Electrical connector assembly with male blade stabilizer with integrated primary lockout reinforcement

Abstract

An electrical connector assembly (10) includes a connector body (16) defining a terminal cavity (18) therein, and a male terminal (20) projecting along a terminal axis to a front end and secured within the terminal cavity (18) by a one-shot feature (22). The electrical connector assembly (10) further includes a terminal stabilizer (24) defining an aperture (26), the terminal stabilizer configured within the connector body (16) and movable from a ready position (28) to a stabilized position (30). The electrical connector assembly (10) further includes a one-shot retention feature integral with the terminal stabilizer (24) and configured to engage the one-shot feature (22) upon movement of the terminal stabilizer (24) from the ready position (28) to the stabilized position (30).

Description

[0001] Cross-reference to related applications

[0002] This application claims priority to U.S. Provisional Patent Application No. 62 / 961,733, filed January 16, 2020, the entire disclosure of which is incorporated herein by reference. Technical Field

[0003] The present invention generally relates to an electrical connector assembly, and more particularly to a connector assembly having a block stabilizer (MBS) with an integrated primary locking reinforcement mechanism (PLR). Background Technology

[0004] In electrical connection assemblies, particularly those used in automotive applications, secondary locking systems play a crucial role in protecting terminals and ensuring proper terminal positioning in the event of primary locking failure due to high connector engagement forces. Male pin stabilizer (MBS) systems are frequently used to protect male pins from damage by external objects. MBS can move from a ready position to a stable position. MBS can be configured to return from the stable position to the ready position or to remain permanently in the stable position. Electrical connector systems may also include an independent secondary locking (ISL) system, which provides a backup for the primary locking system in the event of primary locking failure.

[0005] The topics discussed in the background section should not be considered prior art simply because they are mentioned there. Similarly, problems mentioned in or related to the topics in the background section should not be assumed to have been previously discovered in the prior art. The topics in the background section represent different solutions, which may themselves be inventions. Summary of the Invention

[0006] According to an embodiment of the present invention, an electrical connector assembly is provided. The electrical connector assembly includes: a first connector body defining a first terminal cavity therein; a male terminal projecting along a terminal axis to a front end and secured within the first terminal cavity by a first primary locking feature; and a terminal stabilizer defining an orifice, the terminal stabilizer being disposed within the first connector body and movable from a preparatory position to a stable position (operating position). The front end of the male terminal is received in the orifice. The terminal stabilizer is closer to the front end in the preparatory position than in the stable position. The terminal stabilizer defines a first primary locking retention feature configured to engage a first primary locking feature when the terminal stabilizer is moved from the preparatory position to the preparatory position.

[0007] In example implementations of one or more features of the electrical connector assembly of the previous paragraph, the first primary lockout retention feature is not engaged with the first primary lockout feature when the terminal stabilizer is in the ready position.

[0008] In example implementations of one or more features of the electrical connector assembly of the previous paragraph, the first primary lockout retention feature is received within the first terminal cavity when the terminal stabilizer is moved from the ready position to the stabilized position.

[0009] In example implementations of one or more features of the electrical connector assembly of the previous paragraph, the first primary lockout retention feature is a first rib feature extending parallel to the terminal axis from a first face of the terminal stabilizer defining the aperture.

[0010] In example implementations of one or more features of the electrical connector assembly of the previous paragraph, the electrical connector assembly further comprises a second connector body defining a second terminal cavity therein and configured to mate with the first connector body, and a female terminal secured within the second terminal cavity by a second primary lockout feature and configured to mate with the male terminal. The terminal stabilizer defines a second primary lockout retention feature configured to engage the second primary lockout feature when the terminal stabilizer is moved from the ready position to the stabilized position as the first connector body mates with the second connector body.

[0011] In example implementations of one or more features of the electrical connector assembly of the previous paragraph, the second primary lockout retention feature is a second rib feature extending parallel to the terminal axis from a second face of the terminal stabilizer defining the aperture in an opposite direction from the first face.

[0012] In example implementations of one or more features of the electrical connector assembly of the previous paragraph, the second connector body urges the terminal stabilizer from the ready position to the stabilized position when the first connector body mates with the second connector body.

[0013] In example implementations of one or more features of the electrical connector assembly of the previous paragraph, the terminal stabilizer defines a ready stage lockout feature configured to retain the terminal stabilizer in the ready position until urged by the second connector body.

[0014] In example implementations of one or more features of the electrical connector assembly of the previous paragraph, the first primary lockout retention feature engages the first primary lockout feature prior to the male terminal mating with the female terminal.

[0015] In an exemplary embodiment having one or more features of the electrical connector assembly of the previous paragraph, the second primary locking retention feature engages the second primary locking feature prior to the male terminal mating with the female terminal.

[0016] In an exemplary embodiment having one or more features of the electrical connector assembly of the previous paragraph, the terminal stabilizer defines a retraction feature configured to move the terminal stabilizer from the stable position to the ready position upon the first connector body disengaging from the second connector body.

[0017] According to another embodiment of the present invention, an electrical connector assembly is provided. The electrical connector assembly includes a first connector body defining a first terminal cavity therein, a male terminal projecting to a terminal tip along a terminal axis and secured within the first terminal cavity by a first primary locking feature, and a terminal stabilizer defining an aperture. The terminal stabilizer is disposed within the first connector body and is movable from a ready position to a stable position. The terminal stabilizer defines a means for engaging the first primary locking feature upon movement of the terminal stabilizer from the ready position to the stable position. BRIEF DESCRIPTION OF DRAWINGS

[0018] The present invention will now be described, by way of example, with reference to the accompanying drawings, in which:

[0019] Figure 1A is a perspective view of an electrical connector assembly according to an embodiment of the present invention;

[0020] Figure 1B is a perspective view of a female connector of the electrical connector assembly of Figure 1A according to an embodiment of the present invention;

[0021] Figure 1C is a perspective view of a male connector of the electrical connector assembly of Figure 1A according to an embodiment of the present invention;

[0022] Figure 2A is a perspective rear view of a male blade stabilizer of the male connector of Figure 1C according to an embodiment of the present invention;

[0023] Figure 2B is a perspective front view of the male blade stabilizer of Figure 2A according to an embodiment of the present invention;

[0024] Figure 3A is a cross-sectional view of the male connector of Figure 1C according to an embodiment of the present invention, wherein Figure 2A the male blade stabilizer is in the ready position;

[0025] Figure 3Bis a cross-sectional view of the engagement of the male tab stabilizer with the terminal in the ready position according to an embodiment of the present invention, Figure 3A is an enlarged cross-sectional view of the engagement of the male tab stabilizer with the terminal in the ready position according to an embodiment of the present invention,

[0026] Figure 4A is a cross-sectional view of the engagement of the female connector with the male connector according to an embodiment of the present invention, wherein the male tab stabilizer is in the ready position, Figure 1B Figure 1C is a cross-sectional view of the engagement of the female connector with the male connector according to an embodiment of the present invention, wherein the male tab stabilizer is in the ready position, Figure 2A

[0027] Figure 4B is an enlarged cross-sectional view of the engagement of the male tab stabilizer with the terminal in the ready position according to an embodiment of the present invention, Figure 4A is an enlarged cross-sectional view of the engagement of the male tab stabilizer with the terminal in the ready position according to an embodiment of the present invention,

[0028] Figure 5A is a cross-sectional view of the engagement of the female connector with the male connector according to an embodiment of the present invention, wherein the male tab stabilizer is in the ready position, Figure 1C Figure 1B is a cross-sectional view of the engagement of the female connector with the male connector according to an embodiment of the present invention, wherein the male tab stabilizer is in the ready position,

[0029] Figure 5B is an enlarged cross-sectional view of the engagement of the male tab stabilizer with the terminal in the ready position according to an embodiment of the present invention, Figure 5A is an enlarged cross-sectional view of the engagement of the male tab stabilizer with the terminal in the ready position according to an embodiment of the present invention,

[0030] Figure 6A is a cross-sectional view of the engagement of the female connector with the male connector according to an embodiment of the present invention, wherein the male tab stabilizer is in the ready position, Figure 1B Figure 1C is a cross-sectional view of the engagement of the female connector with the male connector according to an embodiment of the present invention, wherein the male tab stabilizer is in the ready position, Figure 2A

[0031] Figure 6B is an enlarged cross-sectional view of the engagement of the male tab stabilizer with the terminal in the ready position according to an embodiment of the present invention, Figure 5A is an enlarged cross-sectional view of the engagement of the male tab stabilizer with the terminal in the ready position according to an embodiment of the present invention.DETAILED DESCRIPTION

[0032] An electrical connector assembly is presented herein. The electrical connector assembly includes a terminal stabilizer configured to maintain electrical terminals in proper spacing and alignment upon mating of the electrical connector assembly. Such a terminal stabilizer is commonly referred to as a male tab stabilizer device, as male tab terminals generally require stabilization due to their elongated blade or pin. The terminal stabilizer also includes a one-shot retention feature that engages a one-shot feature that retains the terminals within the terminal cavities of the connector. The one-shot retention feature is configured to simultaneously engage a one-shot feature that retains a male terminal within one connector body and a one-shot feature that retains a female terminal within another connector body. ​​​​​

[0033] Figure 1A A non-limiting example of an electrical connector assembly (hereinafter referred to as assembly 10) according to one embodiment of the present application is shown. Assembly 10 includes two mating connectors 12, 14 shown in Figure 1B and Figure 1C respectively.

[0034] Figure 1C The first connector 12 shown includes a first connector body 16 defining a plurality of first terminal cavities 18 therein. The first connector 12 also includes a plurality of male terminals 20 projecting to a terminal tip along a terminal axis and disposed within the first terminal cavities 18. The male terminals 20 are secured within the first terminal cavities 18 by a first primary locking feature 22 in the form of a cantilevered arm having an angled latch on a free end that engages a tab on the male terminal 20 to secure the male terminal 20 within the first terminal cavity 18. The first connector 12 also includes a terminal stabilizer 24 shown in Figure 2A and Figure 2B defining a plurality of apertures 26 that receive the male terminals 20. The terminal stabilizer 24 is disposed within the first connector body 16 and is movable from a ready position 28 shown in Figure 3A and Figure 3B to a stabilized position 30 shown in Figure 6A and Figure 6B The terminal stabilizer 24 in the ready position 28 is closer to the terminal tip of the male terminals 20 than it is in the locked stage position 30.

[0035] The terminal stabilizer 24 defines a first primary locking retention feature 32 configured to engage the first primary locking feature 22 when the terminal stabilizer 24 is moved from the ready position 28 to the stabilized position 30. When the terminal stabilizer 24 is in the stabilized position 30, the first primary locking retention feature 32 is positioned between the first primary locking feature 22 and a cavity wall of the first terminal cavity 18, thereby inhibiting flexing of the first primary locking feature 22 that can result in the unintended removal of the male terminal 20 from one of the first terminal cavities 18.

[0036] The first primary locking retention feature 32 is sized, shaped, and arranged such that it does not engage the first primary locking feature 22 when the terminal stabilizer 24 is in the ready position 28. When the terminal stabilizer 24 is moved from the ready position 28 to the stabilized position 30, the first primary locking retention feature 32 is received within the first terminal cavity 18 and positioned between the first primary locking feature 22 and the cavity wall. The first primary locking retention feature 32 is in the form of a first rib feature extending parallel to the terminal axis from a first face 34 of the terminal stabilizer 24 that defines the apertures 26.

[0037] Figure 1B The illustrated second connector 14 includes a second connector body 36 that defines a plurality of second terminal cavities 38 therein. The second connector body 36 is configured to mate with a first connector body 16. A plurality of female terminals 40 are secured within the second terminal cavities 38 by a second primary locking feature 42, which is designed and functionally similar to the first primary locking feature 22. The female terminals 40 are configured to mate with male terminals 20. A terminal stabilizer 24 defines a second primary locking retaining feature 44 configured to engage the second primary locking feature 42 when the terminal stabilizer 24 moves from a preparatory position 28 to a stable position 30 as the first connector body 16 mates with the second connector body 36. When the terminal stabilizer 24 is in the stable position 30, the second primary locking retaining feature 44 is located between the second primary locking feature 42 and the cavity wall of the second terminal cavity 38, thereby preventing deflection of the first primary locking feature 22, which could cause the female terminals 40 to be accidentally removed from one of the second terminal cavities 38. The second locking feature 44 is in the form of a second rib feature that extends from the second surface 46 of the terminal stabilizer 24 defining the hole 26 in a direction opposite to the first surface 34 and parallel to the terminal axis.

[0038] When the first connector body 16 mates with the second connector body 36, the second connector body 36 pushes the terminal stabilizer 24 from the ready position 28 to the stable position 30.

[0039] The terminal stabilizer 24 defines a preparatory phase locking feature 48, which is configured to hold the terminal stabilizer 24 in a preparatory position 28 until it is pushed by the second connector body 36.

[0040] like Figure 5A and Figure 5B As shown, before the male terminal 20 is mated with the female terminal 40, the first primary locking retaining feature 32 engages the first primary locking feature 22. For example... Figure 4A and Figure 4B As shown, before the male terminal 20 is mated with the female terminal 40, the second primary locking feature 44 also engages the second primary locking feature 42.

[0041] Terminal stabilizer 24 defines retraction feature 50, which is configured to move terminal stabilizer 24 from stable position 30 to ready position 28 when the first connector body 16 disengages from the second connector body 36.

[0042] During initial assembly, the terminal stabilizer 24 is set in a pre-position within the first connector body 16. The first primary lock retention feature is set at a distance from the first primary lock feature 22 to allow the first primary lock feature 22 to flex so that the male terminal 20 can be trouble free inserted into the first terminal cavity 18. During mating of the first connector 12 with the second connector 14, the second primary lock retention feature travels between the second primary lock feature 42 and the cavity wall of the second terminal cavity 38 and reinforces the second primary lock feature 42 to make it a reliable form lock system. The female housing pushes the terminal stabilizer 24 all the way down to the final position.

[0043] During movement of the terminal stabilizer 24 from the pre-position 28 to the stabilized position 30, the first primary lock retention feature 32 supports the first primary lock feature 22 before the male terminal 20 begins to mate with the female terminal 40. This ensures that the first primary lock feature 22 is well reinforced before the terminal engagement which would exert more force on the first primary lock feature 22.

[0044] The primary lock retention feature on the terminal stabilizer 24 can eliminate the need for a secondary lock feature that is typically used to reinforce or support a primary lock feature. With this terminal stabilizer 24, both the male secondary lock component and the female secondary lock component can be eliminated from the connector design and provide the benefit of reducing the overall cost of the electrical connector assembly 10.

[0045] While the illustrated embodiments are directed to electrical connector assemblies, other embodiments adapted for use with other types of connector assemblies for fiber optic cables, pneumatic tubes, hydraulic tubes, or hybrid connector assemblies including two or more of the items listed above can be contemplated.

[0046] While the application has been described in terms of preferred embodiments, it is to be understood that the application need not be limited to the particulars of the embodiments described above and that the application is to be construed broadly within the scope of the appended claims and equivalents thereof. For example, the embodiments described above (and / or aspects thereof) can be used in combination with each other. Also, various modifications can be made to the particular embodiments described above without departing from the scope and spirit of the application. The dimensions, types of materials, orientations of the various components, and the number and positions of the various components as described herein are intended to define parameters of particular embodiments and are by no means limiting and are for the purpose of example only.

[0047] Many other implementations of the application will be apparent to those of ordinary skill in the art in view of the above description, which is intended to be illustrative only. Thus, it will be apparent to one of ordinary skill in the art that the application is not intended to be limited to the embodiments described above but is to be accorded the full scope consistent with the claims, with all claims to be afforded the full breadth consistent with the language thereof.

[0048] As used herein, "one or more" includes a function performed by one element, a function performed by more than one element in a distributed manner, several functions performed by one element, several functions performed by several elements, or any combination of the above.

[0049] It should also be understood that, although the terms first, second, etc. are used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first contact could be termed a second contact, and, similarly, a second contact could be termed a first contact, without departing from the scope of the various described embodiments.

[0050] The terminology used in the description of the various described embodiments herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used in the description of the various described embodiments and the appended claims, the singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It also should be understood that the term "and / or" as used herein refers to and encompasses any and all possible combinations of one or more of the associated listed items. It should be further understood that the terms "includes," "including," "comprises," and / or "comprising," as used herein, specifically intend to recite the existence of the stated features, integers, steps, operations, elements, and / or components but do not preclude the existence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0051] As used in this document, the terms "if" and "when" are optionally used to express the meaning "when" or "upon" or "in response to a determination" or "in response to a detection." Similarly, the phrases "if determined" or "if [a stated condition or event] is detected" are optionally interpreted to express "upon a decision" or "in response to a decision" or "[upon detecting the stated condition or event]" or "in response to detecting [the stated condition or event]."

[0052] In addition, while terms of approximation or orientation can be used herein, these elements should not be limited by these terms. Unless otherwise specified, all approximations or orientations are used for the purpose of distinguishing one element from another, and unless otherwise specified, do not indicate any particular order, sequence of operations, direction, or orientation.

Claims

1. An electrical connector assembly (10), comprising: a first connector body (16) defining a terminal cavity (18) therein; a male terminal (20) projecting to a tip along a terminal axis and secured within the terminal cavity (18) by a first primary lock feature (22); and a terminal stabilizer (24) defining an aperture (26) configured to receive the male terminal (20), the terminal stabilizer disposed within the connector body (16) and movable from a ready position (28) to a stabilized position (30); a first primary lock retention feature (32) being a rib feature extending parallel to the terminal axis from a first face (34) of the terminal stabilizer (24) defining the aperture (26) and configured to engage the first primary lock feature (22) as the terminal stabilizer (24) moves from the ready position (28) to the stabilized position (30); a second connector body (36) defining a second terminal cavity (38) therein and configured to mate with the first connector body (16); a female terminal (40) secured within the second terminal cavity (38) by a second primary lock feature (42) and configured to mate with the male terminal (20), wherein the terminal stabilizer (24) defines a second primary lock retention feature (44) configured to engage the second primary lock feature (42) as the terminal stabilizer (24) moves from the ready position (28) to the stabilized position (30) as the first connector body (16) mates with the second connector body (36). The tip of the male terminal (20) is received in the aperture (26) defined by the terminal stabilizer (24).

2. The electrical connector assembly (10) of claim 1, wherein, The terminal stabilizer (24) is closer to the tip in the ready position (28) than in the stabilized position (30).

3. The electrical connector assembly (10) of claim 2, wherein, The primary lock retention feature (32) is not engaged with the primary lock feature (22) when the terminal stabilizer (24) is in the ready position (28).

4. The electrical connector assembly (10) of claim 1, wherein, The primary lock retention feature (32) is received within the terminal cavity (18) as the terminal stabilizer (24) moves from the ready position (28) to the stabilized position (30).

5. The electrical connector assembly (10) of claim 1, wherein, The second primary lock retention feature (44) is a second rib feature extending parallel to the terminal axis from a second face (46) of the terminal stabilizer (24) defining the aperture (26) in an opposite direction from the first face (34).

6. The electrical connector assembly (10) of claim 1, wherein, The second connector body (36) urges the terminal stabilizer (24) from the ready position (28) to the stabilized position (30) as the first connector body (16) mates with the second connector body (36).

7. The electrical connector assembly (10) of claim 1, wherein, ​ 8. The electrical connector assembly (10) of claim 7, wherein, The terminal stabilizer (24) defines a pre-stage latching feature (48) configured to hold the terminal stabilizer (24) in the pre-position (28) until urged by the second connector body (36).

9. The electrical connector assembly (10) of claim 1, wherein, The first primary latching retention feature (32) engages the first primary latching feature (22) prior to the male terminal (20) and the female terminal (40) being mated.

10. The electrical connector assembly (10) of claim 1, wherein, The second primary latching retention feature (44) engages the second primary latching feature (42) prior to the male terminal (20) and the female terminal (40) being mated.

11. The electrical connector assembly (10) of claim 1, wherein, The terminal stabilizer (24) defines a retraction feature (50) configured to move the terminal stabilizer (24) from the stabilized position (30) to the pre-position (28) upon the first connector body (16) being unmated from the second connector body (36).

12. An electrical connector assembly (10) comprising: a first connector body (16) defining a first terminal cavity (18) therein; a male terminal (20) projecting to a tip along a terminal axis and secured within the first terminal cavity (18) by a first primary latching feature (22); a second connector body (36) defining a second terminal cavity (38) therein and configured to mate with the first connector body (16); a female terminal (40) secured within the second terminal cavity (38) by a second primary latching feature (42) and configured to mate with the male terminal (20); and a terminal stabilizer (24) defining a bore (26) configured to receive the male terminal (20), wherein the terminal stabilizer is disposed within the first connector body (16) and movable from a pre-position (28) to a stabilized position (30), wherein the terminal stabilizer (24) defines means for engaging the first primary latching feature (22) and means for engaging the second primary latching feature upon the terminal stabilizer (24) moving from the pre-position (28) to the stabilized position (30).

13. A method of assembling an electrical connector assembly (10) comprising: providing a first connector body (16) having a male terminal (20) projecting to a front end along a terminal axis, the male terminal (20) secured within a first terminal cavity (18) by a first primary latching feature (22) and a terminal stabilizer (24) defining a bore (26), the terminal stabilizer (24) disposed within the connector body (16) having a first primary latching retention feature (32) and a second primary latching retention feature (44); providing a second connector body (36) having a female terminal (40) secured within a second terminal cavity (38) by a second primary latching feature; inserting the first connector body (16) into the second connector body (36); moving the terminal stabilizer (24) from a ready position (28) to a stable position (30); and engaging the first primary lock retention feature (32) with the first primary lock feature (22) and the second primary lock retention feature (44) with the second primary lock feature (42) as the terminal stabilizer (24) moves from the ready position (28) to the stable position (30).

14. The method of claim 13, wherein, Also included is receiving a tip of the male terminal (20) in the bore (26) of the terminal stabilizer (24).

15. The method of claim 14, wherein, The terminal stabilizer (24) is closer to the tip in the ready position (28) than in the stable position (30).

16. The method of claim 13, wherein, The first primary lock retention feature (32) and the second primary lock retention feature (44) are disengaged from the first primary lock feature (22) and the second primary lock feature (42) when the terminal stabilizer (24) is in the ready position (28).

17. The method of claim 13, wherein, Also included is receiving the first primary lock retention feature (32) and the second primary lock retention feature (44) within the first terminal cavity (18) and the second terminal cavity as the terminal stabilizer (24) moves from the ready position (28) to the stable position (30).

18. The method of claim 13, wherein, The first primary lock retention feature (32) and the second primary lock retention feature (44) are rib features extending parallel to the terminal axis from a face (34) of the terminal stabilizer (24) defining the bore (26).

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