Connector Assembly with Sealed Symmetrical Split Lever

Abstract

Connector assembly with a sealed symmetric split lever. The present invention provides a connector assembly. The connector assembly includes a connector housing adapted to engage with a corresponding mating connector housing. A lever including a first lever arm and a second lever arm is pivotally and sealingly mounted to the connector housing. Each lever arm includes an interlocking device for connecting the first lever arm to the second lever arm in a first position. The interlocking devices of each of the first lever arm and the second lever arm are configured to define complementary symmetric surfaces that interlock with each other when the lever arms are pivotally mounted to the connector housing. When the lever arms are mounted to the connector housing, the lever is configured to move around the connector housing between an open state and a closed state to secure the mating connector housing to the connector housing.

Description

Technical Field

[0001] The present application generally relates to a connector assembly, and more particularly, to a connector assembly for automotive applications, the connector assembly including a pivotable lever to assist in mating a connector housing with a corresponding mating connector housing. Background Art

[0002] Modern vehicles include many devices distributed throughout the vehicle. For example, electrical connectors such as door body connectors can be used to connect electrical components (such as door locks, door airbags, etc.) arranged in the door to corresponding control electronic devices. Generally, connectors arranged at the connection between the vehicle body and the door have strict environmental requirements. In particular, due to the increasing complexity and importance of the electronic devices that must be connected across the mentioned joints, there is a need to provide reliable waterproof and dustproof connector assemblies, especially for more reliable waterproof and dustproof door body connector assemblies.

[0003] Traditionally, slide connectors have been used for these types of door-to-body connections, such as those described in EP2656449. However, in order to mate the connector housings together, these connectors require a relatively large force, which may increase the complexity of the assembly process and further increase the risk that the connector housings are incorrectly assembled, potentially causing them to malfunction during operation. In addition, the connector assembly of EP 2656449 does not provide any means for checking that the connector housings are correctly connected. Thus, there is a risk that the connectors may become loose and disconnected during operation unless an appropriate force is applied, which is difficult to measure without using specialized instruments.

[0004] To reduce the force required to mate the connector housings together, connectors with mating assistance functions have been developed. This mating assistance function is typically in the form of a lever, where one of the connector housings is moved towards the other connector housing by rotating the lever, and the means for rotating the lever actuates cam-type members within both connectors.

[0005] Since these connectors are used in outdoor environments, it is necessary to provide connectors that are both waterproof and dustproof, and thus sealing means that do not impede the rotational movement of the lever are also required. The method of mounting the lever on the connector and the method of rotating the lever must not adversely affect the performance of the sealing member. It is well known that U-shaped levers are difficult to mount because the lever must have sufficient rigidity to withstand the force required to activate the mating assistance function when the lever rotates, but the lever must also have sufficient flexibility to be firmly assembled to the connector, which typically involves elastic deformation of the components of the lever during operation.

[0006] Accordingly, in order to overcome some of the problems in these prior arts, a lever has been developed which is composed of several components and assembled together to form a lever on a connector.

[0007] The prior art document US5252084 discloses a connector for male-female interlocking terminals, wherein a lever is provided on a first connector in a freely pivotable manner. A guide pin provided on a second connector is inserted into a guide slot hole, and the lever is operated to pull the second connector and the first connector together and connect them. The lever is made of multiple parts of various geometries. Thus, when assembling the lever onto the connector, using multiple components may cause confusion and may result in incorrect orientation. In addition, each of these components must be manufactured separately and then provided in a set with other components, which is burdensome in terms of manufacturing resources. Furthermore, the connector assembly does not have a sealing function, especially there is no seal between the lever and the connector housing. Thus, the connector assembly is vulnerable to moisture and dust entering the connector housing, thereby substantially impairing the reliability of the connector.

[0008] The prior art document US5417513 discloses a lever-type connector, which includes a lever, a first connector and a second connector connected to each other. Two pins formed on the first connector are inserted through through-holes formed in each of two separated parts of the lever. Then, these two parts are connected to each other by, for example, an automatic ultrasonic welding device, so that, contrary to the conventional method, it is not necessary to elastically deform one of the parts of the lever when mounting the parts on the first connector. However, in addition to the actual assembly of the lever, the lever does require additional connecting means (such as welding). Thus, specialized equipment may be required, which will increase the complexity and time spent of the connector assembly. Furthermore, depending on the technique and type of welding used to connect the lever, this type of assembly may result in a weak connection between the lever arms, which may break during use. The connector assembly provided in US5417513 does not have a sealing function between the lever and the connector housing. Thus, the connector assembly is vulnerable to moisture and dust entering the connector housing, thereby greatly impairing the reliability of the connector.

[0009] Although there have been a large number of developments in the field of electrical connectors, including the development of various lever structures to improve performance, it is obvious that in order to develop the next generation of electrical component connectors, problems such as lack of mating assistance robustness, difficulty in use, difficulty in assembling the components of the connector or the lever, manufacturing complexity, and maintaining the integrity of the internal space of the connector through a sealing device should be solved. Summary of the Invention

[0010] The object of the present disclosure is to improve the overall method of electrical component connectors, especially in terms of manufacturing, overall ease of use, and connection integrity.

[0011] According to a first aspect of the present disclosure, there is provided a connector assembly, the connector assembly comprising:

[0012] a connector housing adapted to engage with a corresponding mating connector housing;

[0013] a lever including a first lever arm and a second lever arm, each lever arm including at a first position an interlocking device for connecting the first lever arm to the second lever arm,

[0014] each lever arm including at a second position a first mounting member configured to cooperate with a complementary second mounting member on the connector housing so as to pivotally and sealingly mount each lever arm to a corresponding position on the connector housing;

[0015] wherein the interlocking device of each of the first lever arm and the second lever arm is configured to define complementary symmetric surfaces that interlock with each other when the lever arms are pivotally mounted to the connector housing, and wherein, when the lever arms are mounted to the connector housing, the lever is configured to move about the connector housing between an open state and a closed state so as to fix the mating connector housing to the connector housing.

[0016] According to an embodiment of the present invention, a sealing member is provided to make sealing contact with corresponding sealing surfaces on the lever arms and the connector housing.

[0017] According to an embodiment of the present disclosure, the sealing member is integrally formed on each of the lever arms and / or the connector housing.

[0018] According to an embodiment of the present disclosure, the sealing member is formed using a 2K injection molding process.

[0019] The connector assembly of the present disclosure provides mating assistance for fixing connector housings to each other through a split lever. The split lever can be formed by connecting two lever arms provided with substantially symmetrical interlocking devices, and when the lever arms are mounted on the connector housings, the interlocking devices are arranged to interconnect with each other. For example, two substantially identical symmetrical levers can be used to form the lever. In this way, the connector assembly of the present disclosure requires a reduced number of different components, which will simplify the manufacturing and assembly processes. When the pivotable lever is in a static and dynamic state, the connector assembly as described above is protected from dust and moisture. Providing symmetrical levers is beneficial because they can be mass-produced, thus reducing the manufacturing cost. Since the lever arms are symmetrical, there is no confusion about how to orient the lever or which lever to use in which position, thus reducing the installation burden of the connector. Since the lever includes two components, which are first assembled to the connector and then interconnected with each other, the risk of inadvertently damaging the sealing member during installation is greatly reduced. Since the sealing member is a 2k molded sealing member produced as part of the manufacturing process of the connector housing, there is no parting line that increases the integrity of the sealing member. In addition, since the lever is made of two separate lever arms, the lever arms can be manufactured without a parting line. In this way, when mounted on the connector housing, the sealing function of the lever can be greatly improved.

[0020] According to an embodiment of the present invention, the connector housing includes two holes provided on opposite sides of the connector housing, each hole being configured to receive a locking member of the lever arm.

[0021] According to an embodiment of the present disclosure, the locking member includes a locking element configured to cooperate with a mating surface of a mating connector housing to fix the mating connector housing to the connector housing when the lever moves to a closed position.

[0022] According to an embodiment of the present disclosure, the locking element has the form of a gear including at least one gear tooth configured to engage a recess on the mating connector.

[0023] According to an embodiment of the present invention, the first mounting member and the second mounting member include one of a retaining latch and a notch, the retaining latch and the notch being adapted to cooperate with each other to mount each lever arm at opposite positions on the connector housing. The retaining latch can be provided with a capturing member configured to engage a surface of the notch when the lever is mounted on the connector housing, thereby firmly mounting the lever to the connector housing.

[0024] According to an embodiment of the present disclosure, the notch defines a substantially circular edge configured to engage a corresponding retention latch. The edge may be disposed around a corresponding hole provided in the connector housing. The edge may be continuous or discontinuous and significantly reduces the risk of the lever accidentally disengaging from the connector housing when pivoting between the open and closed states.

[0025] The connector as described above benefits from a mating assistance function because when the lever rotates, the gear enables the mating connector to move into the connector. Due to the separating characteristics of the lever, when the lever is installed on the connector in several parts, the requirement for the flexibility of the lever body is significantly reduced. In this way, since the lever can be made of a more robust material, a greater force can be applied to the lever without the risk of the lever or cam breaking.

[0026] According to an embodiment of the present invention, the mating connector housing includes an engagement surface adapted to cooperate with a corresponding engagement surface on the locking member of the connector housing or the lever arm. For example, the corresponding engagement surface may include one of an opening and at least one boss. For example, one or more bosses may be provided on the mating connector housing, and the bosses may be adapted to cooperate with corresponding mating surfaces on the locking members of the connector housing and / or the lever. The corresponding mating surfaces may be in the form of an opening, a flange, an edge, a notch, etc.

[0027] According to an embodiment of the present invention, the interlocking device (8) of each lever arm includes a locking element and a guiding element.

[0028] According to an embodiment of the present disclosure, the guiding element includes a protruding elongated member and a corresponding slot configured to receive the elongated member of another lever arm.

[0029] According to an embodiment of the present disclosure, the locking element includes a protruding locking member and a corresponding elastic member that defines a locking hole configured to receive and fix the protruding locking member of another lever arm.

[0030] Using the locking element and the guiding element on the interlocking device ensures ease of assembly and further ensures a significantly reduced risk of disengagement once the lever arm is installed on the connector housing.

[0031] According to an embodiment of the present disclosure, the lever includes a first connecting device configured to cooperate with a corresponding second connecting device on the connector housing to releasably fix the lever to the connector housing when the lever is in the closed position, wherein the first connecting device and the second connecting device include interconnection elements configured to engage with each other.

[0032] The connector assembly of the present disclosure also provides connection means on the connector housing and the lever, which connection means are configured to engage when the lever is in the closed position. In this way, they prevent the lever from accidentally pivoting from the closed position to the open position. Preferably, when the first connection means and the second connection means engage, an audible sound can be produced, indicating that the first connection means and the second connection means have engaged. In this way, the present invention ensures that the risk of not fully rotating the lever to the closed position during the assembly process is significantly reduced.

[0033] According to an embodiment of the present disclosure, the connector assembly includes a Connector Position Assurance (CPA) member that is movable from a starting position to an end position, wherein, in the end position, the CPA member prevents the latching means from disengaging.

[0034] Advantageously, the CPA feature of the present disclosure is provided to further enhance the connection of the first connection means and the second connection means provided on the connector housing and the lever. The lever as described above benefits from the CPA member, which ensures that once the lever is in place, the lever cannot accidentally rotate, resulting in the disengagement of the components of the connector assembly. As a result, the closed position is ensured, and thus the engagement of the connector housing with the mating connector housing is ensured.

[0035] According to an embodiment of the present invention, the interlocking means of the first lever arm and the second lever arm are arranged symmetrically about the axis of rotation of the lever.

[0036] According to an embodiment of the present disclosure, the lever arm is made of a glass fiber reinforced thermoplastic material, and the glass fiber reinforced thermoplastic material includes a fiber content between 20.0% and 50.0%.

[0037] Since the lever arms are separately mounted on the connector housing, the flexibility requirements of the lever are greatly reduced. In this way, the lever arms can be made of a glass fiber reinforced thermoplastic material containing a fiber content of 20.0% to 50.0%. For example, the glass fiber content can include a fiber content of at least 30.0%.

[0038] According to a second aspect of the present invention, a method of assembling an electrical connector is provided. The electrical connector includes a connector housing, a corresponding mating connector housing, and a lever, the lever including identical first and second lever arms, each lever arm including an interlocking means at a first position for connecting the first lever arm to the second lever arm, the method comprising the steps of:

[0039] Presenting the first lever arm and the second lever on opposite sides of the connector housing;

[0040] Biasing the interlocking means of each arm towards the interlocking means of the other arm to effect interlocking of the first and second arms, the interlocking effecting a sealed connection of the lever arms to the connector housing;

[0041] Engage the connector housing with a corresponding mating connector housing;

[0042] Pivot the lever relative to the connector housing to effect locking of the connector housing with a corresponding mating connector housing.

[0043] According to an embodiment of the present disclosure, a method of assembling an electrical connector includes a step of activating a mating assist feature that includes rotating the lever to a closed position until an audible sound is produced by engagement of corresponding connection means provided on the lever and the connector housing.

[0044] Providing a split symmetric lever according to an embodiment of the present disclosure allows for a less complex manufacturing process. More specifically, each lever arm of the lever can be manufactured using a single mold. In this way, no parting line is formed on the sealing surface of the lever arm. The absence of a parting line on the sealing surface substantially increases the sealing contact with the sealing member and thus enhances the reliability of the connector. In a preferred embodiment, the lever arms are identical, so only one mold needs to be provided, which significantly reduces the cost and complexity of the manufacturing process. BRIEF DESCRIPTION OF THE DRAWINGS

[0045] The following drawings are provided as examples to further explain and describe various aspects of the present disclosure:

[0046] Figure 1 A perspective view of a sealed electrical connector assembly having a symmetric split lever according to an embodiment of the present disclosure;

[0047] Figure 2 A perspective view of a lever arm according to an embodiment of the present disclosure;

[0048] Figure 3a A perspective view of the interlocking means of the lever arm;

[0049] Figure 3b A perspective view of an alternative embodiment of the interlocking means of the lever arm;

[0050] Figure 4 A perspective view of a symmetric split lever in an interlocked position;

[0051] Figure 5 A perspective view of the connector housing;

[0052] Figure 6a A perspective view of a first lever arm, a second lever arm, and a connector in an unassembled position;

[0053] Figure 6bA perspective view of a first lever arm and a second lever arm is shown. The first lever arm and the second lever arm are interlocked to form a lever and are mounted on a connector housing;

[0054] Figure 7a A perspective view of an interlocking device in an interlocked position is shown;

[0055] Figure 7b A perspective cross-sectional view of gear teeth engaged with a protruding surface of a connector housing 2 in a pre-locked position is shown;

[0056] Figure 7c A perspective cross-sectional view of a retaining feature in the form of an elongate arm and a corresponding rim is shown;

[0057] Figure 7d A perspective cross-sectional view of a lever-to-connector housing mounting device is shown;

[0058] Figure 8a A perspective view of a sealed electrical connector assembly in an un-mated configuration is shown, wherein a counter-connector housing is not inserted into the connector housing;

[0059] Figure 8b A perspective view of a sealed electrical connector assembly in a mated configuration is shown, wherein a mating connector has been inserted into the connector housing;

[0060] Figure 9a A perspective cross-sectional view of a boss of a mating connector and a corresponding mating surface is shown;

[0061] Figure 9b A perspective cross-sectional view of a boss engaged in an internal mating surface of a gear member is shown;

[0062] Figure 10a A perspective view of a sealed electrical connector assembly having a symmetric split lever is shown, wherein a CPA member is in a pre-locked position;

[0063] Figure 10b A perspective view of a sealed electrical connector assembly having a symmetric split lever is shown, wherein a CPA member is in a locked position;

[0064] Figure 11a A perspective cross-sectional view of a CPA member and corresponding elements in a connector housing in a pre-locked position is shown;

[0065] Figure 11b A perspective cross-sectional view of a CPA member and corresponding elements in a connector housing in a locked position is shown;

[0066] Figure 12a A perspective cross-sectional view of a first connecting member of a lever that engages with a second connecting member of a connector housing is shown;

[0067] Figure 12b A three - dimensional cross - sectional view of a first connecting device of a lever is shown, the lever being engaged with a connector housing at an intermediate position;

[0068] Figure 12c A three - dimensional cross - sectional view of a first connecting device of a lever engaged with a second connecting device of a connector housing, the second connecting device of the connector housing being further engaged with a CPA member, is shown.

[0069] Figure 12d Shows Figure 12c another three - dimensional cross - sectional view of three engaging elements of;

[0070] Figure 12e Shows Figure 12c and Figure 12d another three - dimensional cross - sectional view of three engaging elements of; and

[0071] Figure 13 A magnified three - dimensional cross - sectional view of a gear is shown when the rod is in a final locked position such that gear teeth are engaged with recesses on a mating surface of a connector housing. DETAILED DESCRIPTION

[0072] The following discussion provides many exemplary embodiments of the subject matter of the present invention. Although each embodiment represents a single combination of invention elements, the subject matter of the present invention is considered to include all possible combinations of the disclosed elements. Thus, if one embodiment includes elements A, B, and C, and a second embodiment includes elements B and D, the subject matter of the present invention is considered to include the other remaining combinations of A, B, C, or D even if not explicitly disclosed.

[0073] For simplicity and clarity of illustration, reference numerals may be repeated in the drawings to indicate corresponding or similar elements. Many details are set forth to provide an understanding of the examples described herein. These examples may be practiced without these details. In other instances, well - known methods, procedures, and components have not been described in detail to avoid obscuring the described examples. The description should not be considered limited to the scope of the embodiments described herein.

[0074] Now referring to Figures 1 to 13 in the accompanying drawings, an example of an electrical connector assembly having a symmetric split lever 5, generally designated 100, is shown. The electrical connector assembly 100 is designed to easily and effectively connect and secure two electrical components in an environment that may be subject to dust and moisture. The electrical connector may be used as a door body connector in automotive applications.

[0075] As Figure 1As shown, the connector assembly 100 includes a connector housing 2 and a mating connector housing 4, which can be joined together by a male-female connection. More specifically, the connector housing 2 can include a female connector housing, while the mating connector housing 4 can include a male connector housing.

[0076] The connector assembly 100 is provided with a two-part lever 5. The lever 5 includes a first lever arm 6 and a second lever arm 7, wherein the lever arms 6, 7 can have symmetric features. For example, the lever arms 6, 7 can be provided with an interlocking device 8 including symmetric complementary surfaces. The lever arms 6, 7 can be made from the same mold or on the same production line. Preferably, the lever arms 6, 7 can be substantially the same and can thus be interchangeable with each other. It should be understood that the term substantially the same means that the lever arms 6, 7 are the same in terms of relevant technical features, but may include negligible irrelevant dissimilarities that do not affect the function of the lever arms 6, 7, such as manufacturing defects, etc. As Figure 1 shown, the lever arms are pivotally mounted on opposite sides of the connector housing 2.

[0077] As Figure 2 shown, each lever arm 6, 7 includes an interlocking device 8 that can be located at the end of the lever arm 6, 7 and a mounting member 10 that can be located at opposite ends of the lever arm 6, 7. The interlocking devices 8 of the lever arms 6 and 7 include symmetric features forming complementary interlocking surfaces, which are configured to interlock with each other when the lever arms 6 and 7 are connected. For example, when the lever arms 6, 7 are arranged around the central rotation axis of the lever 5 (in other words, when the two interlocking surfaces are in contact with each other), the interlocking device 8 of the first lever arm 6 interlocks with the interlocking device 8 of the second lever arm 7. Each interlocking device 8 can include a guiding element 30 and a locking element 28.

[0078] The guiding element 30 includes a protruding elongated member 32 and a corresponding groove 34. Since the protruding elongated member 32 includes a main longitudinal axis parallel to the direction in which the interlocking devices 8 are pushed together, the protruding elongated member 32 ensures the correct alignment of the two interlocking devices 8. In use, the protruding elongated member 32 of the first lever arm 6 moves into the corresponding groove 34 of the second lever arm 7, and in parallel, the protruding elongated member 32 of the second lever arm 7 moves into the corresponding groove 34 of the first lever arm 6. It can be understood that the protruding elongated member 32 and the corresponding groove 34 can be configured in various geometric shapes, such as Figure 3a and Figure 3b show two alternative forms of the guiding element 30. Figure 3a The guiding element 30 in includes a protruding elongated member 32 with a square cross-section and a groove 34 in the form of a substantially square hole in the contact surface of the guiding element 30. Figure 3bThe guiding element 30 includes a protruding elongated member 32 in the form of a cross-shaped extrusion and a groove 34 in the form of a substantially circular hole in the contact surface of the guiding element 30.

[0079] The locking element 28 of the interlocking device 8 may also be provided with a protruding locking member 36 and an elastic member 38 that defines a locking hole. Depending on the position of the guiding device 30 on the interlocking device 8, the guiding device 30 may be activated before the locking element 28. The elastic member 38 may be configured to provide the locking hole. In use, the elastic member 38 may be adapted to elastically deform to allow the elastic member 38 to slide over the protruding locking member 36 such that the protruding locking member 36 engages with the hole defined in the elastic member 38. Figure 7a An example of the interlocking configuration of the first lever arm 6 and the second lever arm 7 is shown.

[0080] As Figure 2 shown, each lever arm 6 and 7 may be provided with a first mounting member 9 that is configured to cooperate with a complementary second mounting member 10 provided on the connector housing 2. For example, the first mounting member 9 may be a retaining member in the form of a retaining latch, for example, that is configured to cooperate with the complementary second mounting member 10 at a corresponding mounting position provided on the connector housing 2. The second mounting member 10 may be in the form of a notch 26 that defines an edge 31 at the mounting position of the connector housing 2. The notch 26 may be in the form of a gap that defines a passage. The notch 26 is configured to cooperate with the retaining latches of the corresponding lever arms 6 and 7. The second mounting member 10 may be provided in any other desired form, such as an opening that is adapted to engage with the corresponding retaining latch. It should also be noted that in the context of the present application, the first mounting member 9 and the second mounting member 10 are interchangeable. Thus, the second mounting member 10 may be provided on the lever arms 6 and 7, while the first mounting member 9 may be provided at the corresponding mounting positions on the connector housing. Each lever arm 6 and 7 may be provided with corresponding locking members 16a and 16b that include a gear mechanism 18 provided with at least one gear tooth 22. The locking members 16a and 16b may have a desired shape, such as cylindrical. As Figure 2 shown, the gear mechanism 18 may be symmetric about the axis of rotation of the lever 5. As Figure 2 shown, a sealing surface 11 may be provided around the locking members 16a and 16b. The sealing surface 11 may be surrounded by a raised edge 13 that defines a space.

[0081] According to one embodiment, the lever arms 6, 7 may be the same and may thus be interchangeable with each other, which eliminates the possibility of confusion regarding how the lever arms 6, 7 are connected and how they should be oriented on the connector housing 2.

[0082] Figure 4A view is shown in which the first lever arm 6 and the second lever arm 7 are interlocked such that they form a U-shaped lever 5. It should be understood that, for illustrative purposes, this figure shows the lever arms 6 and 7 in an interlocked state without the connector housing 2. However, in use, the first lever arm 6 can be directly assembled to the connector housing 2 before being interlocked with the second lever arm 7.

[0083] As Figure 5 shown, the connector housing 2 can be provided with two holes 14a and 14b on opposite sides. Each of the holes 14a and 14b is configured to receive cylindrical locking members 16a and 16b. Around each of the holes 14a and 14b, a sealing surface 21 can be provided with a raised edge 27 for receiving a sealing member 12. As Figure 7c and Figure 7d shown, the sealing member 12 can be in sealing contact with the respective sealing surfaces 11 and 21 on each of the lever arms 6 and 7 and the connector housing 2. According to Figure 7c and Figure 7d the illustrated embodiment, when the levers 6 and 7 are mounted on the connector housing 2, the raised edge 13 of the sealing surface 11 is configured to be received at a respective opening 29 in the connector housing 2, and the raised edge 27 is configured to be received together with the sealing member 12 at a space defined by the raised edge 13. In this way, when the lever 5 is mounted on the connector housing 2, water and dust are prevented from entering the connector housing 2. The sealing member 12 can be integrally formed, for example, using a 2K injection molding process on one of the sealing surfaces 11 and 21. Additionally, the sealing member 12 can be provided in the form of a separate O-ring sealing member. In use, the sealing member 12 is positioned between each of the lever arms 6 and 7 and the connector housing 2 such that it prevents moisture and dust from entering the interior of the connector housing 2. As Figure 5 and Figure 7c shown, the sealing member 12 can be provided at a position around the holes 14a and 14b. As Figure 5 and Figure 7d shown, the second mounting member 10 configured to cooperate with the first mounting member 9 of the lever arms 6 and 7 can be in the form of a notch 26 using a defining edge 31 that substantially surrounds each of the holes 14a and 14b. As Figure 7c and Figure 7d shown, the notch 26 is configured to engage with the respective engaging surfaces of the retaining latches of the lever arms 6 and 7. Once the retaining latches are engaged, due to the profile of the retaining latches, the notch 26 is configured to hold the retaining latches within the channel when the lever 5 rotates between the open and closed states.

[0084] As Figure 7bAs shown, when the lever 5 is in the open position (also referred to as the pre-locked position), the gear teeth 22 are configured to engage with the projecting member 41 (e.g., a node on the surface 50 of the connector housing 2). It should be understood that the term "engage" means that the lever arms 6, 7 can be mounted on the connector housing 2 in such a way that the gear mechanism 18 is set in an orientation relative to the projecting member 41 as Figure 7b shown. To rotate the gear mechanism 18 so that the lever moves from the pre-locked position to the final locked position, an appropriate force is applied to the gear mechanism 18 via the lever 5 such that the gear teeth 22 move on the projecting member 41 towards the closed position. The surface 50 may be provided with a concave surface, thereby allowing the gear mechanism 18 to rotate to the closed position, whereby the gear teeth 22 are configured to engage with the corresponding mating surface of the mating connector housing 4, and the node engages with the corresponding surface 23 of the gear member 18, as Figure 13 shown.

[0085] Figure 9a And Figure 9b show the mating sequence of the connector housing 2 and the mating connector housing 4. As shown, the mating connector housing 4 is configured to mate with the connector housing 2 via the respective mating surfaces 24 and 25. For example, as Figure 9a and Figure 9b shown, the mating connector housing 4 may be provided with one or more bosses or projections configured to engage with the corresponding mating surfaces 25 (e.g., openings, channels, etc.) provided on the locking members 16a and 16b of the connector housing 2 and / or the lever arms 6 and 7.

[0086] Figure 10a And Figure 10b show the connector assembly with the lever 5 in the closed position (also referred to as the final locked position). As shown, a connector position assurance (CPA) member 48 may be provided and fixed in the position between the lever 5 and the connector housing 2. The CPA member 48 is configured to be actuated after the lever 5 has rotated from the open position to the closed position. Insertion of the CPA member 48 ensures that the lever 5 is prevented from accidentally rotating away from the closed position during use. If it is necessary to reverse the mating of the connector housing 2 and the mating connector housing 4, the CPA must be purposefully removed from the connector assembly 100 in order to enable the lever 5 to rotate.

[0087] As Figures 11a to 12eAs shown, the CPA member 48 includes geometric features 62 configured to engage corresponding features (engagement member 47) in the lever 5. In use, the CPA member 48 is inserted into the space formed between the second connection means 42 of the connector housing 2 and the body of the connector housing 2. For example, an opening for inserting the CPA member 48 may be provided behind the second connection means 42. As shown, the CPA member includes an engagement member 61 configured to engage a corresponding engagement member 47 of the first connection means 40 of the lever 5. The CPA member 48 is movable between a start position and a stop position.

[0088] As Figure 12a and Figure 12b shown, in the case where the CPA member is in the starting position, when the lever is in the closed state, the first connection means 40 and the second connection means 42 are configured to engage. For example, the first connection means 40 and the second connection means 42 may be provided with corresponding engagement elements 44, for example in the form of a latch and a corresponding mating surface. Once the first connection means engages with the second connection means, the CPA member 48 is moved from the start position to the end position, as Figures 12c to 12e shown. In the end position, the CPA member 48 exerts a holding force on the second connection mechanism 42 and, for example, prevents accidental movement of the lever.

[0089] Figure 13 A cross-sectional perspective view of the connector assembly with the lever 5 in the closed position is shown. As shown, the gear teeth 22 of the gear mechanism engage recesses on the mating surface 54 of the mating connector housing 4. In this way, the mating connector housing 4 is firmly connected to the connector housing 2.

[0090] Reference is made below to Figure 6a , Figure 6b , Figure 8a and Figure 8b to describe an exemplary method for the connector assembly to illustrate the activation sequence of the features of the connector assembly.

[0091] As Figure 6a shown, the lever arms 6 and 7 are located at opposite mounting positions on the connector housing 2. Each of the lever arms 6 and 7 is mounted to the connector housing 2 by corresponding first mounting members 9 and second mounting members 10 as described above, and the corresponding interlocking devices 8 are connected to each other to form the lever 5. In the case where the lever 5 is mounted on the connector housing 2, the retaining latch engages a notch 26 in the connector housing 2, as Figure 6bAs shown. When the notch 26 in the connector housing 2 forms an arcuate path as described above, the retaining latch is free to rotate without accidental detachment, such as moving along the arcuate notch. The sealing member 12 is located on the connector housing 2. In use, when the lever 5 is mounted on the connector housing 2, the sealing member 12 makes sealing contact with both the lever 5 and the connector housing 2. Since the sealing member 12 is annular and located within the sealing area in the mounting member, it does not prohibit the rotational movement of the lever 5 relative to the connector housing 2. As Figure 8a shown, a mating connector housing 4 is provided to the connector housing 2. The connector housing 2 and the mating connector housing 4 can be engaged such that a part of the mating connector housing 4 is located within a part of the connector housing 2, as Figure 8b shown. A boss 24 or another engaging element can be provided on the mating connector housing 4, which mates with the corresponding mating surface 25 of the gear, as Figure 9a and Figure 9b shown. The geometry of the mating surface 25 is such that it allows the boss 24 to rotate within the space defined by the mating surface 25 without disengaging from the mating surface 25. When the lever 5 rotates from its open position where it is assembled on the connector housing 2 to the closed position, the connector housing 2 and the mating connector housing 4 are coupled to each other via the rotatable gear members 18 provided at each of the lever arms 6 and 7. Thus, the lever 5 serves as a mating aid, as known in the art, and is configured to connect the two connector housings 2 and 4. When the lever 5 reaches the closed position, at least one tooth 22 of the gear 18 engages with the mating surface 54, thereby preventing further movement of the gear 18 clockwise or counterclockwise. In addition, when the lever 5 reaches the closed position, the first connecting device 40 on the lever engages with the second connecting device 42 on the connector housing, further strengthening the engagement between the lever 5 and the connector housing 2. The CPA member 48 is additionally inserted at this time, which wedges between the second connecting device 42 and the connector housing 2 such that the first connecting device 40 and the second connecting device 42 cannot disengage from each other.

Claims

1. A connector assembly (100), the connector assembly comprising: A connector housing (2), the connector housing being adapted to engage with a corresponding mating connector housing (4); A lever (5), the lever including a first lever arm (6) and a second lever arm (7), each of the first lever arm (6) and the second lever arm (7) including an interlocking device (8) that connects the first lever arm (6) to the second lever arm (7) at a first position; Each of the first lever arm (6) and the second lever arm (7) includes a first mounting member (9) at a second position, the first mounting member being configured to cooperate with a complementary second mounting member (10) on the connector housing (2) to pivotally and sealingly mount each of the first lever arm (6) and the second lever arm (7) to a corresponding position on the connector housing (2); Wherein, the interlocking device (8) of each of the first lever arm (6) and the second lever arm (7) is configured to define complementary symmetric surfaces, the complementary symmetric surfaces being interlocked with each other when the first lever arm (6) and the second lever arm (7) are pivotally mounted to the connector housing (2), and wherein, when the first lever arm (6) and the second lever arm (7) are mounted to the connector housing (2), the lever (5) is configured to move around the connector housing (2) between an open state and a closed state to fix the mating connector housing (4) to the connector housing (2).

2. The connector assembly (100) according to claim 1, wherein A sealing member (12) is provided to make sealing contact with corresponding sealing surfaces on the first lever arm (6) and the second lever arm (7) and on the connector housing (2).

3. The connector component (100) according to claim 2, wherein, The sealing member (12) is integrally formed on each of the first lever arm (6) and the second lever arm (7) and / or on the connector housing (2).

4. The connector assembly (100) according to claim 3, wherein, The sealing member (12) is formed using a 2K injection molding process.

5. The connector assembly (100) according to claim 1, wherein, The connector housing (2) includes two holes provided on opposite sides of the connector housing (2), each hole being configured to receive a locking member of the first lever arm (6) and the second lever arm (7).

6. The connector assembly (100) according to claim 5, wherein, The locking member includes a locking element, the locking element being configured to cooperate with a mating surface of the mating connector housing (4) when the lever (5) moves to a closed position to fix the mating connector housing (4) to the connector housing (2).

7. The connector assembly (100) according to claim 6, wherein, The locking element is in the form of a gear including at least one gear tooth (22), the at least one gear tooth (22) being configured to engage with a recess on the mating connector housing (4).

8. The connector assembly (100) according to claim 1, wherein, The first mounting member (9) and the second mounting member (10) include one of a retaining member and a notch (26), the retaining member and the notch (26) being adapted to cooperate with each other to mount each of the first lever arm (6) and the second lever arm (7) to a relative position on the connector housing (2).

9. The connector assembly (100) according to claim 8, wherein, The notch (26) defines a generally circular edge (31) that is configured to engage a corresponding retaining latch.

10. The connector assembly (100) according to claim 1, wherein, The mating connector housing (4) includes one or more engagement surfaces that are adapted to cooperate with one or more corresponding engagement surfaces (25) on the connector housing (2) or on the first and second lever arms (6, 7).

11. The connector assembly (100) according to claim 10, wherein, The one or more engagement surfaces include at least one boss (24).

12. The connector assembly (100) according to claim 1, wherein, The interlocking means (8) of the first and second lever arms (6, 7) includes a locking element and a guiding element (30).

13. The connector assembly (100) according to claim 12, wherein, The guiding element (30) includes a projecting elongate member (32) and a corresponding slot (34) configured to receive the elongate member (32) of the other lever arm.

14. The connector assembly (100) according to claim 12 or 13, wherein, The locking element includes a projecting locking member (36) and a corresponding resilient member (38) that defines a locking aperture configured to receive and secure the projecting locking member (36) of the other lever arm.

15. The connector assembly (100) according to claim 6, wherein, The lever (5) includes a first connecting means (40) configured to cooperate with a corresponding second connecting means (42) on the connector housing (2) to releasably secure the lever (5) to the connector housing (2) when the lever is in the closed position, wherein the first and second connecting means (40, 42) include interconnecting elements (44) configured to engage one another.

16. The connector assembly (100) according to claim 15, wherein, The connector assembly includes a connector position assurance CPA member (48) movable from a start position to an end position, wherein in the end position the CPA member (48) is adapted to prevent disengagement of the interconnecting elements (44).

17. The connector assembly (100) according to claim 1, wherein, The first and second lever arms (6, 7) are substantially symmetric.

18. The connector assembly (100) according to claim 1, wherein, The first and second lever arms (6, 7) are made of a glass fiber reinforced thermoplastic material having a fiber content between 20.0% and 50.0%.

19. A method of assembling an electrical connector including a connector housing (2), a corresponding mating connector housing (4), and a lever (5) including first and second lever arms (6, 7), each of the first and second lever arms (6, 7) including an interlocking means (8) at a first position configured to define complementary symmetric surfaces that interlock with one another when the first and second lever arms (6, 7) are pivotally mounted to the connector housing (2) to connect the first lever arm (6) to the second lever arm (7), the method including the steps of: Positioning the first and second lever arms (6, 7) on opposite sides of the connector housing (2); Bias the interlocking device (8) of each of the first lever arm (6) and the second lever arm (7) towards the interlocking device of the other of the first lever arm (6) and the second lever arm (7) to effect interlocking of the first lever arm and the second lever arm, the interlocking effecting a sealed connection of the first lever arm (6) and the second lever arm (7) to the connector housing; Engage the connector housing with the corresponding mating connector housing (4); Pivot the lever (5) relative to the connector housing (2) to effect locking of the connector housing (2) with the corresponding mating connector housing (4).

20. The method of assembling an electrical connector according to claim 19, wherein, The step of activating the mating assistance function includes pivoting the lever (5) to the closed position until an audible sound is produced by the engagement of corresponding connecting means provided on the lever (5) and on the connector housing (2).

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