal 41 having a connection portion 42 extending therefrom in a first generally longitudinal direction and a terminal portion 43 extending therefrom in a second generally longitudinal direction opposite the first generally longitudinal direction. The illustrated connection portion 42 is adapted to be secured to a wire 44 or other electrical conductor in a conventional manner. The illustrated terminal portion 43 is a female terminal adapted to selectively engage a corresponding male terminal (not shown) in a conventional manner. The electrical terminal 41 is preferably formed of an electrically conductive material such as copper or aluminum. However, the electrical terminal 41 can be implemented to have any desired structure and can be formed of any desired material or combination of materials.

[0030] The electrical terminal 41 is provided with a locking surface 45. In the illustrated embodiment, the locking surface 45 is provided on the terminal portion 43 of the electrical terminal 41. However, the locking surface 45 can be provided at any desired location on the electrical terminal 41. The purpose of the locking surface 45 will be explained hereinafter.

[0031] To assemble the electrical connector 10, the terminal position assurance member 30 and the electrical terminal and wire assembly 40 are inserted longitudinally from opposite end portions of the housing 20 into the interior space 21 of the housing 20 until a pre-locked orientation of these components is achieved (as shown in Figure 4 , Figure 5 and Figure 12 ). In this pre-locked orientation (best shown in Figure 12 ), the locking surface 45 provided on the electrical terminal 41 is disposed adjacent the terminal locking member 24 provided on the retention finger 22 of the housing 20. As a result, the electrical terminal and wire assembly 40 cannot be withdrawn longitudinally from the housing 20. At the same time, the locking portion 31a of the terminal position assurance member 30 is not disposed adjacent the end portion of the retention finger 22 of the housing 20. As a result, the flexing movement of the retention finger 22 relative to the housing 20 is not forcibly prevented, as will be explained in more detail below.

[0032] As shown in Figure 5 , when the terminal position assurance member 30 is in the pre-locked position relative to the housing 20, the protrusions 35 provided on the terminal position assurance member 30 are disposed between the first retention recess 25 and the second retention recess 26 provided on the housing 20, respectively. Thus, as will be described in detail hereinafter, the terminal position assurance member 30 can be moved relative to the housing 20 in a first direction (indicated by arrow 50 in Figure 13 or in an opposite second direction (indicated by arrow 51 in Figure 14(As indicated by arrow 51 in the diagram) it moves longitudinally. However, the maximum amount of this relative longitudinal movement in the first direction 50 is limited by the engagement of the first surface 35a on the protrusion 35 of the terminal position retainer 30 and the stop surface 25a provided on the first retaining recess 25 of the housing 20. Similarly, the maximum amount of this relative longitudinal movement in the second direction 51 is limited by the engagement of the second surface 35b on the protrusion of the terminal position retainer 30 and the stop surface 26a provided on the second retaining recess 26 of the housing 20.

[0033] The terminal position guarantee 30 can be moved longitudinally relative to the housing 20 in the first direction 50 from the pre-locked position as follows: Figure 6 , Figure 7 , Figure 8 and Figure 13 The maintenance location is shown. At this maintenance location (in... Figure 13 (Best shown in the diagram), an actuator 33 disposed on the actuator arm 32 of the terminal position retainer 30 engages an angled actuating surface 23 disposed on the retaining finger 22 of the housing 20. As a result, the retaining finger 22 of the housing 20 is deflected such that the terminal locking member 24 disposed on the retaining finger 22 of the housing 20 is not arranged adjacent to the locking surface 45 disposed on the electrical terminal 40. This is possible because, as described above, the locking portion 31a of the terminal position retainer 30 is not arranged adjacent to the end of the retaining finger 22 of the housing 20. As a result, the electrical terminal and wire assembly 40 can be longitudinally withdrawn from the internal space 21 of the housing 20. Therefore, the electrical terminal and wire assembly 40 can be easily and quickly released from the housing 20 (e.g. for repair or replacement) without requiring any special tools or other equipment outside the electrical connector 10.

[0034] like Figure 7 As best shown, the degree of longitudinal movement of the terminal position retainer 30 in the first direction 50 is limited by the engagement of the first surface 35a on the protrusion 35 of the terminal position retainer 30 and the stop surface 25a on the first retaining recess 25 of the housing 20. When the terminal position retainer 30 is in the service position, the second surface 35b on the protrusion 35 of the terminal position retainer 30 engages with (or at least is arranged adjacent to) the inclined surface 25b on the first retaining recess 25 of the housing 20. Thus, the terminal position retainer 30 is forcibly held in the service position. However, by applying force to the terminal position retainer 30 in the second direction 51, the terminal position retainer 30 can be returned from the service position to the pre-locked position. When this occurs, the second surface 35b on the protrusion 35 of the terminal position retainer 30 engages with the inclined surface 25b on the first retaining recess 25 of the housing 20 and moves on the inclined surface 25b on the first retaining recess 25 of the housing 20 until the pre-locked position is reached.

[0035] Optionally, the terminal position assurance 30 can be moved longitudinally in the second direction 51 from the pre-lock position relative to the housing 20 to a lock position as shown in Figure 9 、 Figure 10 、 Figure 11 and Figure 14 . In this lock position (best shown in Figure 14 ), the actuator 33 provided on the actuation arm 32 of the terminal position assurance 30 does not engage the angled actuation surface 23 provided on the retention finger 22 of the housing 20. As a result, the retention finger 22 of the housing 20 is not deflected and the terminal lock member 24 provided on the retention finger 22 of the housing 20 remains adjacent to the locking surface 45 provided on the electrical terminal 41. At the same time, the locking portion 31a of the terminal position assurance 30 is arranged adjacent to the end of the retention finger 22 of the housing 20. As a result, the electrical terminal and wire assembly 40 cannot be pulled out longitudinally from the housing 20.

[0036] As best shown in Figure 10 , the extent of the longitudinal movement of the terminal position assurance 30 in the second direction 51 is limited by the engagement of the second surface 35b provided on the protrusion 35 of the terminal position assurance 30 with the stop surface 26a provided on the second retention recess 26 of the housing 20. When the terminal position assurance 30 is in the lock position, the first surface 35a provided on the protrusion 35 of the terminal position assurance 30 engages (or is at least arranged adjacent to) the inclined surface 26b provided on the second retention recess 26 of the housing 20. Thus, the terminal position assurance 30 is forced to remain in the lock position. However, by applying a force to the terminal position assurance 30 in the first direction 50, the terminal position assurance 30 can be returned from the lock position to the pre-lock position. When this happens, the first surface 35a provided on the protrusion 35 of the terminal position assurance 30 engages the inclined surface 26b provided on the second retention recess 26 of the housing 20 and moves over the inclined surface 26b provided on the second retention recess 26 of the housing 20 until the pre-lock position is reached.

[0037] The principles and modes of operation of the present application have been described and illustrated in its preferred embodiments. However, the application can be practiced otherwise than as specifically illustrated and described without departing from its spirit or scope.

Claims

1. An electrical connector, comprising: a housing having an interior space and a retention finger extending into the interior space; an electrical terminal disposed within the interior space of the housing; and a terminal position assurance member disposed within the interior space of the housing and movable relative to the housing between: (1) a pre-lock position in which the retention finger prevents the electrical terminal from being withdrawn from the interior space of the housing and the terminal position assurance member does not prevent the retention finger from moving relative to the housing; (2) a service position in which the retention finger does not prevent the electrical terminal from being withdrawn from the interior space of the housing; and (3) a lock position in which the retention finger prevents the electrical terminal from being withdrawn from the interior space of the housing and the terminal position assurance member prevents the retention finger from moving relative to the housing. the retention finger is integrally formed with the housing and the retention finger extends within the interior space in a cantilevered manner. when the terminal position assurance member is in the service position, the retention finger engages the terminal position assurance member such that the retention finger does not prevent the electrical terminal from being withdrawn from the interior space of the housing.

2. The electrical connector of claim 1, wherein, the retention finger includes an angled actuation surface that engages an angled actuation surface disposed on the terminal position assurance member when the terminal position assurance member is in the service position.

3. The electrical connector of claim 1, wherein, the retention finger includes a locking member that is disposed adjacent to a locking surface disposed on the electrical terminal when the terminal position assurance member is in the pre-lock position.

4. The electrical connector of claim 3, wherein, the retention finger includes a locking member that is disposed adjacent to a locking surface disposed on the electrical terminal when the terminal position assurance member is in the lock position.

5. The electrical connector of claim 1, wherein, the retention finger includes a locking member that is disposed adjacent to a locking surface disposed on the electrical terminal when the terminal position assurance member is in the pre-lock position and in the lock position.

6. The electrical connector of claim 1, wherein, the terminal position assurance member includes a locking portion that is disposed adjacent to the retention finger when the terminal position assurance member is in the lock position.

7. The electrical connector of claim 1, wherein, the terminal position assurance member is movable in a first direction from the pre-lock position to the service position.

8. The electrical connector of claim 1, wherein, the terminal position assurance member is movable in a second direction from the pre-lock position to the lock position.

9. The electrical connector of claim 1, wherein, the first direction is opposite the second direction.

10. The electrical connector of claim 9, wherein, the terminal position assurance member includes a pair of actuation arms that terminate in respective actuators that engage the retention finger such that the retention finger does not prevent the electrical terminal from being withdrawn from the interior space of the housing when the terminal position assurance member is in the service position.

11. The electrical connector of claim 10, wherein, ​ 12. The electrical connector of claim 1, wherein, ​

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