High-voltage electric connector

Abstract

The invention relates to a high voltage electrical connector. An electrical connector includes a connector housing having a connector body. A connector cavity extends through the connector body and defines a connector axis. The shield is connected to the connector body by a shield wall. The shield defines a window. A latch is attached to the connector housing for movement relative to the connector body between a latched position and a released position. The latch is at least partially located between the shroud and the connector body. The latch has a stop adapted to engage a corresponding catch on a corresponding connector so as to hold the electrical connector in a mating position relative to the corresponding connector. The latch also includes a lift lever. The window is adapted to allow a tool to be inserted therethrough to engage the lift lever.

Description

[0001] Field

[0002] The present disclosure relates to an electrical connector. More particularly, the present disclosure relates to a high-voltage electrical connector that includes an improved connector position assurance member.

[0003] Background

[0004] Electrical components are typically connected to each other using conductive cables, and electrical connectors attached to the cables allow the components to be connected at a desired time. For example, during the manufacture of a larger assembly, electrical components from different sources can be brought together. To ensure that the components are properly connected during assembly, it is known to use a connector position assurance member on the electrical connector. The connector position assurance member is typically located on a first electrical connector and can move to its locked position only when the first electrical connector is properly mated with a corresponding second electrical connector. Once in the locked position, the connector position assurance member prevents the first and second electrical connectors from separating from each other. It is desirable to provide an improved electrical connector and an improved connector position assurance member for an electrical connector.

[0005] Overview

[0006] Various example electrical connectors are described.

[0007] An example electrical connector includes a connector housing. The connector housing has a connector body. A connector cavity extends through the connector body and defines a connector axis. A shroud is connected to the connector body by at least one shroud wall. The shroud defines a window. A latch is attached to the connector housing for movement relative to the connector body between a latched position and a released position. The latch is at least partially located between the shroud and the connector body. The latch has a stop that is adapted to engage a corresponding detent on a corresponding connector to hold the electrical connector in a mated position relative to the corresponding connector. The latch also includes a lifting lever. The window is adapted to allow a tool to be inserted through the window to engage the lifting lever.

[0008] Another example electrical connector includes a terminal housing located within the connector cavity. The terminal housing includes a terminal cavity adapted to receive electrical terminals. The terminal cavity defines a cavity axis that extends through a contact opening of the terminal cavity. The cavity axis also extends through a connection opening of the terminal cavity. The terminal housing includes an insertion opening extending from the terminal cavity that is adapted to allow electrical terminals to be inserted into the terminal cavity in an insertion direction that is substantially perpendicular to the cavity axis. The electrical connector also includes a terminal position assurance member. The terminal position assurance member is movable relative to the terminal housing in the insertion direction to an installed position. A TPA latch engages a TPA detent to hold the terminal position assurance member in the installed position. When in the installed position, the terminal position assurance member covers the insertion opening.

[0009] Another example includes a terminal housing that includes a tab seat extending from a terminal cavity and adapted to receive a tab on an electrical terminal. The terminal housing also includes a stop fixed relative to the terminal cavity, the stop extending from a wall of the terminal cavity toward the cavity axis and located between the tab seat and a connection opening. Further, the terminal position assurance member includes a tab lock that, when the terminal position assurance member is in the installed position, extends partially into the tab seat. A contact guide on the terminal position assurance member is positioned adjacent to a contact opening. The contact guide defines a contact hole and the cavity axis passes through the hole. An electrical connector includes a shield located around the terminal housing and the terminal position assurance member. A shroud on the connector housing is connected to the connector housing by two shroud walls. Each shroud wall defines an assurance slot extending parallel to the connector axis. A latch is connected to the shroud wall for movement relative to the connector body. The electrical connector also includes a connector position assurance member. The connector position assurance member is attached to the connector housing for relative movement parallel to the cavity axis between a pre-locked position and a locked position. The connector position assurance member includes an assurance body. Assurance guides are located on opposite sides of the assurance body. Each assurance guide is located in a respective one of the assurance slots. An assurance lock is positioned on each assurance guide. Assurance arms also extend from the assurance body parallel to the cavity axis. A stop on the latch is adapted to engage a respective detent on a corresponding connector to hold the electrical connector relative to the corresponding connector in a mating position. The cavity axis of the terminal housing is parallel to the connector axis. An assembly lock on the shield engages the connector body to hold the terminal housing relative to the connector housing in place. When the connector position assurance member is in the pre-locked position, the assurance arm engages the stop on the latch to prevent the connector position assurance member from moving relative to the connector housing in the mating direction. When the connector position assurance member is in the locked position, the assurance arm engages the stop to limit movement of the connector position assurance member relative to the connector housing opposite to the mating direction. Further, when the connector position assurance member is in the locked position, the assurance arm is at least partially located between a lifting lever and a window.

[0010] Additional understanding of these examples will become apparent to those of ordinary skill in the art from the following detailed description when read in conjunction with the accompanying drawings. Brief Description of the Drawings

[0012] Figure 1 is a front perspective view of an example electrical connector.

[0013] Figure 2 is Figure 1 a partially exploded view of the electrical connector shown in

[0014] Figure 3 is a front perspective view of an electrical terminal for the Figure 1 and Figure 2 electrical connector shown in

[0015] Figure 4 is Figure 1 and Figure 2 a front perspective view of a terminal housing of the electrical connector shown in

[0016] Figure 5 is Figure 4 a top plan view of the terminal housing shown in

[0017] Figure 6 is Figure 4 a front plan view of the terminal housing shown in

[0018] Figure 7 is similar to Figure 5 a view in which the electrical terminals shown are inserted into the terminal housing.

[0019] Figure 8 is similar to Figure 6 a view in which the electrical terminals shown are inserted into the terminal housing.

[0020] Figure 9 is Figure 4 a front perspective view of the terminal housing shown in

[0021] Figure 10 is Figure 9 a bottom perspective view of a part of the terminal position assurance member shown in

[0022] Figure 11 is a cross-sectional view taken along Figure 10 line 11-11 in

[0023] Figure 12 is similar to Figure 9 a view in which the terminal position assurance member shown is attached to the terminal housing, and two shielding members.

[0024] Figure 13 is similar to Figure 11 a view showing the terminal position assurance member attached to the terminal housing.

[0025] Figure 14 is similar to Figure 12 a view in which the shielding member blocks and the cable shown are attached to the terminal housing.

[0026] Figure 15 is Figure 2 an exploded view of the connector housing assembly shown, including a connector housing, a housing seal, a seal retainer, and a connector position assurance member.

[0027] Figure 16 is Figure 15Enlarged front view of a portion of the connector housing shown, showing the connector latch.

[0028] Figure 17 is a cross-sectional view taken along Figure 16 line 17-17 in

[0029] Figure 18 is an enlarged front perspective view of the connector position assurance member.

[0030] Figure 19 is a cross-sectional view of the assembled electrical connector taken along Figure 1 line 19-19 in

[0031] Figure 20 is a cross-sectional view taken along Figure 19 line 20-20 in

[0032] Figure 21 is a cross-sectional view taken along Figure 19 line 21-21 in

[0033] Figure 22 is a cross-sectional view taken along Figure 19 line 22-22 in which the connector position assurance member is shown in the pre-locked position.

[0034] Figure 23 is a cross-sectional view taken along Figure 22 line 23-23 in

[0035] Figure 24 is a view similar to Figure 22 in which the latch stop shown is in the latched position relative to the corresponding catch.

[0036] Figure 25 is a view similar to Figure 24 in which the latch is shown in the released position.

[0037] Figure 26 is a view similar to Figure 25 in which the corresponding catch is shown in the mating position, the latch is shown in the latched position, and the connector position assurance member is shown in the locked position.

[0038] Detailed Description

[0039] Reference will now be made in detail to the embodiments, examples of which are illustrated in the accompanying drawings. In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the various described embodiments. However, it will be apparent to one of ordinary skill in the art that the various described embodiments may be practiced without these specific details. In other instances, well-known methods, procedures, components, circuits, and networks have not been described in detail so as not to unnecessarily obscure aspects of the embodiments.

[0040] It should also be understood that although, in some instances, the terms first, second, etc. are used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first shield may be termed a second shield, and similarly, a second shield may be termed a first shield, without departing from the scope of the various described embodiments. Both the first shield and the second shield are shields, but not the same shield.

[0041] The terminology used in the description of the various embodiments herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used in the description of the various described embodiments and the appended claims, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It should be further understood that when the terms “includes,” “including,” “comprises,” and / or “comprising” are used in this specification, they specify the presence of the stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0042] Now referring to the drawings, Figure 1 a front perspective view of an electrical connector generally designated 10 is illustrated. Figure 2 is a partial exploded view of the electrical connector 10, showing internal components generally designated 12 and external components generally designated 14, the external components including a connector position assurance member 16.

[0043] Referring to Figure 3, shows a front perspective view of an electrical terminal generally indicated at 18. The electrical terminal 18 is adapted to be used with an electrical connector 10, as described below. The illustrated electrical terminal 18 is a female barrel type terminal, but can be of any desired type of electrical terminal. The illustrated electrical terminal 18 is made of a single piece of metal sheet folded into the illustrated shape. However, the electrical terminal 18 can be made of any required material and by any required process. The electrical terminal 18 includes a connection portion indicated at 20. The illustrated connection portion 20 is a crimping portion and includes a conductor crimping wing 22 and an insulator crimping wing 24. However, the connection portion 20 can be of any desired type of connector. The electrical terminal 18 further includes a contact portion (indicated at 26) attached to the crimping portion 20. The contact portion 26 includes a generally cylindrical barrel 28 positioned about a terminal axis 30. The contact portion 26 further includes a contact spring 31 attached to and located inside the barrel 28. The contact spring 31 is adapted to engage a corresponding male terminal (not shown) to establish an electrical connection between the corresponding male terminal and the barrel 28. The electrical terminal 18 includes a tab 32 extending from the contact portion 26 in a direction generally perpendicular to the terminal axis 30. In the illustrated embodiment, the tab 32 is made of two pieces of metal that define a portion of the barrel 28 and are folded adjacent to each other and extend generally perpendicular to the terminal axis 30. The illustrated tab 32 is located at the end of the barrel 28 closest to the connection portion 20. A space 34 is located between the tab 32 and the conductor crimping wing 22.

[0044] Reference Figure 4 , illustrates a perspective view of a terminal housing generally indicated at 36. The illustrated terminal housing 36 is molded of plastic, but can be made of any required material and by any required process. The illustrated terminal housing 36 includes four terminal cavities 38a, 38b, 38c, and 38d and is configured to receive four terminals similar to terminal 18. Each of the terminal cavities 38a, 38b, 38c, and 38d includes similar features and only one terminal cavity 38a will be described in detail. Figure 5 is a top view of the terminal housing 36, and Figure 6 is an end view of the terminal housing 36.

[0045] The terminal cavity 38a extends through the terminal housing 36 and defines a cavity axis 40a. The terminal cavity 38a includes a connection cavity 42a that is adapted to receive the connection portion 20 of the electrical terminal 18. The terminal cavity 38a also includes a contact cavity 44a that is adapted to receive the contact portion 26 of the electrical terminal 18. The connection cavity 42a is connected to the contact cavity 44a, and the cavity axis 40a extends through both the connection cavity 42a and the contact cavity 44a. The connection cavity 42a defines a connection opening 46a at an end opposite the contact cavity 44a, and the cavity axis 40a passes through the connection opening 46a. Additionally, the contact cavity 44a defines a contact opening 48a at an end opposite the connection cavity 42a, and the cavity axis 40a passes through the contact opening 48a.

[0046] The terminal cavity 38a also defines an insertion opening 50a that is open to both the connection cavity 42a and the contact cavity 44a. The insertion opening 50a is adapted to permit the insertion of the electrical terminal 18 into the terminal cavity 38a, as described below. In the illustrated embodiment, the insertion opening 50a extends the length of the terminal cavity 38a from the connection opening 46a to the contact opening 48a. However, if desired, the insertion opening 50a can have a shorter length.

[0047] The terminal cavity 38a includes a tab seat (generally designated 52a) that is connected to the contact cavity 44a. The tab seat 52a is an opening that extends from the contact cavity 44a and away from the cavity axis 40a. When the electrical terminal 18 is installed in the terminal cavity 38a, the tab seat 52a is adapted to receive the tab 32 on the electrical terminal 18. The tab seat 52a is open to the insertion opening 50a and includes (as best shown in Figure 5 and Figure 6 ) a seat surface 54a that is located on a side of the tab seat 52a opposite the insertion opening 50a.

[0048] The terminal housing 36 includes a stop 56a that extends into the terminal cavity 38a. The stop 56a is adapted to hold the electrical terminal 18 in the terminal cavity 38a, as described below. The stop 56a is located between the tab seat 52a and the connection cavity 42a. The stop 56a is positioned adjacent to the tab seat 52a and extends toward the cavity axis 40a. The illustrated stop 56a is molded as part of the terminal housing 36 and is fixed relative to the terminal cavity 38a.

[0049] Reference Figure 7 shows a view similar to Figure 5 in which the illustrated electrical terminal 18 is installed in the terminal housing 36. Additionally, Figure 8 is similar to Figure 6view, in which the electrical terminal 18 shown is installed in the terminal housing 36. As shown, the electrical terminal 18 is located in the terminal cavity 38a. The connecting portion 20 is located in the connecting cavity 42a, the contact portion 26 is located in the contact cavity 44a, the tab 32 is located in the tab seat 52a, and the stop 56a is located in the space 34.

[0050] To install the electrical terminal 18 in the terminal cavity 38a, the electrical terminal 18 is positioned adjacent to the insertion opening 50a. Then, the electrical terminal 18 is moved relative to the terminal housing 36 in the insertion direction 58a, as Figure 8 shown, and is moved through the insertion opening 50a to Figure 7 and Figure 8 the position shown. The shown insertion direction 58a is substantially perpendicular to the cavity axis 40a. When the electrical terminal 18 is installed in the terminal housing 36, the terminal axis 30 is substantially parallel to the cavity axis 40a. As shown, the connecting portion 20 of the electrical terminal 18 is connected to the wire 60a, and when the electrical terminal 18 is installed in the terminal cavity 38a, the wire 60a extends out of the terminal cavity 38a through the connection opening 46a. The wire 60a is contained in the cable 62, as Figure 1 and Figure 2 shown.

[0051] As Figure 7 best shown in, the tab 32 located in the tab seat 52a provides a visual indication that the electrical terminal 18 is correctly positioned in the terminal cavity 38a. The operator can see the tab seat 52a and the tab 32 through the insertion opening 50a. As Figure 8 shown, the electrical terminal 18 is positioned in the terminal cavity 38a such that the tab 32 is adjacent to the seat surface 54a, and the tab 32 is located between the seat surface 54a and the insertion opening 50a. As a result, at least a portion of the seat surface 54a is not visible through the insertion opening 50a.

[0052] As previously described, the stop 56a is adapted to hold the electrical terminal 18 in the terminal cavity 38a. When the electrical terminal 18 is installed in the terminal cavity 38a, the stop 56a is located in the space 34 between the tab 32 and the connecting portion 20. When the electrical terminal 18 is installed in the terminal cavity 38a, a force applied to the cable 62 or the wire 60a will pull the electrical terminal 18 toward the connection opening 46a. The tab 32 and the barrel 28 will engage the stop 56a to prevent the electrical terminal 18 from moving relative to the terminal housing 36 toward the connection opening 46a. Additionally, as Figure 8 shown, the stop 56a extends from the seat surface 54a in a direction opposite to the insertion direction 58a. As a result, if the electrical terminal 18 rotates relative to the terminal housing 36 about the cavity axis 40a, the tab 32 will still engage the stop 56a when the electrical terminal 18 is pulled toward the connection opening 46a relative to the terminal housing 36.

[0053] Now refer to Figure 9 which shows a front perspective view of the terminal housing 36 and a terminal position assurance member (generally designated by 64). The illustrated terminal position assurance member (TPA) 64 includes two blocks, a first TPA block (generally designated by 66) and a second TPA block (generally designated by 68). However, the terminal position assurance member 64 can include any desired number of blocks. The first TPA block 66 and the second TPA block 68 have similar features, and only the first TPA block 66 will be described in detail.

[0054] The illustrated first TPA block 66 is formed by plastic molding, but can be made of any desired material by any desired process. The first TPA block 66 includes a TPA body 70. The first TPA block 66 includes a TPA latch 72 extending from the TPA body 70. The illustrated first TPA block 66 includes four U-shaped TPA latches 72 (two are visible in Figure 9 ), which extend from the TPA body 70 along the insertion direction 58a. However, the first TPA block 66 can include any desired number of any desired type of latches. The first TPA block 66 includes a cavity cover 74a that extends from the TPA body 70 parallel to the cavity axis 40a. The illustrated first TPA block 66 includes two cavity covers 74a and 74b, and the first TPA block is adapted to cover the terminal cavities 38a and 38b, as described below. However, the first TPA block 66 can include any desired number of cavity covers. As described below, the first TPA block 66 includes a tab lock 76a adapted to hold the tab 32 in the tab seat 52a. The illustrated tab lock 76a extends from the cavity cover 74a, but can be located on any desired part of the first TPA block 66. The tab lock 76a extends from the cavity cover 74a along the insertion direction 58a. The illustrated first TPA block 66 includes two tab locks 76a and 76b, but only one is visible in Figure 9 . The first TPA block 66 also includes contact guides 78a and 78b. The contact guide 78a extends from the outer end of the cavity cover 74a along the insertion direction 58a. The contact guide 78b extends from the outer end of the cavity cover 74b along the insertion direction 58a.

[0055] Refer to Figure 10 which shows an enlarged perspective view of the first TPA block 66. Figure 11 is a cross-sectional view taken along line 11-11 in Figure 10 . The first TPA block 66 includes a cover catch 148a located on the cavity cover 74a. As Figure 11As best shown, the cavity cover 74a shown includes two cover locking portions 148a located on opposite sides of the cavity cover 74a. The first TPA block 66 also includes a guide locking portion 150a located on the contact guide portion 78a. The contact guide portion 78a shown includes two guide locking portions 150a located on opposite sides of the contact guide portion 78a. The cover locking portion 148a and the guide locking portion 150a are adapted to hold the first TPA block 66 in a position relative to the terminal housing 36, as described below.

[0056] Reference Figure 12 , shows a view similar to Figure 9 in which the terminal position assurance member 64 shown is mounted on the terminal housing 36. To mount the first TPA block 66 on the terminal housing 36, the first TPA block 66 is first positioned adjacent to the terminal housing 36 with the TPA latch 72 facing the terminal housing 36. Then, the first TPA block 66 is moved relative to the terminal housing 36 in the insertion direction 58a such that the TPA latch 72 engages the TPA locking portion 80 on the terminal housing 36. Each TPA latch 72 cooperates with a corresponding TPA locking portion 80 to hold the first TPA block 66 in the mounting position on the terminal housing 36, as Figure 12 shown. In this position, the first TPA block 66 prevents the electrical terminal 18 from moving out of the terminal cavity 38a relative to the terminal housing 36 in a direction opposite to the insertion direction 58a.

[0057] When the first TPA block 66 is in the mounting position, the first TPA block 66 covers the insertion opening 50a. In the embodiment shown, the TPA body 70 is positioned adjacent to the connection cavity 42a above a portion of the insertion opening 50a, and the cavity cover 74a is positioned adjacent to the contact cavity 44a above another portion of the insertion opening 50a. It should be understood that the cavity cover 74a shown is optional, and the TPA body 70 can cover the entire insertion opening 50a without using an additional cavity cover 74a.

[0058] In addition, when the first TPA block 66 is in the mounting position, the tab lock 76a is located in the tab seat 52a, and the tab 32 is located between the tab lock 76a and the seat surface 54a. In addition, the contact guide portion 78a is positioned adjacent to the contact opening 48a of the terminal cavity 38a. The contact guide portion 78a defines a contact hole 82a, and the cavity axis 40a passes through the contact hole 82a.

[0059] As Figure 4 best shown, the terminal housing 36 includes two cover notches 152a located on opposite sides of the insertion opening 50a. In addition, the terminal housing 36 includes two guide notches 154a located near the contact opening 48a. Returning to Figure 12, the first TPA block 66 is shown in the installed position; in addition, Figure 13 is a cross-sectional view, similar to Figure 11 , taken along Figure 12 line 13-13 in . When the first TPA block 66 is in the installed position, each cover latching portion 148a on the first TPA block 66 is located in a corresponding one of the cover notches 152a. Each cover latching portion 148a engages the corresponding cover notch 152a to hold the cavity cover 74a in place relative to the insertion opening 50a. In addition, each guide latching portion 150a is located in and engages a corresponding one of the guide notches 154a. Each guide latching portion 150a engages the corresponding guide notch 154a to hold the contact guide 78a in position relative to the contact opening 48a.

[0060] As previously described, the illustrated terminal housing 36 includes four terminal cavities 38a, 38b, 38c, and 38d, as Figure 4 shown. When the illustrated first TPA block 66 is in the Figure 12 shown installed position, the first TPA block serves as a terminal position assurance member for both terminal cavities 38a and 38b. In addition, the second TPA block 68 is shown in the Figure 12 installed position in , where the second TPA block serves as a terminal position assurance member for both terminal cavities 38c and 38d. It should be understood that the second installation direction of the second TPA block 68 is opposite to the installation direction 58a because the second TPA block 68 is located on the side of the terminal housing 36 opposite to the first TPA block 66.

[0061] Also as Figure 12 shown, the electrical connector 10 includes a shield (generally indicated at 84). The illustrated shield 84 includes a first shield 86 and a second shield 88. The illustrated shield 84 is made of a metal plate that is folded into the illustrated shape. However, the shield 84 can be made of any desired material and by any desired process. Figure 14 is a view similar to Figure 12 showing the first shield 86 and the second shield 88 attached to each other around the terminal housing 36 such that the shield 84 is located around the terminal housing 36.

[0062] Now referring to Figure 15 , a exploded view of the external component 14 from Figure 2 is shown. The external component 14 includes a connector housing 90. The illustrated connector housing 90 is molded from plastic, but can be made of any desired material by any desired process. The connector housing 90 includes a connector body 92. A connector cavity 94 extends through the connector body 92 and defines a connector axis 96. The connector cavity 94 is adapted to receive the internal component 12, as described below.

[0063] The connector housing 90 includes a latch 98 that is attached for movement relative to the connector body 92 between a latched position and a released position. The latch 98 is movable relative to the connector body 92 between the latched position and the released position. The latch 98 is adapted to hold the assembled electrical connector 10 in a mounted position relative to a corresponding connector 156 (as Figure 24 shown), as described below. The connector housing 90 includes a shroud 100, and the latch 98 is located between the connector body 92 and the shroud 100.

[0064] Figure 16 is an enlarged end view of the connector housing 90 showing the latch 98 as viewed parallel to the connector axis 96. Figure 17 is a cross-sectional view taken along Figure 16 line 17-17 in

[0065] Figure 18 is Figure 15 An enlarged front perspective view of the connector position assurance member 16 shown. The illustrated connector position assurance member 16 is molded from plastic, but can be made of any desired material and by any desired process. The connector position assurance member 16 includes an assurance member body 104. Assurance member guides 106 extend from the assurance member body 104 in the mating direction 108. The illustrated connector position assurance member 16 includes two assurance member guides 106 that are located at opposite ends of the assurance member body 104. The connector position assurance member 16 includes an assurance member lock 110 that is adapted to hold the connector position assurance member 16 in a position relative to the latch 98, as described below. The illustrated connector position assurance member 16 includes two assurance member locks 110, and each assurance member lock 110 is an elastic portion attached to one of the assurance member guides 106. The connector position assurance member 16 further includes an assurance member arm 112 that extends from the assurance member body 104 in the mating direction 108. The illustrated assurance member arm 112 extends from the assurance member body 104 between the two assurance member guides 106.

[0066] Returning to Figure 15 , the illustrated external component 14 also includes a connector seal 114. The connector seal 114 is adapted to provide a seal between the electrical connector 10 and the corresponding connector 156, as Figure 24As shown. To assemble the external component 14, the connector seal 114 is moved relative to the connector body 92 in a direction opposite to the mating direction 108 into the seal seat 116 located around the connector cavity 94. The seal retainer 118 is moved relative to the connector body 92 in a direction opposite to the mating direction 108 and engages with the retainer lock 120 on the connector body 92. The illustrated seal retainer 118 is molded from plastic, but can be made of any desired material and by any desired process. The seal retainer 118 prevents the connector seal 114 from being removed from the seal seat 116. Additionally, the connector position assurance member 16 is first positioned near the latch 98 and is moved in the mating direction 108 relative to the latch 98 to a pre-locked position. In Figure 2 Figure 1 shows the assembled external component 14 with the connector position assurance member 16 in the pre-locked position. The operation of the connector position assurance member 16 will be described below.

[0067] To assemble the electrical connector 10, the internal component 12 is attached to the external component 14. As Figure 2 shown, the internal component 12 is positioned adjacent to the connector housing 90 with the cavity axis 40a parallel to the connector axis 96. Then, the internal component 12 is moved relative to the connector housing 90 in the mating direction 108. The internal component 12 includes one of a plurality of component guides 122 that extend perpendicularly from the internal component 12 to the cavity axis 40a (one of which is visible in Figure 2 Figure 2). As Figure 5 best shown in Figure 3, the illustrated internal component 12 includes two component guides 122 that are part of the terminal housing 36. The illustrated component guides 122 extend from opposite sides of the terminal housing 36 and have different lengths. When assembling the internal component 12, the component guides 122 extend through the shield 84, as Figure 2 shown in Figure 4.

[0068] Now referring to Figure 19 Figure 5, a cross-sectional view of the electrical connector 10 taken along line 19-19 of Figure 1 Figure 4 is illustrated. Figure 20 Figure 6 is a cross-sectional view taken along line 20-20 of Figure 19 Figure 4. As shown, each component guide 122 is located in a corresponding guide channel 124 defined by the connector housing 90. The guide channels 124 are connected to the connector cavity 94 and extend parallel to the connector axis 96. The illustrated guide channels 124 are located on opposite sides of the connector cavity 94 and extend different distances from the connector axis 96. The component guides 122 of different lengths cooperate with the guide channels 124 to act as anti-misassembly features to ensure that when the internal component 12 and the external component 14 are attached to each other, the internal component 12 is oriented in the desired position relative to the external component 14.

[0069] Reference Figure 21 , shows a cross-sectional view taken along line 21-21 of Figure 19 . When the internal component 12 is inserted into the external component 14, a component lock 126 on the internal component 12 (as shown in Figure 14 ) engages with a component catch 128 on the external component 14 to hold the internal component 12 in place relative to the external component 14. In the illustrated embodiment, the component lock 126 is a metal lance bent from the shield 84, and the component catch 128 is a molded tab on the side of the connector cavity 94. Additionally, in the illustrated embodiment, the internal component 12 includes four component locks 126. As best shown in Figure 14 , two component locks 126 are visible on one side of the internal component 12, and the other two component locks 126 are on the hidden side of the internal component 12.

[0070] Returning to reference Figure 2 , the electrical connector 10 also includes a cable seal 130 and an end cap 132, both of which are located around the cable 62. To complete the assembly of the electrical connector 10, the cable seal 130 is placed in the connector housing 90, and the end cap 132 engages the connector housing 90 to hold the cable seal 130 in place. Then the electrical connector 10 is in the assembled state shown in Figure 1 .

[0071] Now referring to Figure 22 , shows a cross-sectional view of the latch 98 and the connector position assurance member 16 taken along line 22-22 of Figure 19 . Figure 23 is a cross-sectional view taken along line 23-23 of Figure 22 . The connector position assurance member 16 is shown in the pre-locked position of Figure 22 and Figure 23 . As shown in Figure 19 , each assurance guide 106 is located in a corresponding assurance slot 134. The assurance slots 134 are located on opposite sides of the connector position assurance member 16. Each assurance slot 134 is defined by one of the shield walls 102. The assurance guides 106 are capable of moving in the corresponding assurance slots 134 parallel to the mating direction 108 to allow the connector position assurance member 16 to move relative to the connector housing 90.

[0072] As shown in Figure 23As shown, each securing lock 110 engages a corresponding securing catch 136 to hold the connector position securing member 16 relative to the connector housing 90 in a pre-locked position. The securing catches 136 are located on opposite sides of the connector position securing member 16. Each securing catch 136 is located on one of the shield walls 102. Additionally, the securing arms 112 engage stops 138 on the latch 98 to prevent the connector position securing member 16 from moving relative to the connector housing 90 in the mating direction 108.

[0073] Referring Figure 24 , a view similar to Figure 22 is shown, showing when the electrical connector 10 mates with a corresponding connector 156. When the electrical connector 10 mates with the corresponding connector 156, the electrical connector 10 is initially positioned adjacent to the corresponding connector 156 and then moved relative to the corresponding connector 156 in the mating direction 108 to Figure 24 the partially mated position shown. The corresponding catches 140 on the corresponding connector 156 engage the stops 138 on the latch 98 and prevent the electrical connector 10 from moving further relative to the corresponding connector 156 in the mating direction 108. The latch 98 is adapted to prevent the electrical connector 10 from moving relative to the corresponding catches 140 beyond the partially mated position without additional manual operation.

[0074] As Figure 1 best shown in

[0075] As Figure 25 shown, by applying a force on the lifting lever 146, the latch 98 is capable of moving relative to the connector body 92 to a release position. This also moves the stop 138 relative to the connector body 92 and relative to the corresponding catches 140. When the latch 98 is in the release position, the electrical connector 10 is capable of moving relative to the corresponding catches 140 in the mating direction 108 to the mated position, as Figure 26 shown. Then, the operator can release the force on the lifting lever 146 to allow the latch 98 to return to Figure 26 the latch position shown.

[0076] When the corresponding latching portion 140 is in the mating position, the connector position assurance member 16 can move relative to the connector housing 90 in the mating direction 108 to a locking position, which is also shown in Figure 26 . In the locking position, the assurance member arm 112 engages the stop 138 to restrict movement of the connector position assurance member 16 relative to the connector housing in the mating direction 108, thereby holding the connector position assurance member 16 in a locked position relative to the latch 98. In addition, the assurance member arm 112 is at least partially located between the window 142 and the lifting lever 146 to prevent a tool 144 from being used to engage the lifting lever 146.

[0077] Also as Figure 26 shown, the latch 98 is adapted to prevent the electrical connector 10 from moving relative to the corresponding latching portion 140 from the mating position without additional manual operation. To disconnect the electrical connector 10 from the corresponding connector 156, the previous operations are reversed. The connector position assurance member 16 moves from the locking position opposite to the mating direction 108 to a pre-locking position. Then a tool 144 can be inserted through the window 142 to engage the lifting lever 146 in order to lift the latch 98 to a release position, as shown in Figure 25 . Then, the electrical connector 10 can move relative to the corresponding latching portion 140 in a direction opposite to the mating direction 108 to the Figure 24 shown partially mated position.

[0078] It should be understood that in the illustrated embodiment, the lifting lever 146 is located at the distal end of the latch 98 to provide a mechanical advantage when an operator uses a tool 144 to lift the latch 98. However, the lifting lever 146 can be located on any desired portion of the latch 98. In addition, when the connector position assurance member 16 is in the locking position, any desired portion of the connector position assurance member 16 can be used to interfere with the operation of the lifting lever 146.

[0079] Those of ordinary skill in the art will understand that various modifications and substitutions can be developed for the described and illustrated embodiments in accordance with the general teachings of the present disclosure, and that various elements and features in one example described and illustrated herein can be combined with various elements and features in another example without departing from the scope of the invention. Accordingly, the specific examples disclosed herein have been selected by the inventors solely for the purpose of describing and illustrating examples of the invention and are not intended to limit the invention or the scope of its protection, which is given by the full scope of the appended claims and any and all equivalents thereof.

Claims

1. An electrical connector, comprising: a connector housing, the connector housing including a connector body, a connector cavity, a shroud, and a latch; the connector cavity extending through the connector body; the shroud being connected to the connector body by at least one shroud wall, the shroud defining a window; and the latch being attached to the connector housing and movable relative to the connector body between a locked position and a released position, the latch being at least partially located between the shroud and the connector body, the latch including a stop and a lifting lever, the stop being adapted to engage a corresponding detent on a corresponding connector to hold the electrical connector relative to the corresponding connector in a mating position, the lifting lever being located between the window and the connector body.

2. The electrical connector according to claim 1, wherein, The latch is connected to two shroud walls for movement relative to the connector body.

3. The electrical connector according to claim 1, wherein, The window is adapted to allow a tool to be inserted through the window to engage the lifting lever.

4. The electrical connector according to claim 3, wherein, The connector cavity defines a connector axis; the electrical connector further including a connector position assurance member attached to the connector housing for relative movement parallel to the connector axis between a pre-locked position and a locked position, the connector position assurance member including an assurance member body and an assurance member arm, the assurance member arm extending from the assurance member body parallel to the connector axis; wherein, when the connector position assurance member is in the pre-locked position, the assurance member arm engages the stop to prevent the connector position assurance member from moving to the locked position, and the assurance member arm is adapted to prevent the tool from engaging the lifting lever when the connector position assurance member is in the locked position.

5. The electrical connector according to claim 1, wherein, The connector cavity defines a connector axis; the electrical connector further including a connector position assurance member attached to the connector housing for relative movement parallel to the connector axis between a pre-locked position and a locked position, the connector position assurance member including an assurance member body and an assurance member arm, the assurance member arm extending from the assurance member body parallel to the connector axis; wherein when the connector position assurance member is in the pre-locked position, the assurance member arm engages the stop to prevent the connector position assurance member from moving to the locked position, and when the connector position assurance member is in the locked position, the assurance member arm is at least partially positioned between the lifting lever and the window.

6. The electrical connector according to claim 1, wherein, The connector cavity defines a connector axis; wherein two shroud walls respectively define assurance member slots extending parallel to the connector axis; the electrical connector further including a connector position assurance member attached to the connector housing for relative movement parallel to the connector axis between a pre-locked position and a locked position, the connector position assurance member including an assurance member body and assurance member guides located on opposite sides of the assurance member body, each of the assurance member guides being located in a corresponding assurance member slot.

7. The electrical connector according to claim 6, wherein the connector position assurance member further includes a position assurance lock located on each of the assurance member guiding portions within the assurance member guiding portion; wherein each of the assurance member guiding portions of the assurance member guiding portion engages a corresponding assurance member locking portion to hold the connector position assurance member in the pre-locked position.

8. The electrical connector according to claim 1, wherein, The connector cavity defines a connector axis; The electrical connector further includes a connector position assurance member attached to the connector housing for relative movement parallel to the connector axis between a pre-locked position and a locked position, the connector position assurance member including an assurance member body and an assurance member arm extending from the assurance member body parallel to the connector axis; wherein when the connector position assurance member is in the pre-locked position, the assurance member arm engages the stop to prevent the connector position assurance member from moving to the locked position, and when the connector position assurance member is in the locked position, the assurance member arm is at least partially positioned between the lifting lever and the window.

9. The electrical connector according to claim 1, further including a terminal housing located within the connector cavity, the terminal housing including a terminal cavity adapted to receive electrical terminals, the terminal cavity defining a cavity axis, an insertion opening, the cavity axis extending through a contact opening of the terminal cavity and further extending through a connection opening of the terminal cavity, the insertion opening extending from the terminal cavity and adapted to permit the electrical terminals to be inserted into the terminal cavity in an insertion direction substantially perpendicular to the cavity axis.

10. The electrical connector according to claim 9 further includes a terminal position assurance member that is movable relative to the terminal housing in the insertion direction to an installed position, wherein a TPA latch engages a TPA stop to hold the terminal position assurance member in the installed position, and wherein, The terminal position assurance member covers the insertion opening.

11. The electrical connector according to claim 10, wherein the terminal position assurance member further includes a contact guiding portion positioned adjacent to the contact opening, the contact guiding portion defining a contact hole, and the cavity axis passes through the contact hole.

12. An electrical connector, comprising: a connector housing including a connector body and a connector cavity extending through the connector body; a terminal housing located within the connector cavity, the terminal housing including a terminal assurance member locking portion and a terminal cavity adapted to receive electrical terminals, the terminal cavity having a contact opening, a connection opening, an insertion opening, and defining a cavity axis extending through the contact opening and the connection opening, the insertion opening extending from the terminal cavity and adapted to permit the electrical terminals to be inserted into the terminal cavity in an insertion direction substantially perpendicular to the cavity axis; and a terminal position assurance member movable relative to the terminal housing in the insertion direction to an installed position, wherein a TPA latch engages a TPA locking portion to hold the terminal position assurance member in the installed position, and wherein the terminal position assurance member covers the insertion opening.

13. The electrical connector according to claim 12, wherein the terminal position assurance member further comprises a TPA body and a cavity cover, the cavity cover extending from the TPA body and covering at least a portion of the insertion opening, the cavity cover including cover locking portions located on opposite sides, each cover locking portion engaging a corresponding cover notch on the terminal housing.

14. The electrical connector according to claim 13, wherein the terminal position assurance member further comprises a contact guide portion, the contact guide portion being attached to the cavity cover and positioned adjacent to the contact opening, the contact guide portion defining a contact hole and the cavity axis passing through the contact hole, the contact guide portion including two guide locking portions, the guide locking portions engaging corresponding guide notches on the terminal housing.

15. The electrical connector according to claim 12, wherein the terminal housing further comprises a tab seat extending from the terminal cavity and adapted to receive a tab on the electrical terminal, and the terminal position assurance member further comprises a tab lock extending partially into the tab seat.

16. The electrical connector according to claim 15, wherein the terminal housing further comprises a stop portion, the stop portion being fixed relative to the terminal cavity and extending from the wall of the terminal cavity toward the cavity axis, and being located between the tab seat and the connection opening.

17. The electrical connector according to claim 12, wherein the terminal position assurance member further comprises a contact guide portion, the contact guide portion being positioned adjacent to the contact opening, the contact guide portion defining a contact hole, and the cavity axis passing through the contact hole.

18. The electrical connector according to claim 17, wherein the contact guide portion includes two guide locking portions, the guide locking portions engaging corresponding guide notches on the terminal housing.

19. The electrical connector according to claim 12, wherein, The connector housing includes a shroud and a latch, the shroud being connected to the connector body by a shroud wall, the shroud defining a window, the latch being attached to the connector housing and movable relative to the connector body between a latched position and a released position, the latch being at least partially located between the shroud and the connector body, the latch including a stop and a lift lever, the window being adapted to allow a tool to be inserted through the window to engage the lift lever.

20. An electrical connector, comprising: a terminal housing including a terminal cavity adapted to receive electrical terminals, the terminal cavity having a contact opening, a connection opening, an insertion opening, a tab seat, a stop portion, and defining a cavity axis extending through the contact opening and the connection opening, the insertion opening extending from the terminal cavity and adapted to allow the electrical terminals to be inserted into the terminal cavity in an insertion direction substantially perpendicular to the cavity axis, the tab seat extending from the terminal cavity and adapted to receive tabs on the electrical terminals, the stop portion being fixed relative to the terminal cavity and extending from the wall of the terminal cavity toward the cavity axis, the stop portion being located between the tab seat and the connection opening; Terminal position assurance member, which can move relative to the terminal housing in the insertion direction to an installation position, wherein the terminal position assurance member covers the insertion opening, the terminal position assurance member includes a TPA latch, a tab lock, and a contact guide portion, the TPA latch engages a TPA locking portion on the terminal housing to hold the terminal position assurance member in the installation position, the tab lock partially extends into the tab seat, the contact guide portion is positioned adjacent to the contact opening, the contact guide portion defines a contact hole, and the cavity axis passes through the contact hole; Shielding member, which is located around the terminal housing and the terminal position assurance member; Connector housing, the connector housing includes a connector body, a shield, and a latch, the connector body defines a connector cavity, the connector cavity extends through the connector body and defines a connector axis, the shield is connected to the connector body by two shield walls, each shield wall defines an assurance member slot extending parallel to the connector axis, the shield defines a window, the latch is at least partially located between the shield and the connector body, the latch is connected to the shield wall and can move relative to the connector body between a locked position and a released position, the latch includes a stop and a lifting lever, and the window is adapted to allow a tool to be inserted through the window to engage the lifting lever; and Connector position assurance member, which is attached to the connector housing for relative movement parallel to the cavity axis between a pre-locked position and a locked position, the connector position assurance member includes an assurance member body, assurance member guide portions located on opposite sides of the assurance member body, each assurance member guide portion of the assurance member guide portions located in the corresponding assurance member slot, an assurance member lock located on each assurance member guide portion in the assurance member guide portion, and an assurance member arm extending parallel to the cavity axis from the assurance member body; wherein the stop on the latch is adapted to engage a corresponding locking portion on the corresponding connector to hold the electrical connector relative to the corresponding connector in a mating position; wherein the terminal housing is located in the connector cavity, the cavity axis is parallel to the connector axis, and a component lock on the shielding member engages the connector body to hold the terminal housing relative to the connector housing in place; and wherein when the connector position assurance member is in the pre-locked position, the assurance member arm engages the stop on the latch to limit the movement of the connector position assurance member relative to the connector housing in the mating direction parallel to the cavity axis; and wherein the assurance member arm engages the stop to prevent the connector position assurance member from moving relative to the connector housing in a direction opposite to the mating direction, and when the connector position assurance member is in the locked position, the assurance member arm is at least partially located between the lifting lever and the window.

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