Mounting assembly for electrical connector

Abstract

An electrical connector (100) includes a housing (120) having a shield (140) surrounding a cavity (144) at a mating end (122) and a base (130) having a flange (132) at a mounting end (124) configured to be mounted to a mounting surface of a panel (32). The electrical connector includes a contact assembly (180) received in the housing, the contact assembly having contacts configured to mate with a mating electrical connector. The electrical connector includes a seal (114) coupled to the flange and surrounding the base. The seal is configured to engage the mounting surface of the panel. The electrical connector includes a locking lever (200) coupled to the housing. The locking lever is configured to engage with the panel to secure the housing to the panel.

Description

Technical Field

[0001] The subject matter herein relates generally to electrical connectors. Background Art

[0002] Connector systems use electrical connectors to interconnect various components. Some connector systems transfer power and / or data from one component to another. For example, a power connector can be used to connect a power source (such as a battery) to a load (such as a motor). For example, in an electric vehicle, a battery can be connected to an inverter or a motor through a plug connector and a header connector. The header connector is installed to one of the components (such as a motor), and the plug connector is arranged at the end of the cable harness wired between the battery and the plug connector. The connection of the header connector to the component involves bolting the mounting flange of the header connector to a panel or other structure of the component. For example, four bolts can be used in the four corners of the mounting flange. Bolting requires assembly time and hardware (such as nuts and bolts) to establish a connection between the header connector and the structure.

[0003] There remains a need for a connector system having a boltless and reliable connection between an electrical connector and a structure. Summary of the invention

[0004] In one embodiment, an electrical connector is provided, which includes a housing extending between a mating end and a mounting end. The mating end is configured to mate with a mating electrical connector. The mating end includes a shield surrounding a cavity. The mounting end is configured to be mounted to a panel. The mounting end includes a base and a flange extending from the base. The base of the housing is received in an opening in the panel. The flange of the housing is mounted to a mounting surface of the panel. The electrical connector includes a contact assembly, which is received in the housing. The contact assembly includes a contact retainer, which retains at least one contact, and the at least one contact is configured to mate with the mating electrical connector. The electrical connector includes a seal coupled to the flange and surrounding the base. The seal is configured to engage with the mounting surface of the panel. The electrical connector includes a locking rod coupled to the housing. The locking rod is configured to engage with the panel to fix the housing to the panel. BRIEF DESCRIPTION OF THE DRAWINGS

[0005] The present invention will now be described by way of example with reference to the accompanying drawings, in which:

[0006] Figure 1 is a perspective view of an electrical connector system utilizing mounting features according to an exemplary embodiment.

[0007] Figure 2 is a top perspective view of a portion of an electrical connector system showing a portion of a header connector according to an exemplary embodiment.

[0008] Figure 3 is a bottom perspective view of a portion of an electrical connector system showing a header connector mounted to a panel according to an exemplary embodiment.

[0009] Figure 4 is a cross-sectional view of a portion of a joint connector according to an exemplary embodiment.

[0010] Figure 5 is an enlarged cross-sectional view of a portion of a joint connector according to an exemplary embodiment.

[0011] Figure 6 is a bottom perspective view of a portion of a joint connector according to an exemplary embodiment.

[0012] Figure 7 is a bottom perspective view of a portion of a header connector showing a locking lever in an open position according to an exemplary embodiment.

[0013] Figure 8 is a bottom perspective view of a portion of a joint connector showing a locking lever in a closed position according to an exemplary embodiment.

[0014] Fig. 9 is a cross-sectional view of a portion of a joint connector showing a locking lever in a closed position and an extended position according to an exemplary embodiment.

[0015] Fig.10 is a bottom perspective view of a portion of a joint connector showing a locking lever in a retracted position according to an exemplary embodiment.

[0016] Fig.11 is a bottom perspective view of a portion of a header connector showing a locking lever in a locked position according to an exemplary embodiment.

[0017] Fig.12 is a cross-sectional view of a portion of a joint connector showing a locking lever in a locked position according to an exemplary embodiment.

[0018] Fig.13 is a cross-sectional view of a portion of a joint connector showing a locking lever in a locked position according to an exemplary embodiment.

[0019] Fig.14 is a cross-sectional view of a portion of a joint connector showing a locking lever in a locked position according to an exemplary embodiment.

[0020] Fig.15 is a cross-sectional view of a portion of a joint connector according to an exemplary embodiment.

[0021] Fig.16 is a cross-sectional view of a portion of a joint connector according to an exemplary embodiment.

[0022] Fig.17 is a cross-sectional view of a portion of a joint connector according to an exemplary embodiment. DETAILED DESCRIPTION

[0023] Figure 1 is a perspective view of an electrical connector system 100 utilizing a mounting feature according to an exemplary embodiment. In the exemplary embodiment, the mounting feature includes a locking lever 200. The electrical connector system 100 is an exemplary system utilizing the locking lever 200, and the subject matter herein is not intended to be limited to use with the electrical connector system 100 shown.

[0024] The electrical connector system 100 includes electrical connectors 102, 104 configured to mate at a separable mating interface. In an exemplary embodiment, the electrical connectors 102, 104 are a header connector 102 and a plug connector 104, respectively. The plug connector 104 is a mating electrical connector configured to mate with the header connector 102. The plug connector 104 is shown ready to mate with the header connector 102.

[0025] The joint connector 102 is mounted to a structure 30 of a component. In an exemplary embodiment, the structure 30 is a panel 32 having an upper surface 34 and a lower surface 36. The panel 32 has a mounting area 38, and the joint connector 102 is configured to be mounted to the panel 32 at the mounting area 38. In an exemplary embodiment, the panel 32 includes an opening 40 at the mounting area 38. The joint connector 102 is received in the opening 40 and mounted to the panel 32 at the mounting area 38. In an exemplary embodiment, the panel 32 is conductive. For example, the panel 32 can be made of a metallic material such as steel. The panel 32 can be a sheet of metal. In an exemplary embodiment, the panel 32 is a coated structure, wherein one or more layers of the panel are coated layers. In an exemplary embodiment, the mounting features of the joint connector 102 allow for mounting to the panel 32 by boltless and / or toolless connection. For example, the joint connector 102 can be fixed using a locking rod that fixes the joint connector 102 to the panel 32 without using bolts or other fasteners.

[0026] In an exemplary embodiment, the electrical connector system 100 is a high power connector system for transmitting power between various components that are part of a high power circuit. In a particular application, the electrical connector system 100 is a battery system, such as a battery system of a vehicle (such as an electric vehicle or a hybrid electric vehicle); however, the electrical connector system 100 is not intended to be limited to such a battery system.

[0027] The plug connector 104 is configured to be electrically connected to a component 110, such as through one or more power cables 106. For example, the plug connector 104 can be electrically connected to a battery, a charger, an inverter, a motor, or another type of component. The joint connector 102 is configured to be electrically connected to the component 112, such as through a power bus 108; however, the joint connector 102 can be electrically connected to the component 112 through other means (such as terminals, power lines, or other connectors). For example, the joint connector 102 can be electrically connected to a battery pack, such as through a battery distribution unit, a manual service disconnect, a charger, an inverter, a motor, or another type of component. The battery distribution unit can manage the power capacity and function of the electrical connector system 100, such as by measuring current and adjusting power distribution to the battery pack.

[0028] In the illustrated embodiment, the electrical connector system 100 is a right-angle connector system in which the connectors 102, 104 are mated in a direction perpendicular to the power line 106. However, in an alternative embodiment, the power line 106 can extend from the plug connector 104 in a direction parallel to the mating direction. In various embodiments, the engagement direction is a vertical mating direction. For example, the plug connector 104 is mated to the joint connector 102 in a vertical downward direction. Optionally, the plug connector 104 can be removably coupled to the joint connector 102 to disconnect the high-power circuit of one or more components (e.g., a battery pack, a motor, an inverter, or other components of a vehicle), for example, for maintenance, repair, or other reasons. When mating, one or more joint contacts of the joint connector 102 are mated with corresponding plug terminals of the plug connector 104, for example, at its mating interface.

[0029] The header connector 102 includes a header housing 120 and a contact assembly 180. The header housing 120 holds the contact assembly 180. The contact assembly 180 is configured to mate with the plug connector 104 to establish an electrical connection with the plug connector 104. The contact assembly 180 is configured to be electrically connected to the component 112, such as through a bus bar, cable, wire, or other type of electrical connector.

[0030] The connector housing 120 has a mating end 122 at a top 123 of the connector housing 120 and a mounting end 124 at a bottom 125 of the connector housing 120. The connector housing 120 includes a base 130 at the mounting end 124 and a shield 140 extending from the base 130. The shield 140 is disposed at the mating end 122 and surrounds the contact assembly 180. The shield 140 includes a shield wall 142 surrounding a cavity 144. The cavity 144 receives the contact assembly 180. The shield wall 142 extends along a first side 126 and a second side 127 of the connector housing 120, and extends along a front 128 and a rear 129 of the connector housing 120. In this way, the contact assembly 180 is surrounded on all four sides. Optionally, the shield wall 142 at the rear 129 can be shorter than the shield wall 142 at the front 128. The shroud wall 142 may include guiding features, such as tabs, ribs, or channels extending along the shroud wall 142 to guide mating with the plug connector 104. The shroud 140 is configured to be inserted into the plug connector 104.

[0031] In an exemplary embodiment, the shroud 140 includes mounting pins 146 extending from the shroud wall 142. The plug connector 104 is configured to be mounted to the mounting pins 146. For example, a lever 108 rotatably coupled to a housing of the plug connector 104 is configured to be coupled to the mounting pins 146.

[0032] In an exemplary embodiment, the connector shield 148 is coupled to the connector housing 120. The connector shield 148 can be coupled to the shield 140 and / or the base 130. The connector shield 148 is configured to be electrically connected to the plug connector 104 when the plug connector 104 is coupled to the connector 102. In an exemplary embodiment, the connector shield 148 is configured to be electrically connected to the panel 32 so that the plug connector 104 is electrically common to the panel 32. The connector shield 148 can provide shielding around the contact assembly 180. In an exemplary embodiment, the connector shield 148 extends along the inner surface of the shield wall 142, and optionally, the connector shield 148 can extend from the shield 140 into the base 130. For example, the connector shield 148 can be wrapped around the base 130 to the outside of the base 130 to be electrically connected to the panel 32.

[0033] In an exemplary embodiment, the contact assembly 180 includes a contact holder 182 that holds one or more connector contacts 190. For example, the connector contacts 190 can be received in a contact channel that passes through the contact holder 182. The contact holder 182 is made of a dielectric material to isolate the connector contacts 190 from each other and from the connector shield 148. In the illustrated embodiment, the contact holder 182 is separate and discrete from the connector housing 120. However, in alternative embodiments, the contact holder 182 can be integral with the connector housing 120, such as being co-molded with the connector housing 120. For example, the connector housing 120 can have a contact channel molded on the base 130 that receives the connector contacts 190.

[0034] The base 130 holds the contact assembly 180. For example, the contact assembly 180 can be inserted into the base 130. The base 130 can include an opening or channel that receives a portion of the contact assembly 180. The base 130 is configured to be mounted to the panel 32. Optionally, the base 130 can extend through the opening 134 so that the base 130 is located above the upper surface 34 and below the lower surface 36 of the panel 32. In an exemplary embodiment, the base 130 includes a flange 132 extending outwardly from the base 130. The base 130 is configured to be inserted through the opening 40 in the panel 32. The flange 132 is configured to be mounted to the panel 32 at the mounting area 38. For example, the flange 132 faces the upper surface 34 of the panel 32. In an exemplary embodiment, the flange 132 abuts against the mounting surface at the upper surface 34 of the mounting area 38 area. In the exemplary embodiment, a seal interface is defined between the joint connector 102 and the panel 32 , such as at a bottom surface of the flange 132 and an upper surface 34 of the panel 32 .

[0035] In an exemplary embodiment, the mounting features of the joint connector 102 are used to mount the flange 132 to the mounting area 38 at the upper surface 34. For example, the locking lever 200 of the joint connector 102 is used to secure the joint housing 120 to the panel 32. For example, the locking lever 200 can secure the flange 132 to the upper surface 34 of the panel 32. In an exemplary embodiment, the locking lever 200 engages with the lower surface 36 of the panel 32 to press the flange 132 into the upper surface 34 of the panel 32, thereby rigidly securing the joint connector 102 to the panel 32. In an exemplary embodiment, the locking lever 200 is pivotally coupled to the joint housing 120. For example, the locking lever 200 can be rotated from an open position to a closed position to secure the joint connector 102 to the panel 32. In an exemplary embodiment, the rotation of the locking lever 200 from the open position to the closed position secures the joint housing 120 to the panel 32. For example, the flange 132 is pressed downward toward the panel 32 to engage with the panel 32 to form a tight connection between the joint housing 120 and the panel 32. The actuation of the locking lever 200 presses the flange 132 downward to compress the seal between the flange 132 and the upper surface 34 of the panel 32. In an exemplary embodiment, after the locking lever 200 rotates to the closed position, the locking lever 200 can slide from the unlocked position to the locked position. For example, in the unlocked position, the locking lever 200 can rotate freely between the open position and the closed position. In the locked position, the locking lever 200 can be restricted from rotating, thereby keeping the locking lever 200 in the locked position. The locking lever 200 fixes the joint connector 102 to the panel 32 without using fasteners or bolts. The installation action can be performed manually or by an assembly robot. A bulbous connection is provided by the locking lever 200.

[0036] In alternative embodiments, other movements or motions may be used to securely couple the joint connector 102 to the panel 32 without the use of fasteners or bolts. For example, the locking bar 200 may be slidably connected to the joint housing 120 rather than being rotatably coupled to the joint housing 120 and include a ramp or other locking feature to press the joint housing 120 downward into engagement with the panel 32 when the locking bar 200 is actuated (e.g., a wedge drives the joint housing 120 downward during the sliding action).

[0037] Figure 21 is a top perspective view of a portion of an electrical connector system 100 according to an exemplary embodiment, which shows a portion of a joint connector 102. During assembly, the joint housing 120 is loaded from above into the opening 40 in the panel 32. The flange 132 is located above the upper surface 34 of the panel 32. In an exemplary embodiment, a seal (not shown) is located between the flanges 132 at the upper surface 34 of the panel 32. During initial assembly, the seal is not compressed. However, after the locking bar 200 is installed and assembled to the joint housing 120, the seal is compressed between the flange 132 and the panel 32. For example, the flange 132 is pulled downward to engage with the upper surface 34 of the panel 32.

[0038] Figure 3 1 is a bottom perspective view of a portion of the electrical connector system 100 according to an exemplary embodiment, which shows the header connector 102 mounted to the panel 32. The locking lever 200 secures the header connector 102 to the panel 32. The panel 32 is captured between the locking lever 200 and the flange 132. In the exemplary embodiment, the locking lever 200 includes a locking member for locking the locking lever 200 in the locked position ( Figure 3 ) of the joint connector 102. The locking element 202 engages the joint housing 120 to hold the locking bar 200 in the locked position. In an exemplary embodiment, the locking element 202 is releasable to allow the locking bar 200 to be unlocked, such as for removing the joint connector 102 from the panel 32 to repair or replace components of the joint connector 102.

[0039] The contact assembly 180 is Figure 3 130 is shown as being coupled to the connector housing 120. For example, a contact holder 182 is received in an opening 134 in the base 130. The contact holder 182 holds a connector contact 190. In the illustrated embodiment, the contact assembly 180 includes a pair of connector contacts 190. In alternative embodiments, more or fewer plug contacts 190 may be provided. In the illustrated embodiment, the plug contacts 190 are blade contacts. For example, the connector contacts 190 are typically flat plates located in the contact passages 184 of the contact holder 182. The connector contacts 190 may be bus bars configured to be electrically connected to other components. Other types of contacts may be used in alternative embodiments, such as contacts, socket contacts, tuning fork contacts, spring beam contacts, or other types of contacts.

[0040] In an exemplary embodiment, the locking bar 200 is separate and discrete from the joint housing 120. The locking bar 200 is configured to be coupled to the joint housing 120, such as to the sides 126, 127 of the joint housing 120. Optionally, the locking bar 200 may be removably coupled to the joint housing 120. For example, the locking bar 200 may be detachably coupled to the joint housing 120 and may be removed by pulling the locking bar 200 directly away from the joint housing 120.

[0041] In an exemplary embodiment, the locking lever 200 is U-shaped, having a handle 210, a first lever arm 212 extending from a first side of the handle 210, and a second lever arm 214 extending from a second side of the handle 210. The first lever arm 212 extends to a distal end 216. The second lever arm 214 extends to a distal end 218. The first lever arm 212 extends along the first side 126 of the joint housing 120. The second lever arm 214 extends along the second side 127 of the joint housing 120. In the locked position, the handle 210 extends along the rear portion 129 of the joint housing 120. The locking lever 200 can be moved relative to the joint housing 120 by pushing or pulling the handle 210. In an exemplary embodiment, the locking lever 200 can slide relative to the joint housing 120, such as sliding in a horizontal sliding direction, such as to move the locking lever 200 between the locked position and the unlocked position. The handle 210 is located near the rear portion 129 in the locked position and is configured to be spaced apart from the rear portion 129 in the unlocked position. In an exemplary embodiment, the locking lever 200 is rotatable relative to the joint housing 120 to move the locking lever 200 between the open position and the closed position. The handle 210 is located adjacent to the panel 32 in the closed position. The handle 210 is rotated away from the panel 32 in the open position.

[0042] Figure 4 is a cross-sectional view of a portion of the joint connector 102 according to an exemplary embodiment. Figure 5 FIG. 1 is an enlarged cross-sectional view of a portion of a joint connector 102 according to an exemplary embodiment. Figure 4 and Figure 5 4. The connector housing 120 is shown in a pre-stage position. In the pre-stage position, the connector housing 120 is initially positioned relative to the panel 32, such as in the opening 40. The connector housing 120 is configured to receive the locking rod 200 in the pre-stage position. The connector housing 120 is not fully secured to the panel 32 in the pre-stage position.

[0043] In an exemplary embodiment, the flange 132 includes a seal pocket 136 that receives the seal 114. The seal 114 is configured to be sealingly coupled to the joint housing 120 and is configured to be sealingly coupled to the panel 32. In various embodiments, the seal 114 can be a rubber gasket. In an exemplary embodiment, the seal 114 is compressible. Compression of the seal 114 creates a tight seal to the joint housing 120 and the panel 32. In an exemplary embodiment, a locking rod 200 is used to compress the seal 114, wherein the locking rod 200 is coupled to the joint housing 120.

[0044] In an exemplary embodiment, the joint housing 120 includes a pre-stage latch 150 for securing the joint housing 120 in a pre-stage position on the panel 32. The pre-stage latch 150 is configured to be latchably coupled to the panel 32. In an exemplary embodiment, the pre-stage latch 150 extends from the base 130. The pre-stage latch 150 is received in the opening 40 of the panel 32 and is configured to be latchably coupled to the lower surface 36. When the pre-stage latch 150 is connected to the panel 32, the bottom of the flange 132 is spaced apart from the upper surface 34 of the panel 32. For example, a gap is set between the flange 132 and the upper surface 34 of the panel 32. The seal 114 can span the gap. The seal 114 can maintain the joint housing 120 and the pre-stage position, for example, to keep the pre-stage latch 150 latched to the lower surface 36 of the panel 32. When the locking bar 200 is coupled to the joint housing 120, the seal 114 is compressed and the pre-stage latch 150 is configured to release from the panel 32. For example, the locking bar 200 may pull the flange 132 toward the panel 32 partially or completely surrounding the gap.

[0045] Figure 6 is a bottom perspective view of a portion of header connector 102 according to an exemplary embodiment. Figure 6 1 shows the connector housing 120 with the connector shield 148 and the seal 114 coupled to the connector housing 120. For clarity, the contact assembly 180 ( Figure 3 ) to illustrate a portion of the joint connector 102.

[0046] The seal 114 is received in a seal pocket 136 in the bottom of the flange 132. In the exemplary embodiment, the seal 114 completely surrounds the base 130. For example, the seal 114 is continuous along the two sides 126, 27, the front 128, and the back 129.

[0047] In an exemplary embodiment, the connector shield 148 is coupled to the base 130. The connector shield 148 is located in the opening 134 of the base 130 and extends along the interior of the shield 140. In an exemplary embodiment, the connector shield 148 completely surrounds the opening 134 to provide shielding around the contact assembly 180. The connector shield 148 includes a connection tab 147 that extends inwardly from the wall of the connector shield 148 to dock with the plug connector 104. The connection tab 147 can be positioned along the side and / or front and / or rear of the connector shield 148. The connector shield 148 includes a panel tab 149. The panel tab extends outwardly from the wall of the connector shield 148 to engage with the panel 32. The panel tab 149 can be positioned along the side and / or front and / or rear of the connector shield 148.

[0048] In an exemplary embodiment, the connector housing 120 includes a pre-stage latch 150. In the illustrated embodiment, the pre-stage latch 150 is positioned along the front 128 and rear 129 of the base 130. In alternative embodiments, other positions are possible. The pre-stage latch 150 can extend from the flange 132 along the base 130. In alternative embodiments, the pre-stage latch 150 can extend from the base 130. The pre-stage latch 150 can be deflected relative to the base 130. For example, the pre-stage latch 150 can be deflected inwardly toward the base 130 to pass through the opening 40 in the panel 32, such as during mating with the panel 32 and unmating from the panel 32. Each pre-stage latch 150 includes a latch surface 152. The latch surface 152 is positioned along the outside of the pre-stage latch 150. The latch surface 152 faces outward. For example, the latch surface 152 faces the flange 132. The panel 32 is configured to be captured between the latch surface 152 and the flange 132. Optionally, the pre-stage latch 150 includes a ramp surface 154 below the latch surface 152. The ramp surface 154 is configured to engage the panel 32 to deflect the pre-stage latch when the joint housing 120 is loaded through the opening 40 in the panel 32.

[0049] In an exemplary embodiment, the joint housing 120 includes a final stage latch 160. The final stage latch 160 is configured to be latchably coupled to the panel 32. The final stage latch 160 is used to secure the joint housing 120 in the final stage, such as to hold the flange 132 against the panel 32. In the final stage, the seal 114 is compressed and sealingly coupled to the flange 132 and the panel 32. In the illustrated embodiment, the final stage latch 160 is positioned along the front 128 and the rear 129 of the base 130. In alternative embodiments, other positions are possible. The final stage latch 160 can extend from the flange 132 along the base 130. In alternative embodiments, the final stage latch 160 can extend from the base 130. The final stage latch 160 can be deflected relative to the base 130. For example, the final stage latches 160 can be deflected inwardly toward the base 130 to pass through the opening 40 in the panel 32, such as during mating with and unmating from the panel 32. Each final stage latch 160 includes a latch surface 162. The latch surface 162 is located along the outer side of the final stage latch 160. The latch surface 162 faces outward. For example, the latch surface 162 faces the flange 132. The panel 32 is configured to be captured between the latch surface 162 and the flange 132. Optionally, the final stage latch 160 includes a ramp surface 164 below the latch surface 162. The ramp surface 164 is configured to engage the panel 32 to deflect the final stage latch when the joint housing 120 is loaded through the opening 40 in the panel 32.

[0050] In an exemplary embodiment, the joint housing 120 includes a lever pin 170 extending outwardly from the base 130. The locking rod 200 is configured to be coupled to the lever pin 170. The locking rod 200 can be rotatably coupled to the lever pin 170 and / or slidably coupled to the lever pin 170. In the illustrated embodiment, the lever pin 170 is located at the sides 126, 127 of the base 130. In alternative embodiments, other positions are possible. In an exemplary embodiment, the lever pin 170 is spaced apart from the flange 132. For example, the lever pin 170 can be located near the bottom 125 of the joint housing 120. In various embodiments, the lever pin is cylindrical. However, in alternative embodiments, the lever pin 170 can have other shapes.

[0051] In an exemplary embodiment, the joint housing 120 includes a guide track 172 to guide the relative movement of the locking rod 200 relative to the joint housing 120. For example, the guide track 172 is used to guide the rotational movement of the locking rod 200 relative to the joint housing 120. In an exemplary embodiment, the joint housing 120 includes one or more guide rails 174, and the guide rail 174 has a guide surface 176 for forming the guide track 172. Optionally, the rod pin 170 can form a part of the guide track 172. For example, the guide track 172 can be defined between the guide surface 176 of the guide rail 174 and the rod pin 170. Other types of guide features can be used to guide the movement of the locking rod 200 relative to the joint housing 120.

[0052] Figure 7 is a bottom perspective view of a portion of the header connector 102 showing the locking lever 200 in an open position. Figure 8 is a bottom perspective view of a portion of the header connector 102 showing the locking lever 200 in a closed position. Fig. 9 is a cross-sectional view of a portion of the joint connector 102 showing the locking lever 200 in a closed position and an extended position. Fig.10 is a bottom perspective view of a portion of the header connector 102 showing the locking lever 200 in a retracted position. Fig.11 is a bottom perspective view of a portion of the header connector 102 showing the locking lever 200 in the locked position.

[0053] During assembly, the connector housing 120 is initially coupled to the panel 32 by inserting the base 130 through the opening 40. The pre-stage latch 150 engages the panel 32 to hold the connector housing 120 in the pre-stage position ( Figure 7 ). When the joint housing 120 is in the pre-stage position, the locking rod 200 can be coupled to the joint housing 120. The final stage latch 160 is non-latchedly coupled to the panel 32 in the pre-stage position. Instead, the final stage latch 160 can be located in the opening 40 of the panel 32 or above the upper surface 34 of the panel 32. After the locking rod 200 is actuated (e.g., closed), the joint housing 120 moves from the pre-stage position to the final stage position. The joint housing 120 moves downward from the pre-stage position to the final stage position. For example, the flange 132 moves toward the panel 32 so that the final stage latch 160 passes through the opening 40 and engages with the lower surface 36 of the panel 32. The final stage latch 160 is in the final stage position ( Figure 8) can be latchably coupled to the panel 32. When the final stage latch 160 is coupled to the panel 32, the final stage latch 160 can prevent the joint housing 120 from moving relative to the panel 32. The pre-stage latch 150 can be located at a first distance from the flange 132, and the final stage latch 160 can be located at a second distance from the flange 132. The second distance can be less than the first distance, so that when the final stage latch 160 is coupled to the panel 32, the flange 132 is positioned closer to the panel 32 than the pre-stage latch 150.

[0054] During the installation of the joint connector 102 to the panel 32, the locking rod 200 moves from the open position to the closed position, and then is removed from the extended position to the retracted position. The locking rod 200 can be locked to the joint housing 120 in the retracted position. In an exemplary embodiment, the locking rod 200 rotates between the open position and the closed position, such as by rotating the handle 210 toward the panel 32 to the closed position. The rotational action between the open position and the closed position causes the joint connector 102 to be placed on the panel 32. For example, the flange 132 moves toward the panel 32 and is placed on the upper surface 34 of the panel 32 to compress the seal 114 and form a sealed connection between the flange 132 and the panel 32. In an exemplary embodiment, the locking rod 200 slides forward between the extended position and the retracted position. By pressing the handle 210 toward the rear 129 of the joint housing 120 to lock the locking rod 200 relative to the joint housing 120, the locking rod 200 slides forward to the retracted position. In the locked position, the locking bar 200 is prevented from opening, thereby holding the joint housing 120 tightly against the panel 32 to maintain a sealed connection between the joint housing 120 and the panel 32 .

[0055] In an exemplary embodiment, the lever arms 212, 214 each include a pin channel 220 that receives the lever pin 170. The pin channel 220 is disposed along an inner surface 222 of the respective lever arms 212, 214. The pin channel 220 opens at the respective distal ends 216, 218 to receive the lever pin 170. In an exemplary embodiment, the pin channel 220 includes a pin recess 224 and a pin track 226 extending from the pin recess 224. When the lever pin 170 is located in the pin recess 224, the locking lever 200 can rotate on the lever pin 170. For example, when the lever pin 170 is located in the pin recess 224, the locking lever 200 can rotate between an open position and a closed position. When the locking lever 200 is in the closed position, the lever pin 170 can slide in the pin track 226. The locking lever 200 is configured to slide between an extended position and a retracted position by sliding the lever pin 170 in the pin track 226.

[0056] In the exemplary embodiment, the locking lever 200 includes an inner edge 230 and a front edge 232 extending along each of the lever arms 212, 214. The locking lever 200 includes a fulcrum 234 between the inner edge 230 and the front edge 232. In the illustrated embodiment, the fulcrum 234 is bent between the inner edge 230 and the front edge 232. The front edge 232 is configured to face the panel 32 in the open position. The front edge 232 can engage the lower surface 36 of the panel 32 in the open position. The inner edge 230 is configured to face the panel 32 in the closed position. In the illustrated embodiment, the inner edge 230 is the top edge of the lever arms 212, 214. The inner edge 230 can engage the lower surface 36 of the panel 32 in the closed position. The fulcrum 234 is configured to engage the panel 32 when the locking lever 200 is rotated between the open position and the closed position. The locking lever 200 rotates between a first position (open position) and a second position (closed position) relative to the joint housing 120. As the fulcrum 234 rotates on the panel 32, the joint housing 120 moves relative to the panel 32. For example, when the locking lever 200 rotates from the open position to the closed position, the lever action caused by the locking lever 200 between the panel 32 and the joint housing 120 causes the joint housing 120 to move downward relative to the panel 32. In the exemplary embodiment, the front edge 232 is positioned closer to the pin recess 224 than the inner edge 230, and therefore closer to the lever pin 170. As the fulcrum 234 rotates along the panel 32 (when the locking lever 200 rotates from the open position to the closed position), the lever pin 170 is pushed further downward away from the panel 32 by the locking lever 200, which causes the joint housing 120 and therefore the flange 132 to move downward. When the fulcrum 234 rotates from the open position to the closed position on the panel 32, the seal 114 is compressed between the flange 132 and the upper surface 34 of the panel 32. In order to maintain the locking lever 200 and the closed position and prevent the handle 210 of the locking lever 200 from returning to the open position, the locking lever 200 is moved forward to the retracted position ( Fig.10 ) and then lock in the retracted position ( Fig.11 ).

[0057] In the retracted position, the handle 210 is adjacent the rear portion 129 of the base 130. In the exemplary embodiment, the base 130 of the connector housing 120 includes a locking recess 138. The locking element 202 of the locking lever 200 is configured to be received in the locking recess 138 to secure the locking lever 200 in a locked position relative to the connector housing 120.

[0058] Fig.12 is a cross-sectional view of a portion of the joint connector 102 showing the locking lever 200 in a locked position according to an exemplary embodiment. Fig.13 is a cross-sectional view of a portion of the joint connector 102 showing the locking lever 200 in a locked position according to an exemplary embodiment. Fig.14is a cross-sectional view of a portion of the joint connector 102 showing the locking lever 200 in a locked position according to an exemplary embodiment.

[0059] In an exemplary embodiment, the locking rod 200 includes a locking element recess 240 in the handle 210. The locking element 202 is received in the locking element recess 240. In an exemplary embodiment, the locking element 202 can move in the locking element recess 240, for example, between an unlocked position and a locked position. In the illustrated embodiment, the locking element 202 can be pushed downward from the unlocked position to the locked position. The locking element 202 is locked to the joint housing 120 in the locked position. The locking element 202 is unlocked from the joint housing 120 in the unlocked position. The locking rod 200 is restricted from moving relative to the joint housing 120 in the locked position (e.g., sliding to an extended position or rotating to an open position). The locking rod 200 is free to move relative to the joint housing 120 in the unlocked position (e.g., sliding to an extended position).

[0060] In an exemplary embodiment, the locking element 202 includes a button 250 at the bottom of the locking element 202 and a cavity 252 at the top of the button 250. The connector housing 120 includes a locking tab 139, such as at the bottom 125 of the base 130. When the locking element 202 is moved to the locked position, the locking tab 139 is received in the cavity 252. For example, when the button 250 is pressed upward to the locked position, the locking tab 139 is received in the cavity 252. When the locking tab 139 is received in the cavity 252, the locking bar 200 cannot move away from the connector housing 120. Other types of locking features may be used in alternative embodiments.

[0061] In an exemplary embodiment, the locking element 202 includes a latch beam 260 extending from the button 250. The latch beam 260 is configured to engage with the joint housing 120. In various embodiments, the latch beam 260 can maintain the locking bar 200 and the locked position, and the latch beam 260 can engage one of the final stage latches 160 to prevent the final stage latch 160 from unlocking. For example, the latch beam 260 can operate as a secondary latch feature of the final stage latch 160.

[0062] Fig.15 is a cross-sectional view of a portion of joint connector 102 according to an exemplary embodiment. Fig.15The lever pin 170 is shown located in the pin track 226. The lever pin 170 can slide in the pin track 226. The lever arms 212, 214 are received in the guide track 172 between the guide surface 176 of the guide rail 174 and the lever pin 170. For example, the locking rib 228 of the locking lever 200 is located in the guide track 172 and can move in the guide track 172 to guide the movement of the locking lever 200 relative to the joint housing 120. The guide track 172 and the pin track 226 guide the movement of the locking lever 200 relative to the joint housing 120. For example, the guide track 172 and the pin track 226 guide the sliding movement in the horizontal sliding direction. Other types of guide features can be used in alternative embodiments.

[0063] Fig.16 is a cross-sectional view of a portion of joint connector 102 according to an exemplary embodiment. Fig.17 is a cross-sectional view of a portion of joint connector 102 according to an exemplary embodiment. Fig.16 and Fig.17 The pin track 226 and the pin pocket 224 in the lever arms 212, 214 of the locking lever 200 are shown. The lever pin 170 of the joint housing 120 is shown in the pin pocket 224 and aligned with the pin track 226.

[0064] In one aspect, an electrical connector is provided, including a housing extending between a mating end and a mounting end. The mating end is configured to mate with a mating electrical connector. The mating end includes a shield surrounding a cavity. The mounting end is configured to be mounted to a panel. The mounting end includes a base and a flange extending from the base. The base of the housing is received in an opening in the panel. The flange of the housing is mounted to a mounting surface of the panel. A contact assembly is housed in the housing. The contact assembly includes a contact holder that holds at least one contact that is configured to mate with the mating electrical connector. A seal is coupled to the flange and surrounds the base. The seal is configured to dock with the mounting surface of the panel. A locking lever is coupled to the housing. The locking lever is configured to engage with the panel to secure the housing to the panel.

[0065] Optionally, the locking bar may secure the housing to the panel without the use of fasteners.

[0066] Optionally, the locking lever may be rotatably coupled to the housing.

[0067] Optionally, the locking bar may be slidably coupled to the housing.

[0068] Optionally, the locking bar can be movable between a first position and a second position relative to the housing. When the locking bar moves from the first position to the second position, the locking bar can move the housing relative to the panel to compress the seal.

[0069] Optionally, the housing may include a pre-stage latch and a final stage latch. The flange of the housing may be movable from a pre-stage position to a final stage position relatively closer to the mounting surface of the panel. The pre-stage latch may be latchably coupled to the panel in the pre-stage position. The final stage latch may be latchably coupled to the panel in the final stage position.

[0070] Optionally, the locking lever may be actuated to move the housing from the pre-stage position to the final-stage position.

[0071] Alternatively, the leading stage latch may be located at a first distance from the flange and the final stage latch may be located at a second distance from the flange. The second distance may be less than the first distance.

[0072] Optionally, the base includes a lever pin extending outwardly from the base, and the locking lever includes a pin recess receiving the lever pin.

[0073] Optionally, the locking lever may be rotatably coupled to the lever pin.

[0074] Optionally, the base may include a guide rail.The locking bar may include a locking rib received in the guide rail to fix the locking bar relative to the housing.

[0075] Optionally, the locking bar may include a locking element. The locking element may be actuated to lock the locking bar to the housing.

[0076] Optionally, the base of the housing may include a locking recess.The locking bar may include a locking element received in the locking recess to fix the locking bar relative to the housing.

[0077] Optionally, the locking lever may include a fulcrum configured to engage the panel. The locking lever may rotate relative to the housing between a first position and a second position. When the fulcrum rotates on the panel, the housing may move relative to the panel.

[0078] Optionally, the locking lever may be pivotally coupled to the housing to move from a vertical position to a horizontal position.The locking lever may be slidably coupled to the housing to move from a first horizontal position to a second horizontal position.

[0079] Optionally, the locking lever may include a handle, a first lever arm extending from a first side of the handle, and a second lever arm extending from a second side of the handle. The first lever arm may be coupled to the first side of the base, and the second lever arm may be coupled to the second side of the base. The handle may be actuated to move the first lever arm and the second lever arm relative to the housing.

[0080] Optionally, the handle can be pivoted relative to the housing from an open position to a closed position. The handle can be away from the panel in the open position, and the handle can engage the panel in the closed position. When the handle is pivoted from the open position to the closed position, the first arm and the second arm can move the flange closer to the panel.

[0081] Optionally, the handle can slide relative to the housing from an extended position to a retracted position. The handle can be spaced apart from the base in the extended position. The handle can engage the base in the retracted position. The handle can be configured to lock to the base in the retracted position.

[0082] CROSS-REFERENCE TO RELATED APPLICATIONS

[0083] This application claims the benefit of U.S. Provisional Application No. 63 / 509,536, filed on June 22, 2023, the subject matter of which is incorporated herein by reference in its entirety.

Claims

1. An electrical connector (100), comprising: A housing (120) extending between a mating end (122) and a mounting end (124), the mating end being configured to mate with a mating electrical connector, the mating end including a shroud (140) surrounding a cavity (144), the mounting end being configured to be mounted to a panel (32), the mounting end including a base (130) and a flange (132) extending from the base, the base of the housing being received in an opening (40) in the panel, the flange of the housing being mounted to a mounting surface of the panel; a contact assembly (180) received in the housing, the contact assembly comprising a contact holder (182) holding at least one contact, the at least one contact being configured to mate with the mating electrical connector; a seal (114) coupled to the flange and surrounding the base, the seal being configured to engage the mounting surface of the panel; as well as A locking bar (200) is coupled to the housing, the locking bar being configured to engage the panel to secure the housing to the panel.

2. The electrical connector (100) of claim 1, wherein the locking lever (200) secures the housing (120) to the panel (32) without the use of fasteners.

3. The electrical connector (100) according to claim 1, wherein the locking lever (200) is rotatably coupled to the housing (120).

4. The electrical connector (100) according to claim 1, wherein the locking lever (200) is slidably coupled to the housing (120).

5. An electrical connector (100) according to claim 1, wherein the locking rod (200) moves between a first position and a second position relative to the housing (120), and when the locking rod moves from the first position to the second position, the locking rod causes the housing to move relative to the panel (32) to compress the seal (114).

6. An electrical connector (100) according to claim 1, wherein the shell (120) includes a pre-stage latch (150) and a final-stage latch (160), and the flange (132) of the shell moves from a pre-stage position to a final-stage position relatively closer to the mounting surface of the panel (32), the pre-stage latch can be latched to the panel in the pre-stage position, and the final-stage latch can be latched to the panel in the final-stage position.

7. The electrical connector (100) of claim 6, wherein the locking lever (200) is actuated to move the housing (120) from the pre-stage position to the final-stage position.

8. The electrical connector (100) of claim 6, wherein the leading stage latch (150) is located at a first distance from the flange (132), and the final stage latch (160) is located at a second distance from the flange, the second distance being less than the first distance.

9. The electrical connector (100) according to claim 1, wherein the base (130) includes a lever pin (170) extending outward from the base, and the locking lever (200) includes a pin recess (224) for receiving the lever pin.

10. The electrical connector (100) according to claim 9, wherein the locking lever (200) is rotatably coupled to the lever pin (170).

11. The electrical connector (100) according to claim 1, wherein the base (130) includes a guide track (172), and the locking rod (200) includes a locking rib (228), and the locking rib (228) is received in the guide track to fix the locking rod relative to the housing (120).

12. The electrical connector (100) of claim 1, wherein the locking lever (200) comprises a locking element (202) that is actuated to lock the locking lever to the housing (120).

13. An electrical connector (100) according to claim 1, wherein the base (130) of the shell (120) includes a locking recess, and the locking rod (200) includes a locking element (202), and the locking element (202) is received in the locking recess to fix the locking rod relative to the shell.

14. An electrical connector (100) according to claim 1, wherein the locking rod (200) includes a fulcrum (234) configured to engage the panel (32), the locking rod rotates between a first position and a second position relative to the housing (120), and when the fulcrum rotates on the panel, the housing moves relative to the panel.

15. The electrical connector (100) according to claim 1, wherein the locking lever (200) is pivotally coupled to the housing (120) to move from a vertical position to a horizontal position, and the locking lever is slidably coupled to the housing to move from a first horizontal position to a second horizontal position.

16. An electrical connector (100) according to claim 1, wherein the locking lever (200) includes a handle (210), a first lever arm (212) extending from a first side of the handle, and a second lever arm (214) extending from a second side of the handle, the first lever arm being coupled to a first side of the base (130), the second lever arm being coupled to a second side of the base, and the handle being actuated to move the first lever arm and the second lever arm relative to the housing (120).

17. An electrical connector (100) according to claim 16, wherein the handle (210) is pivoted from an open position to a closed position relative to the housing (120), the handle is away from the panel (32) in the open position, and the handle engages the panel in the closed position, and when the handle is pivoted from the open position to the closed position, the first arm and the second arm cause the flange (132) to move closer to the panel.

18. An electrical connector (100) according to claim 17, wherein the handle (210) slides from an extended position to a retracted position relative to the housing (120), the handle is spaced apart from the base (130) in the extended position, the handle engages the base in the retracted position, and the handle is configured to be locked to the base in the retracted position.

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