Electric connector with dual-purpose terminal locking piece

Abstract

An electrical connector that supports different types of electrical connections is described. An electrical connector includes a terminal support unit including an array of apertures and configured to support a terminal module seated in the terminal support unit. The terminal module supports at least one terminal requiring strict relative positioning, such as a high-speed data terminal. The electrical connector includes a terminal lock connected with the terminal support unit to stabilize and lock the terminal array passing through the array of apertures and lock the terminal module in a mating position.

Description

Technical Field

[0001] Electrical connectors are commonly used in many commercial, industrial, and military applications to interface electrical systems, power supplies, signals, computing, and communication systems. In some applications, such as vehicle applications, it may be desirable to have an electrical connector that couples a number of electrical conductors that support a vehicle wiring harness in a single connector or connection system to reduce the cost or complexity associated with installing one or more electrical systems in a vehicle.

[0002] In recent years, vehicles have been designed to support applications such as communication and computing systems that require high-speed data transfer. In some examples, implementing high-speed data cable connections as well as traditional automotive interconnections is a unique challenge in the design, manufacture, and installation of vehicle electrical systems. In some examples, the connection of high-speed data cables such as coaxial cables or twisted pair cables for automotive Ethernet applications has strict coupling standards that require careful control of the interface between male and female terminals. Aptiv's AMEC and AMEC+ Ethernet connection systems are an example of high-speed data cable connections.

[0003] There is a need to improve electrical connectors to support the electrical connection of a number of conductors, including different types of conductors such as high-speed data conductors, in a single connector. There is also a need for connectors that are easy to manufacture and / or install in a vehicle and that can resiliently achieve a desired decoupling (disengagement) during vehicle manufacture, transportation, or use. Summary of the Invention

[0004] Improvements to electrical connectors that support the coupling of different types of electrical terminals are described. According to one example, an electrical connector is described that includes a terminal support unit that includes an array of terminal apertures configured to receive a plurality of terminals. The connector also includes a terminal module configured to sit adjacent to the array of terminal apertures in the terminal support unit and configured to carry at least one terminal. The connector also includes a terminal lock configured to be inserted into a track defined in the terminal support unit to lock the plurality of terminals in matching positions in the array of terminal apertures. The terminal lock also docks with the terminal module to lock the terminal module in a matching position sitting in the terminal support unit.

[0005] According to another example, a method is described. The method includes supporting a plurality of terminals passing through an array of terminal apertures with a terminal support unit that includes the array of terminal apertures. The method also includes sitting a terminal module in the terminal support unit adjacent to the array of terminal apertures, where the terminal module carries at least one terminal. The method also includes inserting a terminal lock into a track defined in the terminal support unit to lock a first plurality of terminals in matching positions of the plurality of terminals in a first array of terminal apertures and docking with the terminal module to lock the terminal module in a matching position in the terminal support unit.

[0006] According to another example, a terminal lock is described. The terminal lock includes a plurality of terminal apertures, the terminal apertures including contact surfaces configured to engage terminals of a terminal array inserted through the apertures. The terminal lock further includes a pair of positioning arms including positioning ends that engage one or more recesses in a track to define the position of the terminal lock. The terminal lock further includes a plurality of engagement features configured to dock with the track to guide the terminal lock to a locked position to stabilize and lock the terminal array through the apertures in a mating position of the terminal array and to engage a terminal module adjacent to the terminal lock to lock the terminal module in a mating position. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] The present invention will now be described by way of example with reference to the accompanying drawings, in which:

[0008] Figure 1 An isometric view of an electrical connector according to one or more embodiments is depicted.

[0009] Figure 2 An exploded view of components of an electrical connector according to one or more embodiments is depicted.

[0010] Figure 3 A top view of an electrical connector according to one or more embodiments is depicted.

[0011] Figure 4 A side view of an electrical connector according to one or more embodiments is depicted.

[0012] Figure 5 A cross-sectional view of an electrical connector according to one or more embodiments is depicted.

[0013] Figure 6 A cross-sectional view of an electrical connector according to one or more embodiments is depicted.

[0014] Figure 7A A top view of a terminal position assurance module of an electrical connector according to some embodiments is depicted.

[0015] Figure 7B An isometric view of a terminal position assurance module according to some embodiments is depicted.

[0016] Figure 7C An alternative isometric view of a terminal position assurance module according to some embodiments is depicted.

[0017] Figure 8A An isometric view of a terminal module according to some embodiments is depicted.

[0018] Figure 8B A cross-sectional view of an electrical connector according to some embodiments is shown;

[0019] Figure 9A Shows a top view of a terminal support unit according to some embodiments, where the terminal lock is in the working position.

[0020] Figure 9B Shows the opposite side of a terminal support unit according to some embodiments, where the terminal lock is in the working position.

[0021] Figure 9C Shows an isometric view of a terminal support unit according to some embodiments, where the terminal lock is in the working position.

[0022] Figure 9D Shows a cross-sectional view of a terminal support unit according to some embodiments, where the terminal lock is in the working position.

[0023] Figure 10A Shows a top view of a terminal support unit according to some embodiments, where the terminal lock is in the locked position.

[0024] Figure 10B Shows the opposite side of a terminal support unit according to some embodiments, where the terminal lock is in the locked position.

[0025] Figure 10C Shows an isometric view of a terminal support unit according to some embodiments, where the terminal lock is in the locked position.

[0026] Figure 10D Shows a cross-sectional view of a terminal support unit according to some embodiments, where the terminal lock is in the locked position.

[0027] Figure 11 Is a flowchart showing a method of forming an electrical connector according to some embodiments. Detailed Description

[0028] The present disclosure is directed to an electrical connector configured to support reliable coupling between multiple electrical terminals, where the multiple electrical terminals include different types of terminals. The described connector includes a terminal lock that can provide advantages over other known electrical connectors, the terminal lock being configured not only to lock the terminals in a mating position, but also to lock the terminal module of the connector in the mating position. For example, the described connector is capable of accommodating many different types of connectors for simultaneous mating, including traditional automotive terminals as well as high-speed data terminals or other terminals with strict relative positioning requirements. In some examples, the described connector may be less costly and / or simpler to implement / install compared to traditional electrical connectors. For example, the described connector can achieve proper mating of complex terminal couplings that require highly precise relative positioning, as well as more traditional array-based connections that may not have such strict coupling requirements, within the same connector. Additionally, compared to traditional electrical connectors, the described connector may be particularly resilient to accidental disconnection.

[0029] Figure 1 is a schematic view depicting an electrical connector 100 in a locked position according to some embodiments. Figure 2 is a view depicting an exploded view of the connector 100 according to some embodiments. Figure 3 is a top view of the connector 100 according to some embodiments. Figure 4 is a side view of the connector 100 according to some embodiments. Figure 5 is along Figure 4 a cross-sectional view of the connector 100 taken along the cutting line 5-5 shown in Figure 6 is a cross-sectional view of the connector 100 taken along the cutting line 6-6 shown in Figure 4 according to some embodiments.

[0030] The connector 100 is configured to receive terminals associated with multiple electrical conductors, such as electrical conductors carried by a cable associated with a vehicle's wiring harness, and enable the conductors to be electrically coupled within the housing 110 of the connector 100. The connector 100 is configured to support the coupling of many cables within the housing 110, and the electrical couplings can include different types of cables. In some examples, the connector 100 can be uniquely configured to couple many traditional automotive conductors, such as conductors carrying data, signals, grounds, or power for various systems associated with a vehicle, as well as to couple other types of conductors, such as high-speed data conductors. For example, the connector 100 can be adapted to couple coaxial and / or twisted pair cables configured to transmit data at very high speeds, as well as traditional automotive cables.

[0031] Now referring to Figure 2, the connector 100 includes a housing 110. The housing 110 supports a terminal support unit 150 within the housing 110, and the terminal support unit is configured to support a first plurality of terminals (not shown) for connection thereto. The connector 100 further includes a terminal support unit 120 configured to support a corresponding second plurality of terminals that terminate the cables of the vehicle wiring harness. The terminal support units 120, 150 are configured to be mated with each other within the housing 110 via a blade stabilizer (terminal piece stabilizer) 170 disposed between the terminal support units 120, 150. In some examples, the blade stabilizer 170 stabilizes and protects the terminals of the connector 100 from damage. Mating the terminal support units 120, 150 together within the housing 110 couples the corresponding first and second pluralities of terminals carried by the terminal support units 150, 120, thereby establishing a plurality of electrical connections within the housing 110.

[0032] As Figure 1 shown, the connector 100 is lockable to fix the terminal support units 120, 150 within the housing 110 and to fix the terminal connection portion within the housing 100. According to Figure 1 an example, the connector includes a lever 103 that is movable from an unlocked position (not shown) to a horizontal or locked position (as Figure 1 shown). The lever 103 interacts with a gear 101 that is configured to interact with a corresponding gear 111 (as Figure 6 shown) fixed to the housing 110, defining the movement of the lever 110 from the unlocked position to the locked position, in which the components within the housing are accessible and removable, while the locked position fixes the internal components in place within the housing 110, as Figure 6 shown in the cross-sectional view. The connector 100 further includes a connector position assurance (CPA) 108 that can be inserted into a slot defined in the lever 103 to interact with the housing 110 to lock the lever 103 in place to prevent the connector 100 from accidentally disconnecting. The connector 100 shown herein is a lever-lock connector that utilizes the lever 103 to secure the connector 100, as an example of a connector locking mechanism. In other embodiments, other types of mechanisms not explicitly depicted or described herein may also be used to lock the connector 100.

[0033] The connector 100 can be installed in a vehicle as part of the vehicle manufacturing process. In some examples, the connector 100 is disposed on the surface of the vehicle and is fixed within the vehicle by straps, ties, screws, bolts, adhesives, or other fixing mechanisms. In other examples, as Figure 1 and Figure 2As shown, the connector 100 can be fixedly attached through an aperture 107 formed in a substrate 105 associated with a vehicle. According to these examples, the housing 110 includes a plurality of slots 106 configured to receive tabs 104 that interface with the substrate 105 around the perimeter of the aperture 107 to secure the connector 100 in a position, such as within a vehicle. The substrate 105 can be, for example, a floor panel or a wall panel of a vehicle component, or other structure associated with a vehicle component.

[0034] As described above, the connector 100 is configured to establish a plurality of electrical connections (electrical connection portions) within the housing 110, including different types of electrical connections, such as high-speed data connections and legacy automotive system connections. Now referring to Figure 5 , the terminal support unit 150 includes an aperture array 151A, 151B and a terminal module 130A located between the aperture arrays 151A, 151B. The terminal support unit 120 similarly includes an aperture array 152A, 152B and a terminal module 130B located between the aperture arrays 152A, 152B. As Figure 5 the example of Figure 6 shows, when the connector 100 is locked as

[0035] shown, the terminal support units 120, 150 mate together within the housing 110 to establish a plurality of terminal connections within the connector 100, including terminals passing through the aperture arrays 151A, 151B, 152A, 152B and terminals supported by the terminal modules 130A and 130B.

[0036] Figures 7A to 7C Depicts a top view, a perspective view, and an alternative perspective view of a terminal lock 140 according to some embodiments. The terminal lock 140 can be configured to stabilize and lock the terminals of the connector 100 in a mating position to mate with corresponding terminals within the connector 100.

[0037] As Figures 7A to 7CAs shown, the terminal locking member 140 includes a plurality of terminal apertures 143 and a plurality of contact surfaces 147. Each terminal aperture 143 is configured to receive an electrical terminal through the aperture 143, and the plurality of contact surfaces 147 are configured to contact and stabilize each terminal and lock it in a matching position within the aperture 143. The terminal locking member 140 further includes a positioning arm 142, and the positioning arm 142 includes a positioning end 145 and an alignment end 148, wherein the alignment end 148 is configured to interact with a corresponding channel 158 formed in the terminal support unit 150 (see Figure 9C ). The terminal locking member 140 further includes locking features 144 disposed at respective corners of the terminal locking member 140. As described in further detail below, the locking features 144 can engage with the terminal support units 120, 150 and the terminal module 130 depicted in FIG. 8 to lock the respective terminals of the connector 100 in matching positions.

[0038] In some examples, the terminal locking member 140 can have an aperture pattern corresponding to the aperture pattern of the aperture arrays 151A, 151B, and in some examples, this aperture pattern can be non-uniform. For example, as Figure 9A the example shows, each of the aperture arrays 151A, 151B includes a leftmost column of apertures that are larger and rounder than the other apertures of the aperture pattern. Referring to Figures 7A to 7C , the terminal locking member 140 has an aperture pattern corresponding to the pattern of the aperture arrays 151A, 151B and includes a leftmost column of apertures that are larger than the other apertures of the terminal locking member 140.

[0039] In some examples, referring to Figure 2 , the terminal locking member 140 can be used as a pair of substantially identical terminal locking members 140A, 140B that are configured to lock terminals in matching positions through corresponding aperture arrays 151A, 151B on opposite sides of the terminal modules 130A, 130B, as Figure 2 and Figure 5 shown. According to these examples, the first pair of terminal locking members 140A and 140B can be substantially identical to each other (e.g., the same parts) and include apertures of different sizes to match the non-uniform aperture arrays 151A, 151B.

[0040] In some examples, the terminal locking members 141A and 141B can similarly include an aperture pattern to match the non-uniform aperture array, and in some examples, the terminal locking members 1411 and 141B are substantially identical to each other (e.g., are the same components). In some examples, the terminal locking members 141A, 141B can have an aperture pattern that is flipped relative to the aperture pattern of the terminal locking members 140A, 140B such that when the terminal locking member 140B is locked and the corresponding terminal support units 120, 150 are matched, apertures of similar size are arranged opposite each other.

[0041] Figure 8A and Figure 8B depicts an isometric view of a terminal module 130 that includes a plurality of terminal apertures 137 on an upper surface 135 of a housing, the terminal apertures 137 being configured to support at least one terminal for connection thereto. For example, the terminal module 130 may carry high-speed data terminals, or other terminals that require a strict relative position for proper mating.

[0042] In some examples, the terminal module 130 supports the connection of multiple high-speed data terminals and / or other conventional terminals according to the needs of a particular application. In some examples, the module 130 may be interchangeable as the module 130 can be swapped out to support different applications. For example, a first pair of modules 130A, 130B that include terminal apertures 137 to support the coupling of coaxial terminals may be interchangeable in terminal support units 120, 150 with a second pair of modules 130A, 130B that include different terminal apertures 137 to support the coupling of another type of high-speed data terminal such as twisted pair terminals. Still other modules 130A, 130B may support the coupling of terminals associated with different types of coaxial cables, different types of twisted pair cables, and / or other types of high-speed data or other cables. In this way, the connector 100 can be specifically customized to support high-speed and other terminal connections suitable for a particular vehicle application.

[0043] As Figure 8A shown, the terminal module 130 includes a bottom surface 133 and may include flanges 136 on opposite outer surfaces 138, 139 of the module 130. Now referring to Figure 5 , the surface 135 and / or the flange 136 may have a profile configured to fit within one or more terminal support units 120, 150. For example, as shown in the example of Figure 5 , the surface 135 and / or the flange 136 may fit within corresponding recesses 171 formed in the bottom surface of the housing 110. In other examples not shown, the surface 135 and / or the flange may similarly interface with the terminal support unit 120.

[0044] Referring again to Figure 8A , the module 130 further includes primary locking features 172 on opposite outer surfaces 138, 139 of the module 130 that are configured to engage corresponding features of the respective terminal support units 120, 150 to secure the module 130 in a working position within the terminal support units 120, 150. Figure 8B depicts an example of a terminal support unit 120 that includes a primary locking feature 182. Although not shown here, the terminal support unit 150 may similarly include a primary lock 182 within an aperture 153.

[0045] In some examples, the terminal module 130 can be inserted into the orifice 153 until the primary locking feature 172 interacts with the primary lock 182, thereby fixing the module 130 in the working position within the terminal support unit 120. In the working position, it may not be easy to remove the terminal module 130 from the terminal support unit 120 without releasing the primary lock 182 such that the feature 172 of the module 130 can move through the lock 182.

[0046] As Figure 8A shown in the example of, the module 130 also includes a plurality of locking features 134 on the respective opposing surfaces 137, 139 of the module 130, which can interact with corresponding features of the connector 100 to lock the module 130 in a mating position within the connector 100. For example, when the terminal module 130 is fixed in the working position by the primary lock 182, the locking features 134 can be arranged relative to the terminal support units 120, 150 to engage with the terminal locks 140, which are configured to lock the terminal module 130 in the mating position such that the terminal locks 140 become secondary locks for locking the terminal module 30 in the mating position.

[0047] Figure 9A is a top view of a side of the terminal support unit 150 according to some embodiments, where the terminal locks 140A, 140B are in the working position. Figure 9B is a top view of an opposing side of the terminal support unit 150 according to some embodiments, where the terminal locks 140A, 140B are in the working position. Figure 9C is an isometric view of the terminal support unit 150 according to some embodiments, where the terminal locks 140A, 140B are in the working position. Figure 9D is according to some embodiments of the terminal support unit 150 along Figure 9A the cutting line 9D depicted in, where the terminal locks 140A, 140B are in the working position.

[0048] Figure 10A is a top view of a side of the terminal support unit 150 according to some embodiments, where the terminal locks 140A, 140B are in the locked position. Figure 10B is a top view of an opposing side of the terminal support unit 150 according to some embodiments, where the terminal locks 140A, 140B are in the locked position. Figure 10C is an isometric view of the terminal support unit 150 according to some embodiments, where the terminal locks 140A, 140B are in the locked position. Figure 10D is according to some embodiments of the terminal support unit 150 along Figure 10A the cutting line 10D depicted in, where the terminal locks 140A, 140B are in the locked position.

[0049] As Figure 9A shown, the terminal support unit 150 includes orifice arrays 151A, 151B. Each of the orifice arrays 151A, 151B includes a plurality of orifices 167 configured to receive terminals of a terminal array (not shown) for electrical connection therewith. In some examples, the orifice arrays 151A, 151B may be configured to carry terminals corresponding to more traditional automotive signal conductors, such as conductors carrying low-speed signals, data, power, or ground conductors related to vehicle systems.

[0050] In addition to the orifice arrays 151A, 151B, the terminal support unit 150 also supports the terminal module 130 in the terminal support unit 50. As Figure 9A shown, the terminal support unit 150 includes an orifice 153 sized and shaped to accommodate the terminal module 130 to fit through the orifice 153 and be fixed in place in the region 152 between the orifice arrays 151A, 151B. In some examples, the terminal module 130 and the terminal support unit 150 include a primary locking feature that secures the terminal module 130 in its working position in the orifice 153, as described above with respect to Figure 8B the terminal support unit 120 depicted in

[0051] Now referring to Figures 9A to 9B , the terminal module 130 may be seated in the terminal support unit 150. For example, the terminal module 130 may be inserted upward into the orifice 153 until the primary lock 182 engages the primary locking feature 172, as shown in the example of Figure 8B . In some examples, in the working position, the locking feature 134 of the terminal module 130 engages the recessed surface 190 adjacent to the tracks 157A, 157B. In some examples, in the working position, the locking feature 134 extends at least partially into the adjacent tracks 157A, 157B.

[0052] The terminal locks 140A, 140B may be inserted into the tracks 157A, 157B formed in the terminal support unit 150 and pushed into the tracks 157A and 157B such that the alignment tabs 148 are aligned in the channels 158 until the positioning ends 145 of the arms 142 reach the first recess 155 in the track 157, which defines the working position of the terminal locks 140B, 140A. The locking features 144 at the respective corners of the terminal locks 140A, 140B may engage the tracks 157 to guide the terminal locks 140B, 140A to their working positions in the tracks 157. In the working position, the orifices 143 of the terminal locks 140A, 140B are aligned with the orifice arrays 151A, 151B of the terminal support unit 150 such that the terminals of the respective terminal arrays (not shown) may be inserted through the orifices 143. Now referring toFigure 9D In the working position, the locking feature 144 does not engage with the locking feature 134 of the module 130.

[0053] Once the corresponding terminal array (not shown) has been inserted through the aperture 143, the terminal locks 140A, 140B can be moved to the locked position by further pushing the terminal locks 140A, 140B into the track 157 until the positioning end 145 interacts with a second recess 156 formed in the track, where the second recess defines the locked position of the terminal locks 140, 140B.

[0054] Reference Figure 10A , when moved to the locked position, the contact surface 147 associated with each aperture 143 of the terminal locks 140A, 140B can contact the terminals supported through the apertures 143 to position each terminal in a mating position. In the locked position, the terminal support unit 150 can mate with a corresponding terminal support unit (such as 120), which itself has a corresponding second terminal locked in the mating position for electrical connection.

[0055] Now refer to Figure 10B and Figure 10D , which shows a top view and a cross-sectional view of the terminal support unit 150, where the terminal locks 140A, 140B are in the locked position and the locking feature 144 of the terminal lock 140B interacts with the locking feature 134 of the module 130 to lock the module 130, including one or more terminals to be supported by the module 130, in the mating position in the connector 100. The locking features 134, 144 can be specifically designed to interact with each other to tightly define the position of the module 130 relative to the terminal support unit 150 such that when mating with a corresponding terminal support unit (e.g., the terminal support unit 120 as shown in Figure 1 and Figure 2 ), the terminals carried by the module 130 are fixed in tightly defined relative positions. In some examples, the locking features 134, 144 are configured to cam the module 130 forward into the track 157 into a tightly locked position relative to the terminal support unit 150.

[0056] In some examples, as shown in Figure 10D , the locking feature 134 and / or the locking feature 144 includes one or more ramp surfaces to facilitate the tightly locked position of the terminal module 130. For example, as shown in Figure 10DAs shown, the locking feature 134 includes a ramp surface 139 that assists the locking feature 144 in traveling to a tight locking position in response to movement of the terminal locks 140A, 140B from the working position to the locking position. For example, the ramp surface 139 can extend into the track 157 and guide the locking feature 144 to a tight locking position relative to the locking feature 134 in the track 157.

[0057] Referring again to Figure 8B the example of, when the terminal module 130 is locked in the mating position by the terminal locks 140A, 140B, the locking feature 134 can be sandwiched between the recessed surface 190 and the locking feature 144, which tightly locks the terminal module 130 in the mating position and firmly fixes the outer surface 135 in a predetermined mating position.

[0058] In some examples, as Figures 9A to 9D and Figures 10A to 10D the examples depict, the connector 100 as described herein can incorporate terminal arrays 151A, 151B on either side of the aperture 153 that supports the terminal module 130 in the region 152. In other examples, the connector 100 can include only a single aperture array 151A, and the connector 100 can include a terminal lock 140A that interacts with one side 136 of the module 130 to lock it in place while another mechanism is used to lock the opposite side 137 of the module 130.

[0059] Returning to the exploded view of Figure 2 in some examples, the connector 100 can incorporate a terminal support unit 120 that corresponds to the terminal support unit 150 and is configured to mate with the terminal support unit 250 to establish a plurality of electrical connections within the connector 100. According to these examples, the terminal support unit 120 can incorporate with Figures 9A to 9D and Figures 10A to 10DThe orifice arrays 152A, 152B corresponding to the orifice arrays 151A, 151B depicted therein, and may also include a terminal module 130B corresponding to the module 130A carried by the terminal support unit 150. According to these examples, the connector 100 can be assembled by inserting the module 130A into the orifice 153 between the orifice arrays 151A, 151B until the main lock 182 engages, and inserting the terminal locks 140A and 140B into the tracks 157 until they reach the working position. The corresponding terminal arrays (not shown) can be arranged to extend through the orifice arrays 151A, 151B. Then, the terminal locks 140A and 140B can be moved to the locked position, in which they stabilize the terminals in the mating position and lock the module 130A in the mating position. In some examples, the terminal locks 140A and 140B can be substantially the same. For example, each of the terminal locks 140A and 140B can have a similar orifice pattern that matches the uniform or non-uniform orifice pattern of the terminal arrays 151A, 151B.

[0060] The terminal support unit 120 can be assembled similarly. For example, the terminal module 130B can be seated in the terminal support unit 120, such as between the respective orifice arrays 152A, 152B of the terminal support unit 20. The respective orifice arrays 152A, 152B can have an orifice pattern that is flipped relative to the orifice pattern of the orifice arrays 151A, 151B such that when the terminal support units 120, 150 are mated, the respective terminals are aligned. The terminal module 130B can carry terminals for terminating cables, such as cables associated with a vehicle wiring harness. The terminal locks 141A and 141B are Figures 7A to 7C substantially similar to the terminal locks 140 shown, but have a flipped orifice pattern corresponding to the orifice arrays 152A, 152B, and an orifice pattern opposite to that of the terminal locks 140A and 140B. The terminal locks 141A and 141B are inserted into the tracks 157 defined in the terminal support unit 120 and moved to the working position. In the working position, the respective terminal arrays (not shown) corresponding to the terminal arrays carried by the terminal support unit 150 are arranged through the orifice arrays 152A, 152B. For example, each terminal array can include terminals for terminating other cables of a vehicle wire harness. Then, the terminal locks 141A and 141B are moved to the locked position, in which the terminals of the corresponding terminal arrays are stabilized in the mating position, which also locks the corresponding module 130B in the mating position.

[0061] Each terminal support unit can be arranged in the housing 110 to form a plurality of electrical connections within the housing 110. For example, the terminal support unit 150 can be inserted into the housing 110 and locked in place within the housing 110. The blade stabilizer 170 can be arranged above the terminal support unit 150, and the terminal support unit 120 can be arranged above the blade stabilizer 170.

[0062] The terminal support units 120, 150 can be mated together to mate corresponding terminals of the orifice arrays 151A, 151B, and corresponding terminals supported by the terminal modules 130A and 130B. For example, the connector 100 can be arranged such that when the lever 103 is moved from the unlocked position to the locked position, a mating force is applied to the terminal support unit 120 to mate and / or lock each terminal in place within the housing 110.

[0063] In some examples, the electrical connector 100 described herein may be particularly suitable for easy installation by a human or robotic operator within a vehicle. For example, using the connector, a wire harness including various types of wires can be fabricated, such as some wires including conventional automotive terminals and other wires including other types of cables, such as high-speed data terminals. The various terminals of the wire harness can be arranged in the terminal support unit 120 and locked in the mating position as described herein, including locking the terminal support module 130B in the mating position with the terminal lock 142. The corresponding terminals can be fixed within the terminal support unit 150, which includes locking the terminal support module 130A in a position that mates with the terminal lock 140. The wire harness can be delivered to the vehicle manufacturer, where the terminal support unit 150 is fixed within the housing 110, and the housing 110 can be arranged in an installation position within the vehicle, such as through an orifice 107 in the substrate 105, and the substrate 105 can be a surface within the vehicle. Then, a human or robotic operator can insert the terminal support unit 120 into the housing 110, mate the terminal support units 120 and 150 together, and lock the connector 100 via the lever 103, and fix the lever 103 in place by inserting the CPA 108.

[0064] Figure 11It is a flowchart showing an example of a method 1100 for assembling an electrical connector according to some embodiments. At step 1101, the method includes seating a terminal module 130 in terminal support units 120, 150 of the electrical connector. In some examples, seating the terminal module in the terminal support units 120, 150 includes engaging a main lock 182. At step 1102, the method further includes inserting a terminal lock 140 into a track 157 defined in the terminal support units 120, 150. For example, inserting the terminal lock 140 may include moving the terminal lock 140 to a working position and inserting it through an array of apertures 151A, 151B of the terminal support units 120, 150 into a terminal array.

[0065] At step 1103, the method further includes moving the terminal lock 140 to a locked position to stabilize the terminal array in a mating position and lock the terminal module 130 in the mating position. In some examples, the terminal support units 120, 150 include multiple arrays of apertures 151A, 151B, and the terminal module 130 is disposed between the arrays of apertures 151A, 151B. According to these examples, the method includes inserting corresponding terminal locks 140A, 140B to stabilize the terminals of each array of apertures 151A, 151B in the mating position such that the terminal locks 140A, 140B together fix the terminal module 130 in the mating position.

[0066] In some examples, inserting the terminal lock 140 includes pushing the terminal lock until it interacts with a locking feature of the terminal module that at least partially extends into the track. In some examples, inserting the terminal lock 140 includes pushing the terminal lock 140 to engage a ramp surface 139 of a locking feature 134 of the terminal module 130 to cam the terminal module 130 forward into a tightly locked mating position in the terminal support unit 150 (e.g., wedging into the end of the track 157).

[0067] Although the invention has been described with reference to one or more exemplary embodiments, those skilled in the art will understand that various changes can be made and elements thereof can be replaced with equivalents without departing from the scope of the invention. Additionally, many modifications can be made to adapt a particular situation or material to the teachings of the invention without departing from its basic scope. Therefore, the invention is not intended to be limited to the specific (one or more) embodiments disclosed, but will include all embodiments falling within the scope of the appended claims.

Claims

1. An electrical connector, comprising: a terminal support unit comprising an array of terminal apertures configured to receive a plurality of terminals; a terminal module configured to be seated in the terminal support unit adjacent to the array of terminal apertures and configured to carry at least one terminal; as well as A terminal lock configured to be inserted into a track defined in the terminal support unit to lock a plurality of terminals in matching positions of the plurality of terminals in the terminal aperture array, wherein the terminal lock is docked with the terminal module to lock the terminal module in the matching position of the terminal module seated in the terminal support unit.

2. The electrical connector according to claim 1, characterized in that: The mating position of the terminal module corresponds to a strict position tolerance of at least one terminal carried by the terminal module.

3. The electrical connector according to claim 1, characterized in that: The terminal support unit includes a primary lock configured to secure the terminal module in a working position in the terminal support unit; and Wherein, the terminal locking member is a secondary locking member for locking the terminal module at a matching position of the terminal module.

4. The electrical connector according to claim 1, characterized in that: The terminal module includes a locking feature extending at least partially into the rail to interact with the terminal lock to lock the terminal module in a mating position of the terminal module.

5. The electrical connector according to claim 1, characterized in that: The terminal lock interacts with the terminal module to cam the terminal module tightly into a mating position of the terminal module in the track.

6. The electrical connector according to claim 1, characterized in that: The terminal aperture array is a first terminal aperture array configured to receive a first plurality of terminals, and further comprising: A second array of terminal apertures is configured to receive a second plurality of terminals, wherein the terminal module is configured to be seated in the terminal support unit between the first array of terminal apertures and the second array of terminal apertures.

7. The electrical connector according to claim 6, characterized in that: The terminal lock is a first terminal lock that docks with a first side of the terminal module, and also includes a second terminal lock, which locks the second plurality of terminals in the second terminal array in a matching position of the second plurality of terminals and docks with a second side of the terminal module, and wherein the first terminal lock and the second terminal lock operate together to lock the terminal module in the matching position of the terminal module seated on the terminal support unit.

8. The electrical connector according to claim 1, characterized in that: The terminal support unit is a first terminal support unit, and further comprises: A second terminal support unit is opposite to the first terminal support unit and is configured to mate with the first terminal support unit to form a plurality of electrical connections.

9. The electrical connector according to claim 8, characterized in that: The terminal module is a first terminal module, wherein the terminal lock is a first terminal lock, and further comprising: a second terminal module configured to mate with the first terminal module and to be seated in the second terminal support unit; and A second terminal lock, the second terminal lock is configured to be inserted into a track defined in the second terminal support unit to lock a corresponding plurality of terminals in matching positions of the plurality of terminals in a corresponding array of terminal openings, wherein the second terminal lock is docked with the second terminal module to lock the second terminal module in a matching position of the second terminal module seated in the second terminal support unit.

10. The electrical connector according to claim 9, characterized in that: The first terminal lock is a first pair of terminal locks, which locks the first terminal module in a matching position of the first terminal module seated in the first terminal supporting unit, wherein the second terminal lock is a second pair of terminal locks, which locks the second terminal module in a matching position of the second terminal module seated in the second terminal supporting unit.

11. A method comprising: Supporting a plurality of terminals passing through the terminal aperture array using a terminal support unit including a terminal aperture array; seating a terminal module in the terminal support unit adjacent to the array of terminal apertures, wherein the terminal module carries at least one terminal; as well as The terminal lock is inserted into a track defined in the terminal support unit to lock the first plurality of terminals in the matching positions of the plurality of terminals in the first terminal aperture array, and docked with the terminal module to lock the terminal module in the matching position of the terminal module in the terminal support unit.

12. The method according to claim 11, characterized in that Seating the terminal module in the terminal support unit includes securing the terminal module in a working position using a primary lock of the terminal support unit.

13. The method according to claim 12, characterized in that Inserting the terminal lock includes pushing the terminal lock until the terminal lock interacts with a locking feature of the terminal module extending into the track.

14. The method according to claim 13, characterized in that The locking feature of the terminal module includes a ramp surface that cams the terminal assembly into a tightly locked mating position in the terminal support unit.

15. The method according to claim 11, characterized in that The terminal aperture array is a first terminal aperture array supporting a first plurality of terminals, and further comprising supporting a second plurality of terminals through a second terminal aperture array with the terminal support unit; and Wherein, seating the terminal module in the terminal support unit includes seating the terminal module between the first terminal aperture array and the second terminal aperture array.

16. A terminal lock, comprising: a plurality of terminal apertures including contact surfaces configured to engage terminals of a terminal array inserted through the apertures; a pair of locating arms, the pair of locating arms including locating ends that engage with one or more recesses in the track to define the position of the terminal lock; as well as A plurality of engagement features are configured to engage with the rails to guide the terminal lock to a locked position, thereby stabilizing and locking the terminal array in a mating position of the terminal array through the apertures, and engaging with a terminal module adjacent to the terminal lock to lock the terminal module in a mating position of the terminal module.

17. The terminal lock according to claim 16, characterized in that: The mating position of the terminal module corresponds to the strict relative position required for mating the terminals carried by the terminal module.

18. The terminal lock according to claim 17, characterized in that: Also includes: A terminal support unit includes a rail and further includes fixing the terminal module seated in the terminal support unit using a main lock of the terminal support unit.

19. The terminal lock according to claim 16, characterized in that: The engagement feature interfaces with a locking feature of the terminal module in the track to lock the terminal module in a mating position with the terminal module.

20. The terminal lock according to claim 19, characterized in that: The engagement feature interfaces with a ramped surface of a locking feature in the track to lock the terminal module in a mating position of the terminal module.

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