Lever lock electrical connector with additional lock

Abstract

An electrical connector includes a first housing portion configured to receive a second housing portion in seated alignment to form a housing of the electrical connector. The connector further includes a first lock on the first housing portion, the first lock including a lever rotatable between an unlocked position, in which the second housing portion is removable from the first housing portion, and a locked position, in which the first housing portion and the second housing portion are secured in seated alignment. The connector also includes a connector position assurance (CPA) device that engages with the first lock in the operative position to hold the lever in the locked position. The connector also includes a second lock that further secures the first housing portion and the second housing portion in a seated alignment in a working position.

Description

Background Art

[0001] Electrical connectors are commonly used in many commercial, industrial, and military applications to implement power, signal, and data systems. In some applications, such as automotive or aerospace applications, it is desirable to provide electrical connectors that are relatively easy to install to support efficient manufacturing processes. In many applications, it is also important that the electrical connectors resist accidental decoupling (detachment) during vehicle use, transportation, maintenance, or assembly. Therefore, there is a need for improved electrical connector designs that are relatively easy to install and provide improved decoupling resistance after installation. Summary of the invention

[0002] An electrical connector is described. The connector includes a first housing portion configured to receive a second housing portion in a seated alignment to form a housing of the electrical connector. The connector also includes a first lock on the first housing portion, the first lock including a rod that can rotate between an unlocked position and a locked position, in which the second housing portion can be moved away from the first housing portion, and in which the first housing portion and the second housing portion are fixed in a seated alignment. The connector also includes a connector position assurance (CPA) device that engages with the first lock in a working position to hold the rod in the locked position. The connector also includes a second lock that further fixes the first housing portion and the second housing portion in a seated alignment in the working position. In some examples, the first lock engages with the second housing portion to fix the first housing portion and the second housing portion in a seated alignment, and the second lock engages the first housing portion in the working position to further fix the first housing portion and the second housing portion in a seated alignment. In some examples, when the connector position assurance device moves from the preparatory position to the working position, the second lock engages with the protruding edge of the first housing portion.

[0003] According to other examples, a method is described. The method includes forming a first housing portion. The method also includes forming a second housing portion configured to be seated and aligned with the first housing portion to form a housing of an electrical connector. The method also includes forming a first lock on the first housing portion, the first lock including a rod that can rotate between an unlocked position and a locked position, in which the second housing portion can be moved away from the first housing portion, and in which the first housing portion and the second housing portion are fixed in a seated alignment. The method also includes forming a connector position assurance device configured to engage with the first lock in a working position to hold the rod in the locked position. The method also includes forming a second lock, in which the second lock further fixes the first housing portion and the second housing portion in a seated alignment in the working position. In some examples, the method also includes forming the first lock to dock with the second housing portion in the locked position, and forming the second lock to dock with the first housing portion in the working position. In some examples, the method also includes forming a ledge on the first housing portion. In some examples, the method also includes forming a second lock to dock with the ledge.

[0004] As another example, a connector position assurance (CPA) device is described. The connector position assurance device includes a fixed arm, which is arranged to be assembled in a channel of a first lock member including a rod of an electrical connector in a preparatory position of the connector position assurance device, and defines a working position of the connector position assurance device. The connector position assurance device also includes a tongue feature, which is configured to hold the first lock member in a locked position in the working position to fix the first shell part and the second shell part in a seated alignment to form a shell of the electrical connector. The connector position assurance device also includes a second lock member, which further fixes the first shell part and the second shell part in a seated alignment. In some examples, the second lock member engages with the first shell part of the electrical connector to hold the first lock member in the locked position, and the first lock member engages with the second shell part in a locked state. In some examples, the second lock member is configured to dock with a protrusion presented by the first shell part in the working position. BRIEF DESCRIPTION OF THE DRAWINGS

[0005] Figure 1 is a diagram illustrating an electrical connector according to some embodiments.

[0006] Figure 2 is a diagram showing an exploded view of an electrical connector according to some embodiments.

[0007] Figure 3 is a diagram showing an electrical connector in an unlocked position according to some embodiments.

[0008] Figure 4is a diagram illustrating a perspective view of an electrical connector in a locked position according to some embodiments.

[0009] Figure 5 is a diagram illustrating a connector position assurance device (CPA) including a second locking member according to some embodiments.

[0010] Fig. 6A is a diagram depicting a perspective view of one example of a CPA and a first housing portion in a ready position according to some embodiments.

[0011] Figure 6B is a diagram depicting a perspective view of one example of a CPA and a first housing portion in a working position according to some embodiments.

[0012] Fig. 7A is a diagram depicting a cross-sectional view of an electrical connector with a CPA in a ready position according to some embodiments.

[0013] Figure 7B is a diagram depicting a cross-sectional view of an electrical connector with a CPA in an operational position according to some embodiments.

[0014] Figure 8 is a diagram depicting a cross-sectional view of one example of a CPA and a first housing portion according to some embodiments.

[0015] Fig. 9 is a flow chart describing one example of a method of providing an electrical connector according to some embodiments. DETAILED DESCRIPTION

[0016] Figure 1 FIG. 1 is a diagram showing an example of an electrical connector 100 according to some embodiments. Figure 1 In the example of FIG. 1 , the connector 100 is shown with the first locking member and the second locking member engaged. Figure 2 is a diagram illustrating an exploded view of example components of an electrical connector 100 according to some embodiments.

[0017] refer to Figure 1 In the example of an electrical connector 100, an electrical connector 100 is configured to support the coupling (coupling) of electrical conductors as part of a larger electrical system, such as the electrical system of a vehicle. The electrical connector 100 is a lever lock connector that includes a housing that serves as an enclosure to secure an electrical connection within the housing. Figure 1 In the example of FIG. 1 , the second housing 120 (which may be referred to as a “wiring harness cover”) defines a head opening 122. The head opening 122 can carry electrical conductors, such as a wiring harness, within the second housing portion 120. The electrical conductors can terminate with a first terminal array that is arranged to mate with a corresponding second terminal array within the first housing portion 110 to form an electrical connection housed within the connector 100. For example, when the rod lock member is such as Figure 1 When engaged as shown, the terminal arrays (not shown) can be brought together in a matching alignment to form a plurality of electrical connections within the housing of the connector 100. Thus, the connector 100 can be used to establish and protect electrical connections between electrical conductors for distributing power, signals and / or data as part of a vehicle electrical system.

[0018] In some examples, the electrical connector 100 may be particularly suitable for efficient implementation in complex vehicle manufacturing processes. For example, the connector 100 described herein may be particularly easy for an operator to secure in a locked position. At the same time, the connector 100 may be relatively well resistant to accidental decoupling or disengagement during further vehicle manufacturing processes, transportation, or use.

[0019] like Figures 1 to 3 As shown, the connector 100 includes a first housing portion 110 configured to receive a second housing portion 120 in a seated alignment to form a housing of the connector 100. The first housing portion 110 and / or the second housing portion 120 may include one or more features that enable an operator to reliably arrange the first housing portion 110 and the second housing portion in a seated alignment.

[0020] For example, Figure 2 As shown, the first housing portion 110 includes an alignment feature 119 configured to receive a ridge 129 present on the second housing portion 120 and an upper surface 115 configured to interact with a corresponding surface 125 of the second housing portion 120 in a sliding engagement. Figure 3 As shown, the first housing portion 110 may further include a stopper 118 , which is used to define a seating position of the second housing portion 120 relative to the first housing portion 100 .

[0021] In an operation as part of the vehicle manufacturing process, a human or machine operator can align the ridge 127 of the second shell portion 120 within the feature 119 and push the second shell portion 120 along the surface 115 of the second shell portion 120 until it reaches the stop 118, thereby defining the seating position of the second shell portion 120 relative to the first shell portion 110.

[0022] like Figure 1 and Figure 2 As shown, the first housing portion 110 includes a first lock 130. The first lock 130 is a rod lock that includes a rod fixed to the first housing portion 110. Figure 1 As shown, the first lock 130 includes a gear 134 (one positioned on each side of the first lock 130), the gear 134 being arranged to engage with a corresponding gear 114 also fixed to the first housing 110, the gear 114 defining the first lock 130 in the following manner: Figure 3 The unlocked position shown is the same as Figure 1 and Figure 4 The range of motion between the locked positions shown fixes the first housing portion 110 and the second housing portion 120 in a seated alignment. The gears 114, 134 can also limit the range of motion of one or more terminal arrays housed in the connector 100 and engage in mating engagement to form multiple electrical connections (electrical connections) in response to the first lock 130 moving to the locked position.

[0023] Figure 3 1 is a schematic diagram of an example electrical connector according to some embodiments showing the first lock 130 in an unlocked position. In this position, the first lock 130 is in a raised position relative to the first housing 110, and the second housing portion 120 is seated in alignment with the first housing portion 110, but is not secured by the first lock 130. A human or machine operator can move the first lock 130 from the unlocked position to the unlocked position by moving the lever downward toward the first housing portion 110. Figure 1 and Figure 4 The locked position shown in FIG. 1 causes the rod to engage with the second housing portion 120 to secure the first housing portion 110 and the second housing portion 120 in a seated alignment. For example, moving the first lock 130 to the locked position can secure at least a portion of the second housing portion 120 between the rod and the first housing portion 110.

[0024] like Figure 4 As shown, according to some embodiments, the second housing portion 120 includes a rod securing feature 128. The feature 128 protrudes from the second housing portion 120 in the path of the first lock 130 and is configured to act as a spring, depressing in response to the force applied by the rod, allowing the rod to move past the feature 128 and reach the locked position. In the locked position, as shown in FIG. Figure 4 As shown, the feature 128 rests above the rod and exerts a downward force on the rod, thereby preventing the operator from opening the first lock 130 unless the feature 128 is pressed to release the rod. In this way, in the locked position, the first lock 130 interacts with the second housing portion 120 to secure the first housing portion 110 and the second housing portion 120 together and aligned.

[0025] like Figure 1 , Figure 2 and Figure 5 As shown in the example of FIG. 1 , the connector 100 includes a connector position assurance (CPA) device 140, which includes a second locking member 150 according to some embodiments. The CPA device 140 is configured to interact with the first locking member 130 and the second housing portion 120 to retain the first locking member 130 in a locked position, such as Figure 1The second locking member 150 interacts with the first housing portion 110 to further secure the first housing portion 110 and the second housing portion 120 in a seated alignment.

[0026] like Figure 5 As shown in the example of FIG. 1 , the CPA device 140 includes a body 141 supporting a tongue 144, a pair of alignment arms 147, and a second locking member 150. Figure 1 , Figure 2 and Figure 3 As shown, the first lock 130 includes a CPA channel 133 that is sized, shaped, and arranged to receive the CPA device 140 (i.e., the alignment arm 147) therein in a sliding engagement. Figure 3 , the second housing portion 120 includes a CPA aperture 123 disposed proximal to and below the rod securing feature 128. Figure 3 , FIG. 6A to FIG. 6B as well as Fig. 7A and Figure 7B , the first housing portion 110 is shown having a flange 116 that is configured to interface with a second lock 150 of the CPA device 140 .

[0027] Fig. 6A is a schematic diagram showing that the CPA device 140 is in a preparatory position in the first locking member 130, Fig. 7A is a cross-sectional view showing the CPA device 140 in a preparatory position. Figure 6B is a perspective view showing the CPA device 140 after being moved to the working position to retain the first locking member 130 in the locked position, Figure 7B is a cross-sectional view showing the CPA device 140 after being moved to the working position.

[0028] The alignment arm 147 is sized and shaped to fit within the CPA channel 133 and to support and align the CPA device 140 in the ready position. Fig. 6A and Fig. 7A As shown, in the ready position, the arm 147 is arranged with the CPA channel 133, which presents the tongue 144 aligned with the CPA aperture 123, and the second locking member 150 is shown in a position to engage the ledge 116, as shown in FIG. Fig. 7A shown.

[0029] The alignment arm 147 also defines the working position of the CPA device 140 relative to the first lock member 130. For example, Figure 7BAs shown in the cross-sectional view of FIG. 1 , the alignment arm 147 (and corresponding channel 133) can extend to a length sufficient to allow the tongue 144 to enter the CPA aperture 123 and engage the rod securing feature 128 to prevent it from being depressed, and / or to enable the second lock 150 to slide into engagement with the protruding edge 116. In addition, the alignment arm 147 may include one or more features 146 (such as Figure 5 ), which corresponds to one or more corresponding features 136 defined in the CPA channel 133 (such as Figure 2 and Figure 3 140 ) to define a fully operational position of the CPA device 140 and / or to secure the position of the CPA device 140 within the CPA channel 133.

[0030] like Fig. 7A and Figure 7B As shown, when the CPA device 140 is moved into the working position within the CPA channel 133 by a human or machine operator, the tongue 144 extends through the CPA aperture 123 between the first housing 110 and the rod securing feature 128. In the working position, the tongue 144 applies a force opposing the feature 128, preventing the feature 128 from being depressed unless the CPA device 140 is removed. Figure 7B As shown, when the CPA device 140 is moved to the operating position within the CPA channel 133, the second lock 150 slides into engagement with the ledge 116, thereby applying a force opposing the ledge 116 to further secure the first housing portion 110 and the second housing portion 120 in the seated alignment.

[0031] According to various embodiments described herein, the electrical connector 100 includes a first lock 130 and a second lock 150, the first lock 130 functions to keep the first housing portion 110 and the second housing portion 120 seated and aligned, and the second lock 150 further keeps the first housing portion 110 and the second housing portion 120 seated and aligned. In some examples, the first lock 130 interacts with the second housing portion 120 (e.g., the lever fixing feature 128), and the second lock 150 interacts with the first housing portion 110 (e.g., the protruding edge 116). In some examples, the first lock 130 holds the first housing portion 110 and the second housing portion 120 by providing a force opposite to separating the first housing portion 110 and the second housing portion 120, and the second lock 150 provides another force opposite to separating the first housing portion 110 and the second housing portion 120. In this manner, unlike the first latch 130 and the tongue 144, which both interact with the second housing portion 120, the second latch 150 interacts with the first housing portion 110 (e.g., the flange 116) to further secure the first housing portion 110 and the second housing portion 120 in a seated alignment. Thus, the second latch 150 serves to further prevent the connector 100 from being accidentally uncoupled.

[0032] like Figure 5 As shown in the example of FIG. 1 , the second locking member 150 includes an extension portion 154 and an engagement portion 152, both of which are sized, shaped and arranged to slideably engage with the protruding edge 116. For example, now referring to Figure 8 , which shows the CPA device 140 in the ready position, the ledge 116 may have a width D1, and the engagement portion 152 may be formed to have a width D2 substantially similar to the width D1. As another example, the extension portion 154 may be formed to extend the engagement portion 152 to engage with the ledge 116 in the working position. For example, the extension portion 154 may be formed to extend the engagement portion 152 to a certain depth so that when the CPA device 140 moves from the ready position to the working position within the CPA channel 133, the engagement portion is closely engaged with the ledge 116. Referring again to Figure 8 , the length of the extension portion 154 may be substantially equal to the distance between the CPA tongue 144 and the protruding edge 116 .

[0033] In some examples, reference Figures 1 to 3 In some examples, the first housing portion 110 includes a lip 112, a surface of which defines a ledge 116. According to these examples, when a first surface 117 of the lip 112 is arranged in seating alignment with the first housing portion 110, it is opposite to the second housing portion 120 (e.g., surface 127), and a second surface of the lip 112 opposite the first surface 117 defines the ledge 116. According to these examples, the length of the extension 154 can be defined by a distance D3 from the upper surface of the lip 112 to the tongue 144 plus a depth D4 of the lip, as shown in FIG. Figure 8 shown.

[0034] Fig. 9 is a flow chart depicting one example of a method 900 for providing an electrical connector (eg, electrical connector 100) according to some embodiments. Fig. 9 As shown, at step 901, the method includes forming a first housing portion (e.g., 110). Fig. 9 As shown, at step 902, the method includes forming a second housing portion (e.g., 120) configured to be seated and aligned with the first housing portion to form a housing of an electrical connector. In some examples, the housing of the electrical connector can accommodate at least one electrical connection formed between electrical conductors as part of a vehicle electrical system.

[0035] like Fig. 9As shown, at step 903, the method includes forming a first lock (e.g., first lock 130) on the first housing portion, the first lock including a rod that can rotate between an unlocked position and a locked position, in which the second housing portion can be moved away from the first housing portion, and in which the first housing portion and the second housing portion are fixed in a seated alignment. For example, the first lock 130 can be configured to dock with the second housing portion to fix the first housing portion and the second housing portion in a seated alignment. For example, the first lock 130 can dock with a rod fixing feature (e.g., rod fixing feature 128) of the second housing portion to fix the first housing portion and the second housing portion in a seated alignment. For example, moving the rod to the locked position may cause the rod fixing feature to be depressed in response to the movement of the rod and apply a force opposite to the rod when the rod reaches the locked position. In some examples, the rod fixing feature is arranged to be depressed to release the rod from the locked position.

[0036] Still Fig. 9 As shown, at step 904, the method includes forming a connector position assurance (CPA) device (e.g., CPA device 140) configured to engage with the first lock in the working position to maintain the first lock in the locked position. For example, the CPA device 140 may include an alignment arm (e.g., alignment arm 147) configured to interface with a channel (e.g., channel 133) shown on the first housing portion, which aligns a tongue (e.g., tongue 144) of the CPA device with a corresponding aperture (e.g., CPA aperture 123) presented on the second housing portion. The CPA aperture 123 may be disposed proximal to a rod securing feature (e.g., rod securing feature 128) presented on the second housing portion. When moved to the ready position, the CPA tongue extends into the CPA aperture, exerting an upward force on the rod securing feature, thereby preventing the first lock from disengaging. In this manner, the CPA device interacts with the second housing portion to secure the first lock in the locked position.

[0037] like Fig. 9 As shown, at step 905, the method includes forming a second lock (e.g., second lock 150) that further secures the first housing portion and the second housing portion in a seated alignment in a working position (e.g., of a CPA device). The second lock can be formed as part of the CPA device. When in the ready position, the second lock is shown with a surface that slidably engages with a ledge (e.g., flange 116) presented by the first housing portion. By engaging with the ledge, the second lock provides additional force to prevent accidental separation of the first housing portion and the second housing portion. In this way, in addition to the first lock, the second lock also secures the connector housing in a seated alignment.

[0038] In some examples, the first lock is formed to engage with the second housing portion to secure the first housing portion and the second housing portion in a seated alignment. In some examples, the CPA device is formed to engage with the second housing portion to retain the first lock in a locked position. In some examples, in addition to the first lock, a second lock is formed to engage with the first housing portion to further secure the first housing portion and the second housing portion in a seated alignment.

[0039] Although the present invention has been described with reference to one or more exemplary embodiments, it will be appreciated by those skilled in the art that various changes may be made and elements thereof may be replaced by equivalents without departing from the scope of the present invention. In addition, many modifications may be made to adapt specific circumstances or materials to the teachings of the present invention without departing from the basic scope of the present invention. Therefore, the present invention is not intended to be limited to the disclosed one or more specific embodiments, but will include all embodiments falling within the scope of the appended claims.

Claims

1. An electrical connector, comprising: a first housing portion configured to receive a second housing portion in seated alignment to form a housing for the electrical connector; a first lock on the first housing portion, the first lock comprising a lever rotatable between an unlocked position in which the second housing portion is removable from the first housing portion and a locked position in which the first housing portion and the second housing portion are secured in a seated alignment; a connector position assurance device, the connector position assurance device engaging with the first locking member in the working position to maintain the lever in the locked position; as well as A second lock further secures the first housing portion and the second housing portion in a seated alignment in the operating position.

2. The electrical connector according to claim 1, characterized in that: The first lock engages the second housing portion to secure the first housing portion and the second housing portion in a seated alignment, wherein the second lock engages the first housing portion in the working position to further secure the first housing portion and the second housing portion in a seated alignment.

3. The electrical connector according to claim 2, characterized in that: The connector position assurance device engages the second housing portion to retain the lever in a locked position.

4. The electrical connector according to claim 2, characterized in that: When the connector position assurance device moves from the ready position to the operating position, the second locking element engages with the protruding edge of the first housing portion.

5. The electrical connector according to claim 4, characterized in that: In the locked position, the second housing portion engages a first surface of a lip on the first housing portion, wherein in the operative position, the second locking element engages a ledge presented by a second surface of the lip.

6. The electrical connector according to claim 1, characterized in that: The second locking member includes an extending portion and an engaging portion.

7. The electrical connector according to claim 6, characterized in that: When the connector position assurance device moves from the ready position to the working position, the extension portion extends the engagement portion to abut against and oppose the protruding edge provided by the first housing portion.

8. The electrical connector according to claim 7, characterized in that: When the connector position assurance device moves from the ready position to the working position, the connector position assurance device engages with the first lock to maintain the rod in the locked position via a tongue extending through an opening in the second shell part; wherein the length of the extension portion is substantially equal to the distance between the tongue and the protruding edge.

9. A method comprising: forming a first housing portion; forming a second housing portion configured to be seated in alignment with the first housing portion to form a housing for the electrical connector; forming a first lock on the first housing portion, the first lock comprising a lever rotatable between an unlocked position in which the second housing portion is removable from the first housing portion and a locked position in which the first housing portion and the second housing portion are secured in a seated alignment; forming a connector position assurance device configured to engage with the first locking member in an operative position to retain the lever in a locked position; as well as A second lock is formed that further secures the first housing portion and the second housing portion in a seated alignment in the operating position.

10. The method according to claim 9, characterized in that Also includes: The first locking element is formed to engage with the second housing portion in the locked position, and the second locking element is formed to engage with the first housing portion in the operating position.

11. The method according to claim 9, characterized in that Forming the first housing portion includes forming a bead on the first housing portion.

12. The method according to claim 10, characterized in that Also includes: The second locking member is formed to abut against the protruding edge.

13. The method according to claim 11, characterized in that The connector position assurance device also includes a tongue formed in the working position extending through the aperture in the second housing portion; and further comprising: The second locking element is formed, and the depth of the second locking element is substantially equal to the distance between the tongue piece and the protruding edge.

14. The method according to claim 9, characterized in that Also includes: The connector position assurance device is formed to interface with the second housing portion to retain the lever in the locked position.

15. A connector position assurance device, comprising: a fixing arm arranged to fit in a channel of a first locking element of an electrical connector including a rod in a preparatory position of the connector position assurance device and to fix the connector position assurance device to the rod in an operating position of the connector position assurance device; a tongue feature configured to retain the first latch in the working position in a locked position to secure the first housing portion and the second housing portion in a seated alignment to form a housing of the electrical connector; as well as A second lock further secures the first housing portion and the second housing portion in seated alignment.

16. The connector position assurance device according to claim 15, characterized in that: Also includes: Snap features are shown on the pair of arms, which are configured to interface with corresponding snap features shown on the rod to define the working position and / or secure the connector position assurance device in the working position.

17. The connector position assurance device according to claim 15, characterized in that: The second lock engages with the first housing portion of the electrical connector to retain the first lock in the locked position, and the first lock engages with the second housing portion in the locked position.

18. The connector position assurance device according to claim 15, characterized in that: The second locking element is configured to engage a ledge provided by the first housing portion in the operative position.

19. The connector position assurance device according to claim 15, characterized in that: The second locking member includes an extending portion and an engaging portion.

20. The connector position assurance device according to claim 16, characterized in that: The extension portion extends the engagement portion to engage with a protruding edge of the first housing portion in the working position.

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