Electrical connector system

Abstract

An electrical connector system has a base and a back cover for securing to the base to close an opening in the base. The rear cover includes a seal that seals the base. The high voltage interlock system detects when the rear cover is in a closed position relative to the base.

Description

Background of the Invention

[0002] The present invention relates to an electrical connector system, and more particularly, to an electrical connector system with a connector position assurance element.

[0003] Electrical connectors are known that provide convenient and quick electrical connections. Such electrical connectors may be used in motor vehicles that utilize high voltages for certain vehicle systems (eg, high voltage charging systems). It would be desirable to employ improved connectors in such systems. SUMMARY OF THE INVENTION

[0005] According to one aspect, the present invention provides an electrical connector system, which includes: a base, the base having a shell, the shell including a first perimeter wall and a second perimeter wall separated from the first perimeter wall, the first perimeter wall being configured to receive a plurality of cables extending through the first perimeter wall and defining a first opening, the first opening being configured to provide an entrance for electrical connection with the plurality of cables, and the second perimeter wall defining a second opening on a side opposite to the first opening; a back cover, the back cover including a plate and a sealing retaining flange, the plate being configured to be fixed against the second perimeter wall to cover the second opening, the sealing retaining flange extending approximately perpendicularly from the plate, and the sealing retaining flange being configured to be assembled within the second perimeter wall when the back cover is in a closed position relative to the base; and a seal extending around the periphery of the sealing retaining flange, the seal being retained by the back cover and movable with the back cover, the seal being configured to be elastically compressed between the sealing retaining flange and the second perimeter wall when the back cover is in a closed position.

[0006] According to one aspect, the present invention provides an electrical connector system, which includes: a base, the base having a shell, the shell including a first peripheral wall and a second peripheral wall separated from the first peripheral wall, the first peripheral wall being configured to receive a plurality of cables extending through the first peripheral wall and defining a first opening, the first opening being configured to provide an entrance for electrical connection with the plurality of cables, and the second peripheral wall defining a second opening on a side opposite to the first opening; a back cover, the back cover including a plate, the plate being configured to be fixed against the second peripheral wall to cover the second opening when the back cover is in a closed position relative to the base; and a high voltage interlock system, the high voltage interlock system including a pair of conductive HVIL pads located on one of the back cover and the shell and a pair of conductive HVIL pins located on the other of the back cover and the shell, wherein each of the HVIL pads is configured to contact a corresponding one of the HVIL pins only when the back cover is in a closed position.

[0007] According to one aspect, an electrical connector system is provided that allows components of a high voltage system to be connected while utilizing a low voltage system (a high voltage interlock (HVIL) system) to indicate that a rear cover is closed. According to one aspect, a seal can be compressed between a flange on the rear cover and a wall on the base to seal between the rear cover and the base while also helping to secure the rear cover in a closed position relative to the base. According to one aspect, the electrical connector system can include a connector position assurance (CPA) member to ensure that the electrical connection is maintained.

[0008]

[0011] Various aspects of the invention will become apparent to those skilled in the art from the following detailed description of the preferred embodiments, when read in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Figure 1 is a schematic perspective view of a portion of an electrical connector system.

[0010] Figure 2 Shown from different perspectives Figure 1 A schematic perspective view of a portion of an electrical connector system.

[0011] Figure 3 Shown from different perspectives Figure 1 A schematic perspective view of a portion of an electrical connector system.

[0012] Figure 4 yes Figure 1 Schematic end view of a portion of an electrical connector system.

[0013] Figure 5 yes Figure 1 Schematic side view of a portion of an electrical connector system.

[0014] Figure 6 yes Figure 1 A schematic perspective view of a portion of an electrical connector system of FIG. 1 , wherein a rear cover is shown in an open position.

[0015] Figure 7 yes Figure 6 A schematic perspective view of a portion of an electrical connector system of FIG. 1 , but on an enlarged scale.

[0016] Figure 8 yes Figure 1 Schematic cross-sectional view of a portion of an electrical connector system.

[0017] Fig. 9 yes Figure 6 A schematic perspective view of a portion of an electrical connector system of FIG. 1 , but on an enlarged scale.

[0018] Fig.10 is similar to Figure 1 Schematic perspective view of a portion of an electrical connector system of the type configured for use with round cables.

[0019] Fig.11 Shown from different perspectives Fig.10 A schematic perspective view of a portion of an electrical connector system.

[0020] Fig.12 Shown from different perspectives Fig.10 A schematic perspective view of a portion of an electrical connector system.

[0021] Fig.13 is similar to Figure 1 Schematic perspective view of a portion of an electrical connector system configured for a fold-flat cable type.

[0022] Fig.14 Shown from different perspectives Fig.13 A schematic perspective view of a portion of an electrical connector system.

[0023] Detailed Description of the Preferred Embodiments

[0024] Referring now to the accompanying drawings, Figure 1-Figure 9 An example of an electrical connector system 20 is shown in FIG. The electrical connector system 20 includes a base 22 and a back cover 24. The base 22 includes a housing 26 that may be formed of an electrically insulating material, the housing 26 having a first peripheral wall 28 and a second peripheral wall 32, the first peripheral wall 28 defining an opening 30 for receiving another portion (not shown) of the electrical connector system 20, and the second peripheral wall 32 defining an opening 34 selectively closed by the back cover 24. The base 22 includes a member 35 defining a cavity 36 and a base hinge 40 of a pivot hinge assembly 42, the cavity 36 being configured to slidably receive a connector position assurance (CPA) member 38. The base hinge 40 includes a pair of hinge arms 44 and a pair of hold-open flanges 46. The base 42 includes a cable connection member 48 defining a pair of cable channels 50, the cable channels 50 being configured to receive a pair of flat cables 52 passing through the cable channels 50. The housing 26 may be formed (e.g., molded) as a single piece.

[0025] exist Figure 1-Figure 9The rear cover 24 of the example shown in FIG. 5 includes a plate 54, a cover hinge arm 56 extending from the plate 54, a pair of snap-fit ​​connectors 58 extending from the plate 54, and a sealing retaining flange 60 extending from the plate 54, all of which can be formed of an electrically insulating material. The cover hinge arm 56 cooperates with a pair of hinge arms 44 to form a pivot hinge assembly 42 that pivotally attaches the rear cover 24 to the base 22. The pair of hold-open flanges 46 each include a barb 62 that, when in the open position (e.g., Figure 6 ), the barbs 62 selectively engage with the edge of the plate 54 to hold the rear cover 24 in the open position until the rear cover 24 is pivoted to the closed position (as shown). Figure 1-Figure 5 and Figure 8 ). When the rear cover 24 is pivoted toward the closed position, a pair of snap-fit ​​connectors 58 slide on the outer surface 63 of the second peripheral wall 32 and resiliently engage with a corresponding pair of barbs 64 extending from the second peripheral wall 32 to help secure the rear cover 24 to the base 22 in the closed position. The rear cover 24 can be formed (e.g., molded) as a single piece. The seal 66 is resilient and is mounted to extend around the periphery of the seal retaining flange 60 and is retained between the plate 54 and a lip 68 extending generally radially outward from the seal retaining flange 60 to maintain the seal 66 in place regardless of whether the rear cover 24 is in the open position or the closed position. The seal 66 has three generally radially outwardly extending protrusions 70 that are resiliently biased against the inner surface 72 of the second peripheral wall 32 when the rear cover 24 is in the closed position to help secure the rear cover 24 to the base in the closed position and seal the rear cover 24 to the base 22 (i.e., to prevent moisture and debris from entering the electrical connector system 20 between the base 22 and the rear cover 24). The term "radially" as used herein refers to extending generally outward away from the center of the structure and generally inward toward the center of the structure (even if the first peripheral wall 28, the second peripheral wall 32 and the seal retaining flange 60 are not circular). When the seal 66 is compressed, the seal 66 generates a bias against the inner surface 72 in a direction perpendicular to the direction in which the rear cover 24 moves when it is pushed to the last distance of the closed position. This biasing force pushed radially outward against the inner surface 72 then helps to maintain the rear cover 24 in the closed position relative to the base 22. The snap-fit ​​connector 58 and seal 66 secure the rear cover 24 in a closed position relative to the base 22 without requiring fasteners to hold them together.

[0026] Figure 1-Figure 9The example of the electrical connector system 20 shown in the figure also includes a high voltage interlock (HVIL) system 74, which is a low voltage system that indicates the state of the back cover 24 relative to the base 22 of the electrical connector system 20 (i.e., closed position or not). The electrical connector system 20 can connect the flat cable 52 to other cables, wherein the connection is part of a high voltage system (e.g., about 250 volts-600 volts), and the HVIL system 74 can form a part of a low voltage (e.g., 5 volts, 12 volts, 24 volts) system for detecting the closed position of the back cover 24, and sealing the electrical components of the high voltage part of the electrical system. The HVIL system 74 includes a pair of conductive HVIL pads 76 fixed to the sealing fixing flange 60 and a corresponding pair of conductive HVIL pins 78 fixed to the second peripheral wall 32 of the base 22. The HVIL pad 76 can be molded into the back cover 24. When the back cover 24 moves between the open position and the closed position, the HVIL pad 76 moves with the back cover 24. The HVIL pin 78 can be molded into the housing 26. The HVIL pad 76 and the HVIL pin 78 are positioned so that when the rear cover 24 is moved to its closed position, each of the HVIL pad 76 and the HVIL pin 78 makes contact with a corresponding one. This contact completes the circuit for the HVIL system 74, providing a low voltage indication that the rear cover 24 is in the closed position, and realizing an HVIL functional indicator about the position of the rear cover 24.

[0027] Figure 1-Figure 9 The illustrated example of the electrical connector system 20 also includes a cable retaining member 80 on the cable connecting member 48. The cable retaining member 80 secures the flat cable 52 to the base 22 when the flat cable 52 is inserted through the cable channel 50 to a final position.

[0028] Figure 10-12 Shown with Figure 1 An example of an electrical connector system 120 similar to that shown in FIG. 1 , but configured for a round cable 152 type. Figure 1 A modification of the electrical connector system shown in and having many Figure 1 The same reference numerals denote corresponding parts in the drawings, and in order to avoid unnecessary repeated description, the detailed description thereof will be omitted. The round cable 152 slides into the first peripheral wall 28 and is fixed therein by the cable fixing member 180. The rear cover 24 can be of the same Figure 1-Figure 9 The embodiment shown in FIG. 1 is operably engaged with the base in substantially the same manner as shown in FIG.

[0029] Fig.13 and Fig.14 Shown with Figure 1An example of an electrical connector system 220 similar to that shown in FIG. 1 , but configured for a folded flat cable 252 type. Since the electrical connector system 220 in this example is a Figure 1 A modification of the electrical connector system shown in and having Figure 1 The same reference numerals denote corresponding parts in the drawings, and in order to avoid unnecessary repeated description, the detailed description thereof will be omitted. The folded flat cable 252 slides into the first peripheral wall 28 and is fixed therein by the cable fixing member 280. The rear cover 24 can be of the same Figure 1-Figure 9 The embodiment shown in FIG. 1 is operably engaged with the base in substantially the same manner as shown in FIG.

[0030] The principles and modes of operation of the present invention have been explained and illustrated in its preferred embodiments. However, it must be understood that the present invention may be implemented in ways other than those specifically explained and illustrated without departing from the spirit or scope of the present invention.

Claims

1. An electrical connector system, comprising: a base having a housing including a first peripheral wall and a second peripheral wall spaced from the first peripheral wall, the first peripheral wall being configured to receive a plurality of cables extending therethrough and defining a first opening, the first opening being configured to provide access for electrical connection to the plurality of cables, and the second peripheral wall defining a second opening on a side opposite the first opening; a rear cover including a plate configured to be secured against the second peripheral wall to cover the second opening, and a sealing retaining flange extending generally perpendicularly from the plate, and configured to fit within the second peripheral wall when the rear cover is in a closed position relative to the base; as well as A seal extends around the periphery of the seal retaining flange, the seal is retained by the rear cover and is movable therewith, the seal being configured to be elastically compressed between the seal retaining flange and the inner surface of the second peripheral wall when the rear cover is in the closed position.

2. The electrical connector system according to claim 1, wherein: The rear cover includes a lip spaced from the plate and extending generally radially outward from the seal retaining flange, wherein the seal is retained between the plate and the lip.

3. The electrical connector system according to claim 1, wherein: The base includes a base hinge arm, and the rear cover includes a cover hinge arm, which is pivotally engaged to the base hinge arm to pivotally secure the rear cover to the base for pivoting between an open position and a closed position, in which the plate is spaced from the second opening to allow access to the second opening, and in the closed position, the plate covers the second opening.

4. The electrical connector system according to claim 3, wherein: The base includes a hold-open flange adjacent the base hinge arm, wherein the hold-open flange is configured to hold the rear cover in the open position and flex to allow the rear cover to move to the closed position.

5. The electrical connector system according to claim 1, wherein: The seal includes a protrusion extending generally radially outward, and the protrusion is configured to press against the inner surface of the second peripheral wall.

6. The electrical connector system according to claim 1, wherein: The base includes a pair of barbs on the outer surface of the second peripheral wall located on opposite sides of the base, and the rear cover includes a pair of snap-fit ​​connectors, each snap-fit ​​connector being configured to mate with and be retained by a corresponding one of the barbs when the rear cover is in the closed position.

7. The electrical connector system of claim 1, further comprising a connector position assurance member, and wherein the housing includes a cavity configured to slidably receive the connector position assurance member.

8. The electrical connector system according to claim 1 further includes a high voltage interlock system, wherein the high voltage interlock system includes a pair of conductive HVIL pads located on one of the rear cover and the shell and a pair of conductive HVIL pins located on the other of the rear cover and the shell, wherein each of the HVIL pads is configured to contact a corresponding one of the HVIL pins when the rear cover is in the closed position.

9. The electrical connector system according to claim 8, wherein: The high voltage interlock system is configured to operate at a voltage lower than a voltage of the plurality of electrical cables.

10. The electrical connector system according to claim 1, wherein: The base includes a cable retaining member configured to retain the plurality of cables to the base.

11. The electrical connector system according to claim 1, wherein: The first peripheral wall is configured to receive the plurality of cables, wherein the plurality of cables are of a flat cable type.

12. The electrical connector system according to claim 1, wherein: The first peripheral wall is configured to receive the plurality of cables, wherein the plurality of cables are of a round cable type.

13. The electrical connector system according to claim 1, wherein: The first peripheral wall is configured to receive the plurality of cables, wherein the plurality of cables are of a folded flat cable type.

14. An electrical connector system, comprising: a base having a housing including a first peripheral wall and a second peripheral wall spaced from the first peripheral wall, the first peripheral wall being configured to receive a plurality of cables extending therethrough and defining a first opening, the first opening being configured to provide access for electrical connection to the plurality of cables, and the second peripheral wall defining a second opening on a side opposite the first opening; a rear cover including a plate configured to be secured against the second peripheral wall to cover the second opening when the rear cover is in a closed position relative to the base; as well as A high voltage interlock system comprising a pair of conductive HVIL pads on one of the rear cover and the housing and a pair of conductive HVIL pins on the other of the rear cover and the housing, wherein each of the HVIL pads is configured to contact a corresponding one of the HVIL pins only when the rear cover is in the closed position.

15. The electrical connector system according to claim 14, wherein: The high voltage interlock system is configured to operate at a voltage lower than a voltage of the plurality of electrical cables.

16. The electrical connector system according to claim 14, wherein: The rear cover is pivotally secured to the base.

17. The electrical connector system according to claim 14, wherein: The rear cover includes a seal configured to be biased radially inwardly against an inner surface of the second peripheral wall when the rear cover is in the closed position.

18. The electrical connector system of claim 17, wherein: The seal is held by the rear cover and moves with the rear cover between the open position and the closed position.

19. The electrical connector system of claim 14, wherein: The HVIL pad is secured to the back cover by being molded into the back cover.

20. The electrical connector system of claim 14, further comprising a connector position assurance member, and wherein the housing includes a cavity configured to slidably receive the connector position assurance member.

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