Electric connector assembly

Abstract

The electrical connector assembly has an auxiliary lever pivotable to pull the first electrical connector into contact with the second electrical connector and a CPA member slidably mounted in the auxiliary lever for selectively locking the auxiliary lever in position relative to the first electrical connector. The electrical connector assembly has a spring terminal mountable within the main housing and retained by a resiliently flexible mounting latch. The electrical connector assembly has an external electromagnetic shielding member mountable within the main housing and retained by the resiliently flexible retention tab.

Description

Background of the Invention

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

[0003] Electrical connector assemblies are known to provide convenient and quick electrical connections. Some electrical connector assemblies may employ a cantilever lever to assist in engaging the electrical connector pair. Some electrical connector assemblies may also provide a connector position assurance (CPA) to ensure that the connection remains securely in place. It is desirable to provide an electrical connector assembly having a cantilever lever and a CPA element that is relatively quick and easy to assemble, relatively quick and easy to mate the connectors together, and maintain the connectors in a desired position. SUMMARY OF THE INVENTION

[0005] According to one aspect, an embodiment provides an electrical connector assembly, which includes: a first electrical connector, the first electrical connector including a main housing, the main housing having a pair of opposing lever pivot pins extending in a lateral direction, an opening configured to receive a second electrical connector, and a locking flange extending in a longitudinal direction and including a locking channel; an auxiliary lever, the auxiliary lever including a pair of spaced lever arms extending in the longitudinal direction and connected by a lever cross member, wherein each lever arm includes a pivot pin hole, the pivot pin hole being configured to cooperate with a corresponding one of the lever pivot pins to pivotally mount the auxiliary lever to the main housing, the auxiliary lever also including a pair of cam grooves (cam The auxiliary lever comprises a cam slot configured to cooperate with a corresponding cam pin of the second electrical connector and to selectively cam the second electrical connector toward and away from the main housing when the auxiliary lever is pivoted relative to the main housing, and the auxiliary lever comprises a CPA cavity in the lever cross member; and a CPA member slidably received in the CPA cavity for sliding in a longitudinal direction and comprising a pair of slider arms that retain the CPA member in the lever cross member for pivoting with the auxiliary lever, and a locking arm configured to longitudinally slide into the locking channel when the auxiliary lever is in the connector fixing position to selectively prevent the auxiliary lever from pivoting relative to the main housing.

[0006] According to one aspect, an embodiment provides an electrical connector assembly including an auxiliary rod for assisting in connecting a pair of electrical connectors together. According to one aspect, an embodiment provides a connector position assurance (CPA) member that ensures that the connector remains in a fully connected position. The CPA member may include a locking arm that selectively fixes the CPA member and the auxiliary rod in a connector fixing position relative to the main housing of the electrical connector assembly. The CPA member may include a disengaging force arm that selectively fixes the CPA member relative to the auxiliary rod. The CPA member may include a sliding arm and a retaining hook that slidably retains the CPA member to the auxiliary rod. The auxiliary rod may include a cam groove that can engage with a cam pin on a second electrical connector to pull the second electrical connector into a fully contacted state (connection safety position) when the auxiliary rod pivots around a rod pivot pin extending from the first electrical connector.

[0007] According to one aspect, an embodiment provides a spring terminal that can be formed from a single piece of metal that is mounted in an electrical connector assembly without requiring welding, adhesives, or fasteners to hold the spring terminal in place. The spring terminal can be secured in place with a mounting latch that engages a retaining slot in a connector body. The spring terminal can be secured in place by a contact spring retaining flange that extends from a main housing of the electrical connector assembly.

[0008] According to one aspect, an embodiment provides an external electromagnetic (EM) shielding that is mounted to a main housing using retaining tabs and a seating flange that engage an outer wall of an opening in the main housing of a first electrical connector. The external electromagnetic shielding does not require fasteners, adhesives, or welding to be retained in the installed position. The external EM shielding may include ribs that contact an internal electromagnetic (EM) shielding to provide continuous electromagnetic shielding between the external EM shielding and the internal EM shielding.

[0009]

[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

[0011] Figure 1 is a schematic perspective view of a portion of an electrical connector assembly.

[0012] Figure 2 Shown from different perspectives Figure 1 A schematic perspective view of a portion of an electrical connector assembly.

[0013] Figure 3Shown from different perspectives Figure 1 A schematic perspective view of a portion of an electrical connector assembly.

[0014] Figure 4 is a schematic perspective view of a main housing of an electrical connector assembly.

[0015] Figure 5 is a schematic perspective view of a connector position assurance (CPA) component.

[0016] Figure 6 is a schematic partial cross-sectional view of a CPA member positioned in a locked position relative to the main housing.

[0017] Figure 7 is a schematic perspective view of the auxiliary rod.

[0018] Figure 8 is a schematic partial cross-sectional elevation view of a CPA member mounted to an auxiliary pole.

[0019] Fig. 9 is a schematic partial cross-sectional perspective view of a CPA member mounted to an auxiliary rod.

[0020] Fig.10 is a schematic perspective view of a connector body on which a spring terminal is mounted.

[0021] Fig.11 is a schematic partial cross-sectional perspective view of a connector body with a spring terminal mounted thereon.

[0022] Fig.12 is a schematic partial cross-sectional perspective view of a connector body mounted to a primary body.

[0023] Fig.13 is a schematic perspective view of a spring terminal.

[0024] Fig.14 is similar to Figure 4 However, it is a schematic perspective view of the main housing shown from a different perspective.

[0025] Fig.15 is a schematic perspective view of an external EM shield.

[0026] Fig.16 is a schematic partial cross-sectional perspective view of an external EM shield mounted to a main housing.

[0027] Fig.17 is a schematic partial cross-sectional perspective view of an outer EM shield and an inner EM shield mounted to a main housing.

[0028] Fig.18 is a schematic partial cross-sectional perspective view of an outer EM shield and an inner EM shield mounted to a main housing.

[0029] Detailed Description of the Preferred Embodiments

[0030] Reference now Figure 1-Figure 3 , shows an example of an electrical connector assembly 20. The electrical connector assembly 20 includes a first electrical connector 22 and a second electrical connector 24 (a portion of the second electrical connector 24 is located at Figure 1 2). The first electrical connector 22 includes a main housing 26 that receives a cable 28. An auxiliary lever 30 is pivotally mounted to the main housing 26, and a connector position assurance (CPA) member 32 is slidably mounted to the auxiliary lever 30. Before the second electrical connector 24 is inserted into the first electrical connector 22, a protective cap 25 can be mounted to the first electrical connector 22. The protective cap 25 can be used, for example, to hold a face seal (not shown) in place on the first electrical connector 22 before the first electrical connector 22 is assembled to the second electrical connector 24.

[0031] When referring to the orientation of the components of the electrical connector assembly 20 herein, the longitudinal direction 31 is oriented in Figure 2 in the direction of the arrow 31 shown, and the transverse direction 33 is oriented in Figure 2 In the direction of arrow 33 shown.

[0032] Now given Figure 1-Figure 3 refer to Figure 4-Figure 9 In the example shown, the main housing 26 includes an opening 34 for receiving the second electrical connector 24, a pair of lever pivot pins 36 extending in the lateral direction 33 (the auxiliary lever 30 pivots around the pair of lever pivot pins 36), and a pair of locking flanges 38, each locking flange 38 including a locking channel 40, which is configured to receive a corresponding one of a pair of locking arms 42 extending from the main body 44 of the CPA member 32 along the longitudinal direction 31.

[0033] In addition to the pair of locking arms 42, the CPA member 32 includes a pair of separation lever arms 46 extending from the main body 44 generally parallel to the locking arms 42, a pair of slide arms 48 extending from the main body 44 generally parallel to the locking arms 42, and a finger pull flange 50 extending across the main body 44 in the lateral direction 33. The separation lever arms 46 are resiliently flexible and each separation lever arm includes a retaining tab 52 extending away from the separation lever arm 46. Each slide arm 48 includes a longitudinally extending slot 54 and a retaining hook 56 extending laterally outward from the slide arm 48.

[0034] The auxiliary lever 30 includes a pair of lever arms 58 extending generally in the longitudinal direction 31, and the pair of lever arms 58 are connected by a lever cross member 60 extending between the lever arms 58. Each lever arm 58 includes a pivot pin hole 62, which cooperates with a corresponding one of the lever pivot pins 36 for pivoting about an axis extending generally in the transverse direction 33. Each lever arm 58 also includes a cam slot 64, which is configured to cooperate with, accommodate and release a cam pin 66 of the second electrical connector 24. The cam slot 64 can also cooperate with, accommodate and release a pin 67 of the protective cap 25 to hold the protective cap 25 in place before assembling the first electrical connector 22 and the second electrical connector 24. The lever cross member 60 includes a CPA cavity 68, which is configured to slidably receive the CPA member 32. The retaining hook cavity 70 within the CPA cavity 68 is configured to cooperate with the retaining hook 56.

[0035] The assembly and operation of the auxiliary rod 30 and the CPA member 32 will now be discussed. The CPA member 32 slides into the CPA cavity 68 of the auxiliary rod 30 (generally in the longitudinal direction 31), and as the retaining hooks 56 begin to slide into the CPA cavity 68, the longitudinally extending slots 54 allow the sliding arms 48 to bend elastically. As the CPA member 32 slides further into the CPA cavity 68 (in the longitudinal direction 31), the retaining hooks 56 reach their respective retaining hook cavities 70, wherein the extending slots 54 expand to push the retaining hooks 56 (in the transverse direction 33) into the retaining hook cavities 70. The CPA member 32 is now retained in the auxiliary rod 30. As the CPA member 32 slides into the CPA cavity 68, the retaining tabs 52 of the separation lever arms 46 cause the separation lever arms 46 to bend elastically, thereby retaining the CPA member 32 in the released position (as shown in FIG. 1 ). Fig. 9 The release position is when the auxiliary lever 30 is pivoted to the full contact (connector fixed) position (as shown in FIG. Figure 2 2. The position of the CPA member 32 relative to the auxiliary lever 30 when the CPA member 32 is not engaged with the main housing 26 (as shown).

[0036] The auxiliary lever 30 is mounted to the main housing 26 by bending the lever arm 58 outwardly in the lateral direction and moving the lever arm 58 around the lateral sides of the main housing 26 until each pivot pin hole 62 of the lever arm 58 is aligned with a corresponding lever pivot pin 36 of the main housing 26. The auxiliary lever 30 can now pivot relative to the main housing 26 about a laterally extending axis.

[0037] Connecting the first electrical connector 22 to the second electrical connector 24 includes pivoting the auxiliary lever 30 about the lever pivot pin 36 to a connector engagement position. The connector engagement position is when the auxiliary lever 30 (from Figure 1-Figure 334. The auxiliary lever 30 is then pivoted counterclockwise such that the lever cross member 60 pivots away from the main housing 26 and the opening at the end of the cam slot 64 extends outwardly from the main housing 26 to a position adjacent to and on the opposite side of the opening 34. The second electrical connector 24 is then aligned with the first electrical connector 22 on the side of the main housing 26 having the opening 34 so that the cam pin 66 will slide through the opening into the corresponding cam slot 64. The first electrical connector 22 and the second electrical connector 24 are pushed toward each other until the cam pin 66 is in the corresponding cam slot 64. Then, as the auxiliary lever 30 pivots, the auxiliary lever 30 pivots from the connector engagement position to the full contact (connector securing) position where the cam pin 66 engages the cam slot 64, thereby pulling the first electrical connector 22 and the second electrical connector 24 into full engagement with each other.

[0038] At this point, with the auxiliary lever 30 in the full contact (connector secured) position, the CPA member 32 is now adjacent the locking channel 40 of the locking flange 38 on the main housing 26. The CPA member 32 then slides longitudinally from its released position to a locked position in which the locking arm 42 engages in the locking channel 40 of the locking flange 38. The locked position is Figure 1 , Figure 6 and Figure 8 As the CPA member 32 slides into the locked position, the retaining tab 52 is aligned with the retaining tab cavity 71 in the rod cross member 60 and is bent downwardly into the retaining tab cavity 71 (as shown in FIG. Figure 8 ), thereby holding the CPA member 32 in the locked position. The CPA member 32 in the locked position prevents the lever cross member 60 of the auxiliary lever 30 from moving away from the main housing 26, thereby preventing the auxiliary lever 30 from pivoting. This keeps the first electrical connector 22 and the second electrical connector 24 fully engaged.

[0039] To separate the first electrical connector 22 from the second electrical connector 24, one can use one's fingers to pull on the flange 50 to pull the CPA member 32 with sufficient force to bend the separation lever arm 46 and allow the retention tab 52 to lift out of the retention tab cavity 71. The CPA member 32 then slides longitudinally until the retention hook 56 engages the end of the retention hook cavity 70 (e.g., Fig. 9 As shown in FIG. 1 , the CPA member 32 is moved to the release position. The CPA member 32 remains mounted on the auxiliary rod 30. When the CPA member 32 is slid into the release position, the locking arm 42 slides out of the locking channel 40. The auxiliary rod 30 can now be moved (relative to the Figure 1 The camming mechanism 60 is pivoted in a counterclockwise direction (as shown) with the cam slot 64 acting on the cam pin 66 to push the first and second electrical connectors 22 and 24 apart.

[0040] Now given Figure 1-Figure 3 refer to Figure 10-13 In the example shown, the connector body 72 is housed within the main housing 26. The connector body 72 includes a pair of cable channels 74, contact spring cavities 76, and alignment posts 78, the pair of cable channels 74 receiving the ends of the cables 28, each contact spring cavity 76 being aligned with a corresponding one of the cable channels 74 and configured to receive a corresponding spring terminal 80, and the alignment posts 78 being adjacent to the contact spring cavity 76. Each spring terminal 80 includes a pair of contact spring portions 82 connected by a base flange 84, a pair of mounting flanges 86, and a mounting latch 90, the pair of contact spring portions 82 being connected by a base flange 84, each mounting flange 86 including an alignment hole 88, the alignment hole 88 cooperating with the corresponding alignment post 78 to align the spring terminal 80 in the corresponding contact spring cavity 76, and the mounting latch 90 being angled to engage a retaining groove 92 in the connector body 72 to retain the spring terminal 80 in the corresponding contact spring cavity 76. The contact spring retaining flange 94 may extend from a portion of the main housing 26 to help secure the spring terminals 80 in their respective contact spring cavities 76. Each spring terminal 80 may be formed from a single piece of sheet metal and may be assembled to the connector body 72 with an elastic snap fit - thus, no fasteners, adhesives, or welding are required to retain the spring terminals 80 in the contact spring cavities 76. The contact spring portions 82 allow for a resilient connection of the electrical contacts.

[0041] Now given Figure 1-Figure 3 refer to Figure 14-18 In the example shown in FIG. 1 , an external electromagnetic (EM) shield 96 is mounted within the opening 34 of the main housing 26. The external EM shield 96 is made of a material that allows electromagnetic shielding of the connector in the electrical connector assembly 20. The external EM shield 96 includes a retaining tab 98 and a base flange 99. The retaining tab 98 is angled radially outward from a wall 100 of the external EM shield 96 and is spaced from the base flange 99 so that when the external EM shield 96 is slid into the opening 34, the retaining tab 98 contacts the outer wall 102 of the opening 34 and elastically bends radially inward until it touches the lip 104 at substantially the same position as the end of the base flange 99 abutting the outer wall 102, at which time the retaining tab 98 springs outward. This secures the external EM shield 96 to the main housing 26. The external EM shield 96 also includes an axially extending rib 106 that protrudes radially outward. The rib 106 is configured to contact the internal electromagnetic (EM) shield 108. The inner EM shield 108 is radially larger than the outer EM shield 96 and includes ribs 110 that contact the ribs 106 on the outer EM shield 96 and abut the rim 104 to position the inner EM shield 108 relative to the outer wall 102 of the opening 34. The inner EM shield 108 is made of a material that allows for electromagnetic shielding of the connector in the electrical connector assembly 20.

[0042] The principles and modes of operation of the present invention have been explained and illustrated in the preferred embodiments of the present invention. However, it must be understood that the present invention can be practiced in a manner different from that specifically explained and illustrated without departing from the spirit or scope of the present invention.

Claims

1. An electrical connector assembly, comprising: a first electrical connector comprising a main housing having a pair of opposed lever pivot pins, an opening, and a locking flange, the lever pivot pin extending in a transverse direction, the opening being configured to receive a second electrical connector, the locking flange extending in a longitudinal direction and comprising a locking channel; an auxiliary lever including a pair of spaced apart lever arms extending in a longitudinal direction and connected by a lever cross member, wherein each lever arm includes a pivot pin hole configured to cooperate with a corresponding one of the lever pivot pins to pivotally mount the auxiliary lever to the main housing, the auxiliary lever including a pair of cam slots configured to cooperate with corresponding cam pins of the second electrical connector and selectively cam the second electrical connector toward and away from the main housing when the auxiliary lever is pivoted relative to the main housing, and the auxiliary lever includes a CPA cavity in the lever cross member; as well as a CPA member slidably received in the CPA cavity for sliding in the longitudinal direction, and including a pair of sliding arms that retain the CPA member in the rod cross member for pivoting with the auxiliary rod, and including a locking arm that is configured to slide longitudinally into the locking channel to selectively prevent the auxiliary rod from pivoting relative to the main housing when the auxiliary rod is in the connector securing position.

2. The electrical connector assembly according to claim 1, wherein: The rod cross member includes a retention tab cavity adjacent to the CPA cavity, and the CPA member includes a separation lever arm having a retention tab extending therefrom, wherein when the CPA member slides longitudinally to the locked position, the retention tab engages the retention tab cavity to bias the CPA member to prevent the CPA member from moving out of the locked position.

3. The electrical connector assembly according to claim 2, wherein: The rod cross member includes a second retaining tab cavity adjacent to the CPA cavity, and the CPA member includes a second separation lever arm having a second retaining tab extending from the second separation lever arm, wherein when the CPA member slides longitudinally to the locked position, the second retaining tab engages the second retaining tab cavity to bias the CPA member to prevent the CPA member from moving out of the locked position.

4. The electrical connector assembly according to claim 2, wherein: The retention tab is configured to abut the rod cross member such that when the CPA member is not in the locked position, the separation lever arm resiliently flexes to bias the CPA member to retain the CPA member out of the locked position.

5. The electrical connector assembly according to claim 4, wherein: The first electrical connector includes a contact spring cavity having a pair of contact spring fixing flanges, and wherein the electrical connector assembly includes a spring terminal installed in the contact spring cavity, wherein the spring terminal includes a pair of contact spring parts, a pair of mounting flanges, and a mounting latch, wherein the pair of contact spring parts are connected by a base flange, each mounting flange extends from a corresponding one of the contact spring parts, and the mounting latch extends outward from the mounting flange to elastically engage a corresponding one of the contact spring fixing flanges to retain the spring terminal in the contact spring cavity.

6. The electrical connector assembly according to claim 4, wherein: The main housing includes an outer wall defining the opening, wherein the outer wall includes an edge, and wherein the electrical connector assembly also includes an external electromagnetic shield having a generally cylindrical wall, the external electromagnetic shield including a radially outwardly angled retaining tab, the retaining tab being configured to elastically bend radially inward against the outer wall and elastically bend outward against the edge to retain the external electromagnetic shield in the opening.

7. The electrical connector assembly according to claim 1, wherein: The CPA cavity includes a pair of retaining hook cavities, and each of the sliding arms includes a retaining hook extending from the sliding arm, the retaining hook being configured to be received in a corresponding one of the retaining hook cavities to retain the CPA member in the rod cross member while allowing the CPA member to slide longitudinally relative to the rod cross member.

8. The electrical connector assembly according to claim 7, wherein: Each of the slide arms includes a longitudinally extending slot configured to allow each of the slide arms to bend elastically when the retaining hook moves into the corresponding retaining hook cavity.

9. The electrical connector assembly according to claim 1, wherein: The first electrical connector includes a contact spring cavity having a pair of retaining grooves, and wherein the electrical connector assembly includes a spring terminal mounted in the contact spring cavity, wherein the spring terminal includes a pair of contact spring parts, a pair of mounting flanges, and a mounting latch, wherein the pair of contact spring parts are connected by a base flange, each mounting flange extends from a corresponding one of the contact spring parts, and the mounting latch extends outward from the mounting flange to elastically engage the corresponding one of the retaining grooves to retain the spring terminal in the contact spring cavity.

10. The electrical connector assembly according to claim 9, wherein: Each of the mounting flanges includes an alignment hole, and the first electrical connector includes an alignment post extending from the first electrical connector, the alignment post being configured to engage a corresponding alignment hole to orient the spring terminal in the contact spring cavity.

11. The electrical connector assembly according to claim 9, wherein: The spring terminal is formed from a single piece of sheet metal.

12. The electrical connector assembly according to claim 11, wherein: The main housing includes an outer wall defining the opening, wherein the outer wall includes an edge, and wherein the electrical connector assembly also includes an external electromagnetic shield having a generally cylindrical wall, the external electromagnetic shield including a radially outwardly angled retaining tab, the retaining tab being configured to elastically bend radially inward against the outer wall and elastically bend outward against the edge to retain the external electromagnetic shield in the opening.

13. The electrical connector assembly according to claim 9, wherein: The main housing includes a contact spring retaining flange extending from the main housing, the contact spring retaining flange biased against at least one of the mounting flanges to bias the spring terminal into the contact spring cavity.

14. The electrical connector assembly according to claim 9, wherein: The main housing includes an outer wall defining the opening, wherein the outer wall includes an edge, and wherein the electrical connector assembly also includes an external electromagnetic shield having a generally cylindrical wall, the external electromagnetic shield including a radially outwardly angled retaining tab, the retaining tab being configured to elastically bend radially inward against the outer wall and elastically bend outward against the edge to retain the external electromagnetic shield in the opening.

15. The electrical connector assembly according to claim 1, wherein: The main housing includes an outer wall defining the opening, wherein the outer wall includes an edge, and wherein the electrical connector assembly also includes an external electromagnetic shield having a generally cylindrical wall, the external electromagnetic shield including a radially outwardly angled retaining tab, the retaining tab being configured to elastically bend radially inward against the outer wall and elastically bend outward against the edge to retain the external electromagnetic shield in the opening.

16. The electrical connector assembly according to claim 15, wherein: The external electromagnetic shield includes a base flange configured to abut the outer wall to secure the external electromagnetic shield in the opening when the retention tabs engage the rim.

17. The electrical connector assembly according to claim 16, wherein: The outer electromagnetic shield is formed from a single piece of sheet metal.

18. The electrical connector assembly according to claim 15, wherein: The outer electromagnetic shield is formed from a single piece of sheet metal.

19. The electrical connector assembly according to claim 15, wherein: The generally cylindrical wall includes radially outwardly extending ribs configured to contact the inner electromagnetic shield when the outer electromagnetic shield is installed in the opening.

20. The electrical connector assembly according to claim 19, wherein: The rim is configured to abut an inner shield rib of the inner electromagnetic shield when the inner electromagnetic shield is installed in the main housing.

Images