Modular electric connector

Abstract

An electrical connector (100) includes a connector housing (110) including a module cavity (134) and a track (140) at an end of the connector housing. A terminal module (200) is received in a corresponding module cavity, each module cavity having a module housing (210) holding a terminal (250) terminated to an end of an electrical wire (14). A wire cover (150) is connected to the rail and includes a wire cavity (158) that receives wires from the terminal module and directs the wires to a wire outlet (166). The wire cover includes module blocking walls (180) positioned along the terminal modules to block removal of the terminal modules from the corresponding module cavities.

Description

Technical Field

[0001] The subject matter of this document generally relates to electrical connectors. Background Art

[0002] Electrical connectors mate together to electrically connect various components, such as via wires. Electrical connectors include mating terminals that connect at a separable mating interface, such as pins and sockets. The electrical performance of the connector is affected by the signal integrity at the mating interface. Signal integrity is affected by the mating depth of the male and female terminals. The connector is designed to have tight mating tolerances to control the mating depth. However, it is difficult to obtain tight mating tolerances, especially for modular connectors with internal modules, where the internal modules increase the tolerances of the interface.

[0003] There is still a need for electrical connectors with a controlled mating depth to improve signal integrity. Summary of the Invention

[0004] In one embodiment, there is provided an electrical connector that includes a connector housing that includes a mating end at a first end of the connector housing. The connector housing includes module cavities separated by partition walls. The connector housing includes tracks at a second end of the connector housing. The electrical connector includes terminal modules received in corresponding module cavities. Each terminal module includes a module housing having a terminal channel. Each terminal module includes terminals received in the corresponding terminal channels. The terminals are terminated to ends of wires extending from an end of the corresponding module housing. The electrical connector includes a wire cover that is coupled to the tracks at the second end of the connector housing. The wire cover includes a wire cavity that receives wires from the terminal modules. The wire cover has a wire outlet. The wire cover guides the wires to the wire outlet. The wire cover includes module blocking walls positioned along the terminal modules to block removal of the terminal modules from the corresponding module cavities.

[0005] In another embodiment, an electrical connector is provided that includes a connector housing having a mating end at a first end of the connector housing configured to mate with a mating electrical connector. The connector housing includes module cavities separated by partition walls. The connector housing includes tracks at a second end of the connector housing. The electrical connector includes a lever rotatably coupled to the connector housing and movable between an open position and a closed position. The lever is configured to securely couple to the mating electrical connector in the closed position. The electrical connector includes terminal modules received in corresponding module cavities. Each terminal module includes a module housing having a terminal channel. Each terminal module includes terminals received in the corresponding terminal channels. The terminals are terminated to ends of wires extending from ends of the corresponding module housing. The electrical connector includes a wire cover coupled to the tracks at the second end of the connector housing. The wire cover includes a wire cavity for receiving wires from the terminal modules. The wire cover has a wire outlet. The wire cover guides the wires to the wire outlet. The wire cover includes module blocking walls positioned along the terminal modules to block removal of the terminal modules from the corresponding module cavities. The wire cover includes a locking lever configured to couple to the lever to hold the lever in the closed position. BRIEF DESCRIPTION OF THE DRAWINGS

[0006] The present invention will now be described by way of example with reference to the accompanying drawings, in which:

[0007] Figure 1 is a perspective view of an electrical connector system according to an exemplary embodiment.

[0008] Figure 2 shows a portion of an electrical connector system according to an exemplary embodiment, showing portions of terminals coupled together.

[0009] Figure 3 shows a portion of an electrical connector system according to an exemplary embodiment, showing portions of terminals coupled together.

[0010] Figure 4 is a rear perspective exploded view of an electrical connector according to an exemplary embodiment.

[0011] Figure 5 is a rear perspective view of a portion of an electrical connector according to an exemplary embodiment.

[0012] Figure 6 is a rear perspective view of a terminal module according to an exemplary embodiment.

[0013] Figure 7 is a rear perspective view of another terminal module according to an exemplary embodiment.

[0014] Figure 8Is a rear perspective view of a portion of an electrical connector according to an exemplary embodiment.

[0015] Figure 9 Is a cross-sectional view of a portion of an electrical connector according to an exemplary embodiment, showing a wire cover coupled to the connector housing and mating with one of the terminal modules.

[0016] Figure 10 Is a perspective view of an electrical connector according to an exemplary embodiment, showing a wire cover having a right-side wire exit.

[0017] Figure 11 Is a perspective view of an electrical connector according to an exemplary embodiment, showing a wire cover having a left-side wire exit.

[0018] Figure 12 Is a top view of an electrical connector according to an exemplary embodiment, showing a locking lever in an open position.

[0019] Figure 13 Is a top view of an electrical connector according to an exemplary embodiment, showing a locking lever in a closed position. Detailed Description

[0020] Figure 1 Is a perspective view of an electrical connector system 10 according to an exemplary embodiment. The electrical connector system 10 includes a first electrical connector 100 and a second electrical connector 300 that mates with the first electrical connector 100. The second electrical connector 300 is a mating electrical connector for the first electrical connector 100 and vice versa. In an exemplary embodiment, the second electrical connector 300 is a plug connector that is configured to be inserted into the first electrical connector 100. In an exemplary embodiment, the first electrical connector 100 is a socket connector that is configured to receive the second electrical connector 300.

[0021] In an exemplary embodiment, the first electrical connector 100 is a cable connector that has one or more cables 12 extending therefrom. Each cable 12 may have one or more wires 14 arranged to form a bundle of the cable 12. In an exemplary embodiment, the second electrical connector 300 is a cable connector that has one or more cables 16 extending therefrom. Each cable 16 may have one or more wires 18 arranged to form a bundle of the cable 16. In alternative embodiments, the first electrical connector 100 and / or the second electrical connector 300 may be board connectors configured to be mounted to a circuit board. In various embodiments, the first electrical connector 100 and / or the second electrical connector 300 may be mounted to another component, such as mounted to a wall or a panel.

[0022] The first electrical connector 100 includes a connector housing 110 that is configured to hold one or more terminals 250 (in Figure 2and Figure 3 as shown in). The terminal 250 is terminated to the end of the corresponding wire 14. In an exemplary embodiment, the electrical connector 100 is a modular connector that holds one or more terminal modules 200 (shown in Figure 4 as shown in). Each terminal module 200 is configured to hold one or more of the terminals 250.

[0023] The second electrical connector 300 includes a connector housing 310 that is configured to hold one or more terminals 450 (shown in Figure 2 and Figure 3 as shown in). The terminal 450 is terminated to the end of the corresponding wire 18. In an exemplary embodiment, the electrical connector 100 is a modular connector that holds one or more terminal modules 400. Each terminal module 400 is configured to hold one or more of the terminals 450.

[0024] In an exemplary embodiment, the first electrical connector 100 includes a guiding feature 112, and the second electrical connector 300 includes a guiding feature 312 to guide the mating of the first electrical connector 100 and the second electrical connector 300. In the illustrated embodiment, the guiding feature 312 is a guiding rib, and the guiding feature 112 is a guiding channel that receives the guiding rib. In alternative embodiments, other types of guiding features may be used. Optionally, the guiding features 112, 312 may be polarizing or keying features for keyed mating of the first electrical connector 100 and the second electrical connector 300.

[0025] In an exemplary embodiment, the first electrical connector 100 includes a fixing feature 114, and the second electrical connector 300 includes a fixing feature 314 to fix the first electrical connector 100 and the second electrical connector 300 together upon mating. The fixing features 114, 314 may include latches, clips, fasteners, or other types of fixing features. In an exemplary embodiment, the fixing feature 314 includes a locking lug 316 that extends outwardly from the side of the connector housing 310 to mate with the fixing feature 114 of the first electrical connector 100. In an exemplary embodiment, the fixing feature 114 of the first electrical connector 100 includes a locking lever 116 that is rotatably coupled to the connector housing 110. The locking lever 116 mates with the locking lug 316 to fix the first electrical connector 100 and the second electrical connector 300. Optionally, as the locking lever 116 rotates to a final or closed position, the locking lever 116 is used to drive the mating of the first electrical connector 100 and the second electrical connector 300. For example, the rotational movement of the locking lever 116 causes an axial movement of the connector housings 110, 310 relative to each other to force the connector housings 110, 310 towards each other to reach a final mating position.

[0026] In an exemplary embodiment, the first electrical connector 100 includes a wire cover 150 coupled to the connector housing 110. The wire cover 150 covers the wires 14 extending from the first electrical connector 100. The wire cover 150 is used to guide or organize the wires 14 at the cable outlet. For example, the wire cover 150 controls the direction of departure of the wires 14 from the first electrical connector 100. In an exemplary embodiment, the wire cover 150 is located behind the terminal module 200 to hold the terminal module 200 in the connector housing 110. In an exemplary embodiment, the wire cover 150 is configured to bias the terminal module 200 in the connector housing 110 forward to ensure proper positioning of the terminals 250 relative to the connector housing 110 for mating with the second electrical connector 300. The wire cover 150 prevents removal of the terminal module 200 from the connector housing 110. For example, the wire cover 150 operates as a separate secondary locking device for the terminal module 200 to hold the terminal module 200 in the connector housing 110. In an exemplary embodiment, the wire cover 150 operates as a module position assurance device to ensure that the terminal module 200 is fully loaded into the connector housing 110. For example, if any of the terminal modules in the terminal module 200 are not properly loaded into the connector housing 110, the wire cover 150 may not be properly coupled to the connector housing 110. For example, the wire cover 150 is configured to be coupled to the connector housing 110 only when all of the terminal modules 200 are fully loaded into the connector housing 110. In an exemplary embodiment, the wire cover 150 houses a component position assurance device 190 that ensures that the locking lever 116 is in a final or closed position to ensure full mating of the first and second electrical connectors 100, 300.

[0027] In an exemplary embodiment, the second electrical connector 300 includes a wire cover 350 coupled to the connector housing 310. The wire cover 350 covers the wires 18 extending from the second electrical connector 300. The wire cover 350 is used to guide or organize the wires 18 at the cable exit. For example, the wire cover 350 controls the direction in which the wires 18 leave the second electrical connector 300. In an exemplary embodiment, the wire cover 350 is located behind the terminal module 400 to hold the terminal module 400 in the connector housing 310. In an exemplary embodiment, the wire cover 350 is configured to bias the terminal module 400 in the connector housing 310 forward to ensure proper positioning of the terminals 450 relative to the connector housing 310 for mating with the second electrical connector 300. The wire cover 350 prevents the removal of the terminal module 400 from the connector housing 310. For example, the wire cover 350 operates as a separate auxiliary locking device for the terminal module 400 to hold the terminal module 400 in the connector housing 310. In an exemplary embodiment, the wire cover 350 operates as a module position assurance device to ensure that the terminal module 400 is fully loaded into the connector housing 310. For example, if any of the terminal modules in the terminal module 400 are not properly loaded into the connector housing 310, the wire cover 350 may not be properly coupled to the connector housing 310. For example, the wire cover 350 is configured to be coupled to the connector housing 310 only when all of the terminal modules 400 are fully loaded into the connector housing 310.

[0028] Figure 2 A portion of an electrical connector system 10 according to an exemplary embodiment is shown, which shows portions of terminals 250, 450 coupled together. Figure 3 A portion of an electrical connector system 10 according to an exemplary embodiment is shown, which shows portions of terminals 250, 450 coupled together. Figure 2 The external contacts 252, 452 of the terminals 250, 450 coupled together are shown. Figure 3 The internal contacts 254, 454 of the terminals 250, 450 coupled together are shown. In an exemplary embodiment, the external contacts 252, 452 are ground or shield contacts for the internal contacts 254, 454.

[0029] The internal contacts 254, 454 are respectively terminated at the ends of the center conductors of the wires 14, 18. For example, the internal contacts 254, 454 may be crimped to the ends of the conductors of the wires 14, 18. In the illustrated embodiment, the internal contact 254 is a socket contact, while the internal contact 454 is a pin contact. Other types of contacts may be used in alternative embodiments. The internal contacts 254, 454 are configured to be held in the external contacts 252, 452 using an insulator to electrically isolate the internal contacts 254, 454 from the external contacts 252, 452.

[0030] The outer contacts 252, 452 are respectively terminated to the ends of the wires 14, 18. For example, the outer contacts 252, 452 can be crimped to the cable shields of the wires 14, 18. The end of the outer contact 452 can be inserted into the end of the outer contact 252. In the illustrated embodiment, the outer contact 252 includes a spring beam or finger 256 configured to engage the outer surface of the outer contact 452. In an exemplary embodiment, the outer contacts 252, 452 include datum surfaces 258, 458. The datum surfaces 258, 458 are configured to be held in the terminal modules 200, 400 at specific positions. For example, the terminal modules 200, 400 can include positioning elements, such as latches that respectively engage the datum surfaces 258, 458, to hold the terminals 250, 450 at specific positions within the terminal modules 200, 400. When the electrical connectors 100, 300 are mated, the datum surfaces 258, 458 are located at a predetermined position (within a specific tolerance) to control the signal integrity and performance of the electrical connector system 10. By way of example, the datum surfaces 258, 458 are configured to be positioned a predetermined distance 500 apart from each other, which ensures proper mating of the terminals 250, 450.

[0031] Figure 4 is a rear perspective exploded view of an electrical connector 100 according to an exemplary embodiment. Figure 5 is a rear perspective view of a portion of an electrical connector 100 according to an exemplary embodiment. Figure 4 and Figure 5 shows the terminal module 200 loaded into the connector housing 110. Figure 4 shows the wire cover 150 ready to be coupled to the connector housing 110.

[0032] The connector housing 110 extends between a front portion 120 and a rear portion 122. In an exemplary embodiment, the front portion 120 defines a mating end 124 of the connector housing 110, and the mating end 124 is configured to mate with a second electrical connector 300. In an exemplary embodiment, the wire cover 150 is coupled to the rear portion 122 of the connector housing 110. The wire 14 is configured to exit the connector housing 110 at the rear portion 122. The connector housing 110 includes a top 126 and a bottom 128. In the illustrated embodiment, the top 126 and the bottom 128 are planar and parallel to each other. However, in alternative embodiments, the top 126 and / or the bottom 128 may be non-planar and not parallel to each other. The connector housing 110 includes a first side 130 and a second side 132 that extend between the top 126 and the bottom 128. In the illustrated embodiment, the sides 130, 132 are planar and parallel to each other. However, in alternative embodiments, the sides 130, 132 may be non-planar and / or not parallel to each other. In the illustrated embodiment, the connector housing 110 is generally box-shaped. In alternative embodiments, the connector housing 110 may have other shapes.

[0033] In an exemplary embodiment, guide features 112 are located on the top 126 and / or the bottom 128. For example, the guide features 112 are recesses or channels formed by shrouds at the top 126 and the bottom 128. Other types of guide features 112 may be used in alternative embodiments. In an exemplary embodiment, the locking lever 116 is coupled to the sides 130, 132 of the connector housing 110. The locking lever 116 is pivotally coupled to an axis extending from the sides 130, 132. In the illustrated embodiment, the handle of the locking lever 116 is located above the connector housing 110. In alternative embodiments, other locations are possible.

[0034] In an exemplary embodiment, the connector housing 110 includes a module cavity 134 that receives a corresponding terminal module 200. The module cavity 134 is separated by a partition wall 136. In the illustrated embodiment, the module cavity 134 is located between the top 126 and the bottom 128 of the connector housing 110. The partition wall 136 is oriented parallel to the sides 130, 132, dividing the connector housing 110 into the module cavity 134. In the illustrated embodiment, the connector housing 110 includes four module cavities 134 that receive corresponding terminal modules 200. In alternative embodiments that include a single module cavity, more or fewer module cavities 134 may be used.

[0035] Also refer to Figure 6 and Figure 7 , Figure 6 is a rear perspective view of the terminal module 200 according to an exemplary embodiment, and Figure 7is a rear perspective view of another terminal module 200 according to an exemplary embodiment. The various terminal modules 200 are designed to be modular to allow different types of terminal modules 200 to be picked and placed into the connector housing 110 according to a particular application. For example, the various terminal modules 200 may have similar external dimensions and features for positioning the terminal module 200 within the module cavity 134 of the connector housing 110. However, the internal features of the various terminal modules 200 may differ from one another. For example, the various terminal modules 200 may hold different types of terminals 250, different sizes of terminals 250, different numbers of terminals 250, etc., to vary the mating configuration of the terminal modules 200 relative to one another.

[0036] Each terminal module 200 includes a module housing 210. The module housing 210 includes guide features 212 to guide the loading of the terminal module 200 into the module cavity 134 of the connector housing 110. In the illustrated embodiment, the guide features 212 include one or more rails formed on one or more sides of the module housing 210. Optionally, the guide features 212 may be sized and / or positioned to define polarization or keying features for keyed mating with the connector housing 110. In an exemplary embodiment, each terminal module 200 includes fixing features 212 to fix the module housing 210 within the module cavity 134. In the illustrated embodiment, the fixing feature 214 includes a deflectable latch 216 configured to latchably couple to the connector housing 110 to hold the terminal module 200 within the module cavity 134. Optionally, the latch 216 may be located at the top and bottom of the module housing 210. In alternative embodiments, other locations are feasible. In an exemplary embodiment, the terminal module 200 may include one or more terminal latches 218 for fixing the terminals 250 within the module housing 210. The terminal latches 218 may extend into the interior of the module housing 210 to interface with the terminals 250 to hold the terminals 250 within the module housing 210.

[0037] In an exemplary embodiment, the module housing 210 extends between a front portion 220 and a rear portion 222. In an exemplary embodiment, the front portion 220 defines a docking end 224 of the module housing 210, and the docking end 224 is configured to dock with a second electrical connector 300. The wire 14 may extend from the rear portion 222 of the module housing 210. The module housing 210 includes a top 226 and a bottom 228. In the illustrated embodiment, the top 226 and the bottom 228 are planar and parallel to each other. However, in alternative embodiments, the top 226 and / or the bottom 228 may be non-planar and not parallel to each other. The module housing 210 includes a first side 230 and a second side 232 that extend between the top 226 and the bottom 228. In the illustrated embodiment, the sides 230, 232 are planar and parallel to each other. However, in alternative embodiments, the sides 230, 232 may be non-planar and / or not parallel to each other. In the illustrated embodiment, the module housing 210 is generally box-shaped. In alternative embodiments, the module housing 210 may have other shapes.

[0038] In an exemplary embodiment, the guiding features 212 are located on the sides 230, 232. For example, the guiding features 212 are ribs extending from the sides 230, 232. The sides may include different numbers and / or positions of guiding features 212. Other types of guiding features 212 may be used in alternative embodiments. In an exemplary embodiment, the latches 216 are located at the top 226 and the bottom 228. In alternative embodiments, other locations are possible.

[0039] In an exemplary embodiment, the module housing 210 includes terminal cavities 234 that receive corresponding terminals 250. In the illustrated embodiment, the terminal cavities 234 are arranged in one or more columns and one or more rows. The number of terminal cavities corresponds to the number of terminals 250. The terminal cavities 234 may have different sizes to accommodate different sizes of terminals 250.

[0040] In an exemplary embodiment, each module housing 210 includes one or more biasing bumps 240 at a rear portion 222 of the module housing 210. The biasing bumps 240 project rearwardly from the rear portion 222 of the module housing 210. The biasing bumps 240 are configured to dock with the wire cover 150 to bias the terminal module 200 forwardly in the module cavity 134 of the connector housing 110. In an exemplary embodiment, each biasing bump 240 includes a ramp 242 extending forwardly and a base 244 at a distal end of the biasing bump 240. The ramp 242 extends from the rear portion 222 of the module housing 210 to the base 244. Optionally, the ramp 242 may be located on both sides of the base 244. The ramp 242 is an angled surface angled relative to the rear portion 222 to guide the wire cover 150 as the wire cover 150 slides along the terminal module 200. Optionally, the ramp 242 may be angled at approximately 45° relative to the rear portion 222. In an exemplary embodiment, the base 244 is a flat surface configured to abut a stop surface of the wire cover 150 when the wire cover 150 is coupled to the connector housing 110. The base 244 may be parallel to the rear portion 222 and / or parallel to the sliding direction of the wire cover 150. The base 244 is positioned a distance behind the rear portion 222 of the module housing 210. This distance corresponds to the amount by which the terminal module 200 is biased forwardly by the wire cover 150 during assembly.

[0041] In an exemplary embodiment, the module housing 210 includes a plurality of biasing bumps 240. For example, the module housing 210 may include at least one biasing bump 240 at or near a top 226 and at least one biasing bump 240 at or near a bottom 228. The module housing 210 may include biasing bumps 240 at both a first side 230 and a second side 232. In the illustrated embodiment, the module housing 210 includes four biasing bumps 240, with one biasing bump 240 located at each corner of the module housing 210 at the rear portion 222. In alternative embodiments, other locations are feasible.

[0042] Return to Figure 4 and Figure 5 , the terminal module 200 is configured to be loaded into a corresponding module cavity 134. For example, the terminal module 200 may be loaded into the module cavity 134 through a rear portion 122 of the connector housing 110. The terminal module 200 may be latchably coupled to the connector housing 110 within the module cavity 134.

[0043] In an exemplary embodiment, the connector housing 110 includes a track 140 at the rear portion 122. The wire cover 150 is coupled to the track 140. Optionally, the wire cover 150 can be loaded into the track 140 from the first side 130 and / or the second side 132. For example, the wire cover 150 can slide laterally into the track 140 onto the connector housing 110. In an exemplary embodiment, the track 140 includes a guide rail 142 that defines a slot 144, and the slot 144 forms the track 140. For example, the connector housing 110 can include an upper guide rail and a lower guide rail 142 that define an upper slot 144 and a lower slot 144 for receiving the wire cover 150. The slot 144 can extend from one side of the connector housing 110 to the other side. For example, the slot 144 can be open at the first side 130 to receive the wire cover 150 and / or can be open at the second side 132 to receive the wire cover 150. The upper guide rail 142 is located near the top 126 of the connector housing 110. The lower guide rail 142 is located near the bottom 128 of the connector housing 110. In various embodiments, the upper and lower guide rails 142 define a T-shaped slot 144. In other embodiments, the upper and lower guide rails 142 define an L-shaped slot 144. In alternative embodiments, the guide rail 142 can define a slot having other shapes, such as a dovetail slot. The guide rail 142 is configured to hold the wire cover 150 on the connector housing 110. For example, the guide rail 142 can prevent the wire cover 150 from separating rearwardly from the connector housing 110. Other types of securing features can be used to secure the wire cover 150 to the connector housing 110. For example, clips, latches, fasteners, or other types of securing features can be used to secure the wire cover 150 to the rear portion 122 of the connector housing 110.

[0044] The wire cover 150 is separate and discrete from the connector housing 110. The wire cover 150 is configured to be coupled to the rear portion 122 of the connector housing 110. The wire cover 150 includes an inner end 152 and an outer end 154. The inner end 152 is located at the front of the wire cover 150. The inner end 152 includes an opening 156 for receiving a wire 14 extending from the terminal module 200. The wire cover 150 includes a wire cavity 158. The opening 156 provides an entrance to the wire cavity 158. The wire 14 extends into the wire cavity 158.

[0045] In an exemplary embodiment, the wire cover 150 includes a cover wall 160 at the outer end 154. The cover wall 160 is located behind the wire cavity 158. The wire cover 150 includes a first end wall 162 and a second end wall 164 that extend between the inner end 152 and the cover wall 160. The wire cavity 158 is located between the first end wall 162 and the second end wall 164. In various embodiments, the wire cover 150 may be oriented such that the first end wall 162 is the upper wall at the top of the wire cover 150 and the second end wall 164 is the lower wall at the bottom of the wire cover 150. In other embodiments, the wire cover 150 may be oriented such that the second end wall 164 is the upper wall and the top of the wire cover 150 and the first end wall 162 is the lower wall and the bottom of the wire cover 150. For example, the wire cover 150 may be inverted 180° to be coupled to the connector housing 110 from the right or left side of the connector housing 110. In this way, the direction in which the wire exits the wire cover 150 can be changed by flipping the wire cover 150 and coupling it to the connector housing 110 from the opposite side. In an exemplary embodiment, the wire cover 150 includes a wire outlet 166 at one of the sides of the wire cover 150. The wire cover 150 includes an opening 168 at the side that defines the wire outlet 166. The wire 14 is configured to exit the wire cover 150 through the opening 168. In an exemplary embodiment, the cover wall 160 closes the opposite side of the wire cover 150 that is opposite to the wire outlet 166. The wire cover 150 covers the wire 14 extending from the module housing 210. The wire cover 150 is used to guide or organize the wire 14 at the wire outlet 166. For example, the wire cover 150 controls the direction in which the wire 14 exits the first electrical connector 100.

[0046] In an exemplary embodiment, the wire cover 150 includes a mounting bracket 170 configured to be coupled to the connector housing 110. The mounting bracket 170 is coupled to the rail 140 at the rear portion 122 of the connector housing 110 to secure the wire cover 150 to the connector housing 110. For example, the mounting bracket 170 can slide into the rail 140 from the right or left side of the connector housing 110. The mounting bracket 170 is located at the inner end 152 of the wire cover 150. In an exemplary embodiment, the mounting bracket 170 includes an upper bracket member 172 and a lower bracket member 174. The upper bracket member 172 is coupled to the upper rail 142, and the lower bracket member 174 is coupled to the lower rail 142. For example, the upper bracket member 172 is received in the upper slot 144, and the lower bracket member 174 is received in the lower slot 144. In an exemplary embodiment, the mounting bracket 170 includes a flange 176 that is received in the slot 144 and coupled to the rail 142. Optionally, the flange 176 can be T-shaped, having an upper flange portion and a lower flange portion received in the upper and lower slot portions of the slot 144. In an alternative embodiment, the flange 176 can have other shapes, such as an L-shape, a dovetail shape, or other shapes configured to secure the flange 176 to the rail 142.

[0047] In an exemplary embodiment, the wire cover 150 includes one or more module blocking walls 180. When the wire cover 150 is coupled to the connector housing 110, the module blocking walls 180 are configured to prevent the terminal module 200 from being removed from the connector housing 110. The module blocking walls 180 are configured to be positioned behind the terminal module 200 to hold the terminal module 200 in the module cavity 134. In an exemplary embodiment, the module blocking walls 180 are configured to engage the biasing bump 240 to bias the terminal module 200 forward in the module cavity 134 of the connector housing 110. In an exemplary embodiment, the module blocking walls 180 are located at the inner end 152 of the wire cover 150. Optionally, the module blocking walls 180 can be located at the front portion of the mounting bracket 170. The module blocking walls 180 can be the frontmost surface of the wire cover 150. In an exemplary embodiment, the wire cover 150 includes an upper module blocking wall 180 and a lower module blocking wall 180. The upper module blocking wall is configured to block the top end of the terminal module 200, and the lower module blocking wall 180 is configured to block the bottom end of the terminal module 200.

[0048] In an exemplary embodiment, the wire cover 150 includes a component position assurance device 190. The component position assurance device 190 is disposed on the first end wall 162. Optionally, the component position assurance device 190 may additionally or alternatively be disposed on the second end wall 164. The component position assurance device 190 includes a sliding lock 192 slidably coupled to the wire cover 150. For example, the sliding lock 192 may move along a sliding direction between an unlocked position and a locked position. The sliding lock 192 is configured to couple to the locking lever 116 when the locking lever 116 is closed and the sliding lock 192 is moved to the locked position. In an exemplary embodiment, the component position assurance device 190 includes a shroud on the wire cover 150. The sliding lock 192 is received in the shroud 194. The sliding lock 192 is configured to move within the shroud 194. The shroud 194 is for guiding the sliding lock 192 between the unlocked position and the locked position.

[0049] Figure 8 is a rear perspective view of a portion of the electrical connector 100 according to an exemplary embodiment. Figure 8 The wire cover 150 is shown partially coupled to the connector housing 110. In the illustrated embodiment, the wire cover 150 is coupled to the connector housing 110 from the left side such that the wire outlet 166 is disposed at the right side of the connector housing 110.

[0050] During assembly, the wire cover 150 is coupled to the track 140 of the connector housing 110. The mounting bracket 170 at the inner end 152 of the wire cover 150 is coupled to the guide rail 142 at the rear portion 122 of the connector housing 110. For example, the mounting bracket 170 slides laterally into the track 140. The flange 176 of the mounting bracket 170 is received in the slot 144 defined by the guide rail 142 of the track 140. The guide rail 142 captures the flange 176 in the slot 144 to hold the wire cover 150 on the connector housing 110. The guide rail 142 prevents the wire cover 150 from being removed rearwardly from the connector housing 110.

[0051] When assembled, the wire cover 150 is located behind the terminal module 200. The wire cover 150 holds the terminal module 200 in the module cavity 134. The wire cover 150 prevents the terminal module 200 from being removed from the module cavity 134. For example, the wire cover 150 operates as a separate secondary locking device for the terminal module 200 to hold the terminal module 200 in the connector housing 110 independent of the latch 216 of the terminal module 200. In an exemplary embodiment, the module blocking wall 180 engages the terminal module 200 to hold the terminal module 200 in the connector housing 110. The module blocking wall 180 blocks the removal of the terminal module 200 from the connector housing 110. In an exemplary embodiment, the module blocking wall 180 abuts the biasing bump 240 at the rear 222 of the module housing 210. When the module blocking wall 180 engages the biasing bump 240, the module housing 210 is biased forward in the module cavity 134. For example, the module housing 210 is pressed forward by the module blocking wall 180. The biasing bump 240 holds the rear 222 of the module housing 210 in front of the wire cover 150. For example, the rear 222 of the module housing 210 may be spaced apart from and in front of the module blocking wall 180, where the biasing bump 240 occupies the space between the rear 222 of the module housing 210 and the module blocking wall 180. The wire cover 150 biases the terminal module 200 in the connector housing 110 forward to ensure proper positioning of the terminals 250 relative to the connector housing 110 for mating with the second electrical connector 300.

[0052] In an exemplary embodiment, the wire cover 150 operates as a module position assurance device to ensure that the terminal module 200 is fully loaded into the connector housing 110. For example, if any of the terminal modules in the terminal module 200 are not properly loaded into the connector housing 110, the wire cover 150 may not be correctly coupled to the connector housing 110. For example, Figure 8 One of the terminal modules 200a that is not fully loaded into the corresponding module cavity 134 is shown. Such a terminal module 200a projects rearward into the track 140. The wire cover 150 cannot slide laterally inside the track 140 due to interference with the terminal module 200a. This interference indicates to the installer that the terminal module 200a is not correctly loaded into the connector housing 110 and that action is required to properly load such a terminal module 200a. After all the terminal modules 200 are fully loaded into the connector housing 110, the wire cover 150 can be correctly coupled to the connector housing 110.

[0053] Figure 9A cross-sectional view of a portion of the electrical connector 100 shows the wire cover 150 coupled to the connector housing 110 and mating with one of the terminal modules 200. During assembly, the terminal module 200 is loaded into the corresponding module cavity 134. The latch 216 is used to secure the terminal module 200 within the connector housing 110. For example, the latch 216 may be latchably coupled to the connector housing 110, such as the latch 216 being received within a latch recess in the connector housing 110. The latch 216 defines a primary securing device for securing the terminal module 200 within the connector housing 110.

[0054] During assembly, the wire cover 150 is coupled to the rear portion 122 of the connector housing 110. For example, the mounting bracket 170 is coupled to the rail 140. The flange 176 is received within the slot 144 and coupled to the guide rail 142 to secure the wire cover 150 to the connector housing 110. The module blocking wall 180 is located behind the terminal module 200. The module blocking wall 180 is configured to mate with the module housing 210 to retain the terminal module 200 within the module cavity 134. The module blocking wall 180 of the wire cover 150 serves as a secondary securing device for securing the terminal module 200 within the connector housing 110. In an exemplary embodiment, the module blocking wall 180 is configured to mate with the biasing bump 240 to bias the terminal module 200 forward within the connector housing 110. For example, the module blocking wall 180 engages the base 244 of the biasing bump 240 to press the terminal module 200 in the forward direction within the module cavity 134. Thus, the terminals 250 held by the module housing 210 similarly move forward to properly mate with the second electrical connector 300.

[0055] Figure 10 A perspective view of the electrical connector 100 shows the wire cover 150 having a wire exit on the right side. Figure 11 A perspective view of the electrical connector shows the wire cover 150 having a wire exit on the left side. The same wire cover 150 may be coupled to the connector housing 110 in two different orientations to define a right-side wire exit and a left-side wire exit by rotating the wire cover 150 180°. The wire cover 150 may be slid onto the connector housing 110 from the first side 130 or the second side 132.

[0056] Figure 12 A top view of the electrical connector 100 shows the locking lever 116 in the open position. Figure 13 A top view of the electrical connector 100 shows the locking lever 116 in the closed position. The locking lever 116 is configured to rotate from the open position to the closed position.

[0057] The component position assurance device 190 on the wire cover 150 is used to secure the locking lever 116 in the closed position. The sliding lock 192 may move from the unlocked position (Figure 12 ) Move to the locked position ( Figure 13 ) to dock with the locking lever 116 and fix the locking lever 116 in the closed position. In an exemplary embodiment, the sliding lock 192 includes a sliding locking element 196 that is configured to dock with the locking lever element 118 of the locking lever 116 when the sliding lock 192 moves to the locked position. The sliding locking element 196 engages the locking lever element 118 to prevent the locking lever 116 from rotating from the closed position. For example, when the sliding locking element 196 engages the locking lever element 118, the locking lever 116 cannot move from the closed position to the open position. In an exemplary embodiment, the locking lever 116 includes a release element 119 that is configured to engage the latch 198 of the component position assurance device 190. The latch 198 engages the shroud 194 to hold the sliding lock 192 in the unlocked position. When the latch 198 is released by the release element 119, the sliding lock 192 can move from the unlocked position to the locked position. The latch 198 can be latchably coupled to the shroud 194 in the locked position to prevent the sliding lock 192 from inadvertently moving back to the unlocked position - which would allow the locking lever 116 to be opened. The component position assurance device 190 provides a visual indication to the installer that the locking lever 116 is fixed in the closed position.

Claims

1. An electrical connector (100), comprising: A connector housing (110), including a mating end (124) at a first end of the connector housing, the connector housing including a module cavity (134) separated by a partition wall (136), the connector housing including a track (140) at a second end of the connector housing; A terminal module (200), received in the corresponding module cavity, each terminal module including a module housing (210) having a terminal channel, each terminal module including a terminal (250) received in the corresponding terminal channel, the terminal being terminated to an end of a wire (14) extending from an end of the corresponding module housing; And A wire cover (150), coupled to the track at a second end of the connector housing, the wire cover including a wire cavity (158) for receiving wires from the terminal modules, the wire cover having a wire outlet (166), the wire cover guiding the wires to the wire outlet, the wire cover including a module blocking wall (180), the module blocking wall (180) being positioned along the terminal module to block removal of the terminal module from the corresponding module cavity.

2. The electrical connector (100) according to claim 1, wherein, The module blocking wall (180) biases the terminal module (200) in the module cavity (134) forward.

3. The electrical connector (100) according to claim 1, wherein, Each module housing (210) includes a biasing bump (240) at an end of the module housing, the module blocking wall (180) engaging the biasing bump to bias the terminal module (200) in the module cavity (134) forward.

4. The electrical connector (100) according to claim 3, wherein, The biasing bump (240) protrudes from an end of the module housing (210).

5. The electrical connector (100) according to claim 3, wherein, Each module housing (210) includes at least one biasing bump (240) at a top (126) of the module housing and at least one biasing bump at a bottom (128) of the module housing.

6. The electrical connector (100) according to claim 3, wherein, The biasing bump (240) includes a ramp (242) extending from an end of the module housing (210) to a base (244) of the biasing bump, the module blocking wall (180) being disposed on the base of the biasing bump.

7. The electrical connector (100) according to claim 3, wherein, The biasing bump (240) protrudes from an end of the module housing (210) to keep the end spaced apart from the wire cover (150).

8. The electrical connector (100) according to claim 1, wherein, Each module blocking wall (180) engages each terminal module (200) to hold each terminal module in the corresponding module cavity (134).

9. The electrical connector (100) according to claim 1, wherein, The wire cover (150) includes a mounting bracket (170), the mounting bracket (170) being received in the track (140) of the connector housing (110) to fix the wire cover to the connector housing.

10. The electrical connector (100) according to claim 9, wherein, The mounting bracket (170) includes the module blocking wall (180).

11. The electrical connector (100) according to claim 1, wherein, The wire cover (150) is configured to be coupled to the connector housing (100) only when all terminal modules (200) are fully loaded into the corresponding module cavities (134).

12. The electrical connector (100) according to claim 1, wherein, The rail (140) is an upper rail adjacent to the top (126) of the connector housing (110). The connector housing further includes a lower rail adjacent to the bottom (128) of the connector housing. The wire cover (150) includes an upper mounting bracket (172) received in the upper rail and a lower mounting bracket (174) received in the lower rail.

13. The electrical connector (100) according to claim 12, wherein, The module blocking wall (180) is located in the upper rail (140) to dock with the terminal module (200).

14. The electrical connector (100) according to claim 1, further comprising a rod rotatably coupled to the connector housing (110) and capable of moving between an open position and a closed position. The rod is configured to be firmly coupled to the mating electrical connector in the closed position. The wire cover (150) includes a locking rod (116) configured to be coupled to the rod to hold the rod in the closed position.

15. The electrical connector (100) according to claim 14, wherein, The locking rod (116) is capable of sliding between a locked position and an unlocked position. The locking rod engages the rod in the locked position to hold the rod in the closed position.

Images