Connector assembly and method of assembling connector assembly

Abstract

A connector assembly comprising a connector comprising a first housing portion (1), a second housing portion (2), and a terminal holder (3) housed in said first housing portion (1). The second housing portion (2) comprises an actuation portion (25), and the terminal holder (3) comprises a wedge-shaped portion (14) configured to be at least partially inserted between the first housing portion (1) and the terminal holder (3). The actuating portion (25) is configured to press against the wedge portion (14) along a mounting displacement when the second housing portion is mounted with the first housing portion (1). The terminal holder (3) and the wedge portion (14) are configured to prevent movement between the first housing portion (1) and the terminal holder (3) parallel to the mating direction (MD) when the actuation portion (25) urges the wedge portion (14).

Description

Technical Field

[0001] A connector assembly and an assembly method for fastening parts of an automotive connector together are described below. Background Art

[0002] Certain types of connector assemblies can accommodate electrical terminals electrically connected to a printed circuit board. In this case, the assembly of the terminals on the printed circuit board, the assembly of the printed circuit and its terminals on the terminal holder, and the assembly of the entire connector are operations that can be performed on separate assembly lines and even by different suppliers. These different assemblies give rise to some limitations where rigid fixing of the connector parts needs to be avoided. For example, it may be advantageous to sandwich the terminal holder between two die-cast housing parts. As a result, the terminals of the assembled connector may not overlap the contacts of the mating connector. Therefore, a solution to this problem is needed.

[0003] The following disclosure relates to a connector including a PCB carrier or holder, but is not limited to such a configuration. The terminals can be mounted on a terminal holder and connected to conductive elements (wires, busbars, etc.) without the need for a PCB.

[0004] In any case, depending on the configuration of the connector assembly, problems of relative movement between the terminal holder and the housing part may occur. Such relative movement particularly impairs the quality and reliability of the electrical contact between the connector and the terminals of a mating connector configured to mate with the connector. In addition, there is a risk that the total load generated by the mating sequence (female and male connectors) is applied to the PCB terminal soldering area.

[0005] A connector assembly and an assembly method that at least partially meet the requirements of modern assembly processes are disclosed below. Summary of the Invention

[0006] The present disclosure relates to a connector assembly including a connector. The connector is intended to mate with and electrically connect to a mating connector. For example, the connector is a male connector and the mating connector is a female connector (but it can also be the opposite). For example, the male connector is a plug. The connector includes a first housing part, a second housing part, and a terminal holder received in the first housing part. At least one terminal is received in the terminal holder. The at least one terminal has a contact portion configured to connect to a terminal received in the mating connector. For example, the contact portion extends substantially along the mating direction of the connector and the mating connector. The second housing part is configured to be mounted together with the first housing part, wherein the second housing part has at least one mounting displacement relative to the first housing part parallel to the mating direction. In other words, the second housing part and the first housing part are mounted with a displacement relative to each other that has at least one component parallel to the mating direction.

[0007] In addition, the second housing part includes an actuating part, and the terminal holder includes a wedge part, the wedge part being configured to be at least partially inserted between the first housing part and the terminal holder. The actuating part is configured to press against the wedge part along the mounting displacement when the second housing part is mounted to the first housing part. The terminal holder and the wedge part are configured to prevent movement parallel to the mating direction between the first housing part and the terminal holder when the actuating part pushes the wedge part.

[0008] The above features have the following advantages:

[0009] - When it is not suitable to use rigid fixing means (screw means, locking means, etc.) to mount the terminal holder in the second housing part, they can eliminate the relative movement between the terminal holder and the second housing part before assembly with the first housing part (even in the case of inevitable clearances due to manufacturing tolerances);

[0010] - They can eliminate the movement in the mating direction between the first housing part and the terminal holder, and thus can achieve a more precise and reliable relative positioning of the connector and the mating connector terminals;

[0011] - They are easy to implement;

[0012] - They can be cost-effective because their molding does not require sliding parts;

[0013] - They can be implemented in various configurations and designs; and so on.

[0014] According to one embodiment, the actuating part has a beam-like shape extending longitudinally parallel to the mating direction. Thus, such an actuating part has a simple shape, is easy to mold, and is durable.

[0015] According to one embodiment, the terminal holder includes a base part and a flexible leg, the flexible leg being connected to the base part at one end by a hinge and including a wedge part at the other end, wherein the flexible leg includes a ramp configured such that when the second housing part is mounted to the first housing part along the mounting displacement, the actuating part interacts with the ramp and the flexible leg rotates about the hinge. For example, the flexible leg is thinner near the hinge than near the wedge part. For example, the wedge part includes at least one first wedge and at least one second wedge, both protruding in a direction substantially perpendicular to the mating direction at the free end of the flexible leg. For example, the actuating part engages in a channel extending substantially parallel to the mating direction, and the first wedge projects at the mouth of the channel. With this configuration, the terminal holder can be molded without using sliding parts.

[0016] According to one embodiment, the actuating part and the wedge part are configured such that the actuating part presses the first side of the wedge part against the first housing part and presses the second side of the wedge part against the terminal holder.

[0017] According to one embodiment, the first wedge includes a first friction surface having a convex shape. This configuration enables a robust wedge friction lock. This locking function (in addition to the locking function provided by the interaction of the second side of the wedge part against the terminal holder) also ensures the correct positioning of the wedge between the first housing part, the second housing part, and the terminal holder, even if the flexible legs are damaged or broken.

[0018] According to one embodiment, the connector assembly is configured such that any movement of the terminal holder relative to the first housing part in the mating direction is controlled only by the interaction between the actuating part and the wedge part.

[0019] According to another aspect, a method for assembling a connector is disclosed below, which method at least includes the following steps:

[0020] - Mount the terminal holder in the first housing part in the insertion direction;

[0021] - Mount the second housing part to the first housing part;

[0022] - Mount the connector to the mating connector in parallel with the mating direction, thereby pushing the second housing part in the mating direction and pressing the actuating part against the wedge part to pivot the wedge part, so as to press the first side of the wedge part against the first housing part and press the second side of the wedge part against the terminal holder.

[0023] According to one embodiment, the insertion direction is perpendicular to the mating direction. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The exemplary embodiments and functions of the present disclosure will be described in more detail below with reference to the drawings, which are shown as:

[0025] - Figure 1 and Figure 2 is a schematic exploded perspective view of an embodiment of the connector assembly;

[0026] - Figure 3 is Figure 1 and Figure 2 a perspective view of the terminal holder of the connector assembly shown in;

[0027] - Figure 4 shows Figure 3 a front view of a part of the terminal holder shown in;

[0028] - Figure 5 isFigure 3 and Figure 4 A perspective view of the wedge portion of the terminal holder shown;

[0029] - Figure 6 and Figure 7 is Figure 3 and Figure 4 A side view of the wedge portion of the terminal holder and the first and second housing portions with which the wedge portion interacts, shown; and

[0030] - Figure 8 is Figure 1 and Figure 2 A perspective view of an embodiment of the connector assembly shown, in which the first housing portion, the second housing portion, and the terminal holder are assembled. DETAILED DESCRIPTION

[0031] The present disclosure relates to a connector assembly 100 (see Figure 8 ). The connector assembly 100 includes at least a connector 10. The connector assembly 100 may also include a mating connector (not shown). Then, the connector 10 is configured to match with the mating connector. For example, the connector 10 is a male connector. For example, the male connector 10 is a plug. The connector 10 includes at least a first housing portion 1, a second housing portion 2, and a terminal holder 3. For example, the first housing portion 1 is a die-cast housing. For example, the die-cast housing is part of a power box. For example, the second housing portion 2 is a plug shroud. For example, the second housing portion 2 is a molded plastic part.

[0032] The terminal holder 3 is also referred to as a pin block. The terminal holder 3 is made of a dielectric material. For example, the terminal holder 3 is a molded plastic part. At least one terminal 4 is received in the terminal holder 3 (see Figure 1 ). Possibly, the terminal holder 3 supports a plurality of terminals 4. Each terminal 4 held by the terminal holder 3 is made of a conductive material. For example, each of these terminals 4 is cut from a sheet of conductive material into male terminals and bent to have a contact portion 5 configured to connect to a female terminal received in the mating connector. The contact portion 5 extends substantially along the mating direction MD of the connector 10 and the mating connector. For example, at least one or each of these terminals 4 is stitched in the terminal holder 3. Alternatively, the terminal holder 3 is overmolded on at least one or each of these terminals 4. Alternatively, at least one or each of these terminals 4 is simply inserted into an opening 6 formed in the terminal holder 3 (see Figure 4 ). For example, each of these terminals 4 extends between a contact portion 5 and a connection portion 7 (see Figure 1)。For example, the connection part 7 is welded to the PCB 8. The contact part 5 extends substantially parallel to the mating direction MD. Thus, when the male connector 10 mates with the female mating connector, it is crucial that the insertion force between the male and female terminals is not transferred or not fully transferred at the solder joints on the PCB 8.

[0033] The terminal holder 3 is mounted in the first housing part 1 together with the terminals 4 and the PCB 8 (see Figure 1 and Figure 2 ). For example, the terminal holder 3 is mounted in the first housing part 1 along the insertion direction ID perpendicular to the mating direction MD.

[0034] Specifically as Figures 3 to 5 shown, the terminal holder 3 includes a base part 9 and an insulating wall 11. The base part 9 has a substantially plate-like shape extending perpendicular to the mating direction MD (when the terminal holder 3 is mounted in the first housing part 1). An opening 6 is made through the base part 9. The wall 11 extends perpendicular to the base part 9.

[0035] The terminal holder 3 further includes a wedge device. The terminal holder 3 may include one or a plurality of wedge devices (e.g., at opposite corners or opposite end sides of the base part 9). For example, each wedge device includes at least one flexible leg 12. Each flexible leg 11 extends substantially parallel to the mating direction MD between the hinge 13 and the wedge part 14 (when the terminal holder 3 is mounted in the first housing part 1). Each hinge 13 connects the flexible leg 12 to the base part 9. More specifically, each flexible leg 12 extends from the corresponding hinge 13 in a direction opposite to the wall 11. In other words, each flexible leg 12 extends from the first side where the wall 11 extends from the base part 9 to the second side opposite to the first side of the base part 9, and the wedge part 14 projects at least partially on the second side. The length of the flexible leg 12 is longer than the thickness of the base part 9.

[0036] Each flexible leg 12 includes an inclined ramp 15, as seen in a cross-section in a plane perpendicular to the wall and parallel to the mating direction MD (see Figure 5 ), and the ramp 15 is configured such that the flexible leg 12 is thinner near the hinge 13 than near the wedge part 14. Advantageously, the terminal holder 3 includes a guide wall 16 facing the ramp 15. Advantageously, the distance between the flexible leg 12 and the guide wall 16 aligned with the hinge 13 (in a direction perpendicular to the mating direction MD) is greater than the distance towards the wedge part 14. For example, the guide wall 16 extends in a plane parallel to the mating direction MD, while the ramp 15 is angled with respect to the mating direction MD.

[0037] The wedge-shaped portion 14 includes at least one first wedge member 17 and at least one second wedge member 18. In the illustrated example, the wedge-shaped portion 14 includes one first wedge member 17 and two second wedge members 18 (see Figure 5 ).

[0038] The first wedge member 17 projects below the ramp 15 at the free end of the flexible leg 12 in a direction opposite to that of the second wedge members 18. In other words, the first wedge member 17 projects in the channel 19 that is at least partially defined by the flexible leg 12 and the guide wall 16, at the end of the channel or at the mouth of the channel 19. In the illustrated example, the first wedge member 17 projects at the mouth of the channel 19. The first wedge member 17 includes a blocking surface 20 facing the outlet of the channel 19. In the illustrated example, the blocking surface 20 at least partially closes the mouth of the channel 19. The blocking surface 20 forms an angle less than or equal to 90° with the longitudinal direction of the flexible leg 12 and an angle greater than 90° with the ramp 15 (see Figure 6 ). When the flexible leg 12 is not deflected, the blocking surface 20 forms an angle greater than or equal to 90° with the guide wall 16. When the flexible leg 12 is fully deflected, the blocking surface 20 forms an angle less than or equal to 90° with the guide wall 16 (see Figure 7 ). The first wedge member 17 further includes a first friction surface 21. Advantageously, the first friction surface 21 has a convex shape, and its curvature basically points in the direction of the channel 19.

[0039] Each second wedge member 18 extends in the gap 28 located between the terminal holder 3 and the first housing part 1. The terminal holder 3 includes an inclined surface 22. When the flexible leg 12 is not deflected, the inclined surface 22 is offset from the second wedge member 18 in a plane perpendicular to the mating direction MD (see Figure 6 ). When the flexible leg 12 is deflected, the second wedge member 18 is located below the inclined surface 22, in the gap 28 between the inclined surface 22 and the first housing part 1 (see Figure 7 ).

[0040] Each second wedge member 18 includes a second friction surface 23. The second friction surface 23 forms an angle greater than or equal to 90° with the longitudinal direction of the flexible leg 12. The flexible leg 12 can be deflected to a position where the friction surface 23 is pushed against the inclined surface 22. Each second wedge member 18 further includes a bottom surface 24 that guides towards the first housing part 1.

[0041] The second housing part 2 includes at least one actuating part 25 (see Figure 6 and Figure 7)。For example, the second housing part 2 includes as many actuation parts 25 as there are wedge devices. In the example shown, the actuation parts 25 have a beam-like shape extending longitudinally parallel to the mating direction MD. The shape of each actuation part 25 is adapted to penetrate and slide into the corresponding channel 19. The thickness of the actuation part 25 is greater than the minimum dimension of the channel 19 in a direction perpendicular to the guiding wall 16 (see Figure 6 and Figure 7 ).

[0042] It can be noted that the channel 19 and two other channels 26 (see Figure 4 and Figure 5 ) can be used for molding the flexible legs 12 as well as the first wedge 17 and the second wedge 18 without using additional molding sliders. Thus, the manufacturing process of the connector assembly 100 according to the present disclosure remains cost-effective.

[0043] According to the present invention, the assembly process of the connector assembly 100 at least includes the following steps:

[0044] - Mount the terminal holder 3 in the first housing part 1; for example, the terminal holder 3 is inserted into the first housing part 1 along the insertion direction ID (see Figure 1 );

[0045] - Mount the second housing part 2 onto the first housing part 1 (see Figure 2 ); for example, the second housing part 2 is inserted into the first housing part 1 along an installation direction parallel to the mating direction MD to form the connector 10;

[0046] - Mount the connector 10 together with a mating connector (not shown); for example, the mating connector includes a die-cast part that is mounted against the die-cast part (the first housing part 1) of the connector 10; by doing so, the window 27 (see Figure 8 ) is closed, and the second housing part 2 is pressed into and held within the first housing part 1; in other words, the second housing part 2 is mounted together with the first housing part 1, where the second housing part 2 has at least one mounting displacement relative to the first housing part 1 parallel to the mating direction MD; by doing so, at least one actuation part 25 is pushed into the corresponding channel 19 along the mating direction MD (see Figure 6 ); thus, each actuation part 25 slides along the corresponding ramp 15; then, each flexible leg 12 flexes, and the corresponding second wedge 18 moves under the inclined surface 22 while the first friction surface 21 contacts the first housing part 1 (see Figure 8) Since the first friction surface 20 is convex, if the actuating part 25 presses the blocking surface 20 against the appropriate side of the contact point between the first friction surface 21 and the first housing part 1, the first wedge 17 tends to rotate to push the second friction surface 23 against the inclined surface 22; in other words, when the connector 10 is fitted with a mating connector, the mating connector pushes the second housing part 2 in the mating direction MD, thereby pushing the actuating part 25 against the wedge part 14, causing the wedge part 14 to pivot, so that one side of the wedge part 14 is pressed against the first housing part 1 and the other side of the wedge part 14 is pressed against the terminal holder 3; it can be noted that even if the flexible leg 12 breaks, the wedging function of the wedge part 14 remains effective.

[0047] As a result of the above assembly process, the movement of the terminal holder 3 relative to the first housing part 1 in the mating direction MD is cancelled. In other words, the gap 28 between the terminal holder 3 and the first housing part 1 is compensated. Any movement of the terminal holder 3 relative to the first housing part 1 in the mating direction MD is only controlled by the interaction between the actuating part 25 and the wedge part 14, i.e. such movement is not controlled by tightening devices, latching devices, etc. In addition, the movement of the second housing part 2 relative to the terminal holder 3 and the first housing part 1 in the mating direction MD is also cancelled.

[0048] It can be noted that even if the claimed invention is illustrated and described with the first housing part 1 being a die-cast housing and the second housing part 2 being a plug shroud, the present invention can also be used in other types of connector assemblies that require gap compensation.

[0049] The advantage of the connector assembly disclosed above is that it increases the contact overlap between the respective terminals of the connector 10 and the mating connector. The present invention also has the advantage of reducing or eliminating the relative movement between the terminal holder 3 and the PCB 8 (which preserves the solder joints between the terminals and the PCB).

Claims

1. A connector assembly (100), the connector assembly comprising a connector (10), the connector including a first housing part (1), a second housing part (2), and a terminal holder (3) received in the first housing part (1). Among them, At least one terminal (4) is received in the terminal holder (3), the at least one terminal (4) having a contact portion (5) configured to connect to a terminal received in a mating connector, the contact portion (5) extending substantially along a mating direction (MD) of the connector (10) and the mating connector. Wherein the second housing part (2) is configured to be mounted together with the first housing part (1), and wherein the second housing part (2) has at least one mounting displacement relative to the first housing part (1) parallel to the mating direction (MD). It is characterized in that - the second housing part (2) includes an actuating part (25), and the terminal holder (3) includes a wedge part (14), the wedge part (13) being configured to be at least partially inserted between the first housing part (1) and the terminal holder (3); - the actuating part (25) is configured to press on the wedge part (14) along the mounting displacement when the second housing part (2) is mounted together with the first housing part (1); and - the terminal holder (3) and the wedge part (14) are configured to prevent movement parallel to the mating direction (MD) between the first housing part (1) and the terminal holder (3) when the actuating part (25) pushes the wedge part (14).

2. The connector assembly (100) according to claim 1, wherein, The actuating part (25) has a beam-like shape extending longitudinally parallel to the mating direction (MD).

3. The connector assembly (100) according to claim 1 or 2, characterized in that, The terminal holder (3) includes a base part (9) and flexible legs (12), the flexible legs being connected to the base part at one end by a hinge (13) and including the wedge part (14) at the other end, wherein the flexible legs (12) include a ramp (15) configured such that when the second housing part (2) is mounted together with the first housing part (1) along the mounting displacement, the actuating part (25) interacts with the ramp (15) and the flexible legs (12) rotate about the hinge (13).

4. The connector assembly (100) according to claim 3, wherein, The flexible legs (12) are thinner near the hinge (13) than near the wedge part (14).

5. The connector assembly (100) according to claim 3 or 4, characterized in that, The wedge part (14) includes at least one first wedge piece (17) and at least one second wedge piece (18), both protruding in a direction substantially perpendicular to the mating direction (MD) at the free end of the flexible legs (12).

6. The connector assembly (100) according to claim 5, wherein, The first wedge piece (17) includes a first friction surface (21) having a convex shape.

7. The connector assembly (100) according to claim 5 or 6, characterized in that, The actuating part (25) engages in a channel (19) substantially parallel to the mating direction (MD), and the first wedge piece (17) protrudes at the mouth of the channel (19).

8. The connector assembly (100) according to any one of the preceding claims, characterized in that, The actuating part (25) and the wedge part (14) are configured such that the actuating part (25) pushes a first side of the wedge part (14) against the first housing part (1) and a second side of the wedge part (14) against the terminal holder (3).

9. The connector assembly (100) according to any one of the preceding claims, characterized in that, The connector assembly is configured such that any movement of the terminal holder (3) relative to the first housing part (1) in the mating direction (MD) is controlled only by the interaction between the actuating part (25) and the wedge part (14).

10. A method of assembling a connector assembly (100) according to any one of the preceding claims, comprising at least the following steps: - mounting the terminal holder (3) in the first housing part (1) in the insertion direction (ID); - mounting the second housing part (2) together with the first housing part (1); - mounting the connector (10) together with a mating connector parallel to the mating direction (MD), thereby pushing the second housing part (2) in the mating direction (MD) and pushing the actuating part (25) against the wedge part (14) to pivot the wedge part (14), so as to press a first side of the wedge part (14) against the first housing part (1) and a second side of the wedge part (14) against the terminal holder (3).

11. The method according to claim 10, wherein The insertion direction (ID) is perpendicular to the mating direction (MD).

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