ELECTRICAL CONNECTOR WITH SEALING PROTECTION AND METHOD FOR ASSEMBLING AN ELECTRICAL CONNECTOR

Abstract

Electrical connector (12) comprising: a first housing part (22) and a second housing part (24) joined to one another, the first housing part (22) providing an aperture (30) configured to receive a terminal (68) of a wire, the second housing part (24) providing a hole (34) configured to receive the wire, the first housing part (22) comprising a surface (23) configured to fit with another connector (14) having a further terminal (74) that can engage with the terminal (68), the first housing part (22) further comprising a guide wall (37) forming a pocket (36) that receives the second housing part (24); a seal (26) that is caught between the first and second housing parts (22, 24) and configured to engage with the other connector (14);and a secondary lock (28) carried by the first housing part (22), wherein the secondary lock (28) is displaceable between an unlocked position and a locked position, wherein secondary lock retaining elements (42) are provided by a hook (44) on the guide wall (37) and a first tab (46) on a flange of the secondary lock (28), wherein the first tab (46) is displaceable between the locked position and the unlocked position relative to the hook (44).

Description

This disclosure relates to an electrical connector and a seal.Sealed connector assemblies are widely used in the automotive industry to protect the electrical wire terminals from the ingress of dust, moisture and water. Typically, a seal is disposed between male and female plastic connectors that each carry the wire terminals. Due to the interference fit between the connectors, the seal may rollover relative to the female connector during insertion or removal of the male connector.Terminal position assurance structures are commonly used for automotive electrical connectors to provide additional locking for the terminals. A common secondary barrier used to provide terminal position assurance is generally employed from the outside of one of the connectors having a large aperture to accommodate the secondary barrier. Some types of secondary locks may also be configured to prevent the seal from rollover.Examples of electrical connectors are known from the publications DE 10 2013 016 022 A1, U.S. Pat. No. 2020 / 0 321 721 A1, DE 102 09 050 A1, U.S. Pat. No. 2011 / 0 217 859 A1 and DE 10 2017 221521 A1. The publications DE 10 2013 016 022 A1, US 2020 / 0 321 721 A1 and US 2011 / 0 217 859 A1 each disclose an electrical connector comprising: first and second housing parts fixed to each other, the first housing part providing an aperture and the second housing part providing a hole, the aperture being configured to receive a terminal of a wire, the hole being configured to receive the wire, the first housing part including a surface configured to mate with another connector that carries another terminal engageable with the terminal; and a seal captured between the first and second housing parts and configured to engage with the other connector. The publication DE 102 09 050 A1 discloses a connector with two housing parts, a locking mechanism and a seal. The publication DE 10 2017 221521 A1 discloses a connector in which a guide wall of a first housing part abuts against a seal in order to prevent the ingress of liquids. The publication US 2020 / 0 321 721 A1 discloses a method of assembling an electrical connector comprising: inserting a secondary lock into a first housing part to provide a sub-assembly; locating a seal on a second housing part; securing the first and second housing parts together and around the secondary lock; and capturing the seal between the first and second housing parts.The object underlying the present application is achieved by an electrical connector having the features of claim 1 and by a method for assembling an electrical connector having the features of claim 10.In an exemplary embodiment, an electrical connector includes first and second housing portions that are secured together and each provide an aperture and a hole. The aperture is configured to receive a terminal of a wire. The hole is configured to receive the wire. The first housing part includes a surface configured to mate with another connector that mates another terminal engageable with the terminal. A seal is captured between the first and second housing portions and is configured to engage the other connector.In another embodiment of the above, the first housing part includes a guide wall forming a pocket that receives the second housing part. The guide wall encloses at least a part of the second housing part.In another embodiment of any of the above, the first and second housing portions include housing locking members that secure the first and second housing portions together in a snap-fit relationship.In another embodiment of any of the above, the housing locking elements are provided by a clip having a window on one of the first and second housing parts. A tab on the other of the first and second housing parts is received in the window.In another embodiment of any of the above, the guide wall includes a gap configured to receive the clip. The tab is provided on the first housing part. The guide wall abuts at least 50% of the seal.In another embodiment of any of the above, the connector includes a secondary lock supported by the first housing portion. The secondary lock is slidable between unlocked and locked positions. The secondary stop is configured to abut the port in the locked position and is configured to allow insertion of the port into the aperture in the unlocked position.In another embodiment of any of the above, the secondary barrier retains elements that secure the secondary barrier to the first housing portion to provide a subassembly.In another embodiment of any of the above, the first housing portion includes a guide wall that forms a pocket that receives the second housing portion. The guide wall encloses at least a part of the second housing part. The secondary lock retains elements provided by a clip on the guide wall and a tab on a rim of the secondary lock. The tab is slidable relative to the clip between the locked and unlocked positions.In another embodiment of any of the above, the first housing and the secondary lock include first and second protrusions, respectively. The second protrusion is disposed at the unlocked position on one side of the first protrusion. The second protrusion is disposed on an opposite side of the one side in the locked position.In another embodiment of any of the above, the connector includes a terminal disposed in the aperture. The aperture corresponds to a first aperture. The secondary barrier includes an opening and includes a second aperture providing a lip. The opening is configured to receive a tool that moves the secondary lock from the unlocked position to the locked position. The lip blocks the port in the locked position.In another exemplary embodiment, a method of assembling an electrical connector includes inserting a secondary lock into a first housing portion to provide a subassembly. The method includes disposing a seal on a second housing portion. The method includes securing the first and second housing portions to each other and around the secondary lock. The method further includes capturing the seal between the first and second housing portions in response to the attaching step.In another embodiment of any of the above, the first housing portion and the secondary barrier each include first and second apertures aligned with one another. The method includes a terminal disposed in the first aperture. The method further includes a step of sliding the secondary barrier from an unlocked position to a locked position to prevent the secondary barrier port from passing the second aperture.In another embodiment of any of the above, the pushing step includes pushing a second protrusion past the first protrusion to the locked position.In another embodiment of any of the above, the inserting step includes snapping secondary lock retaining members together.In another embodiment of any of the above, the securing step includes receiving the second housing part in a pocket provided by a guide wall of the first housing part. The guide wall provides a first shoulder and the second housing portion provides a second shoulder. The capturing step includes applying the seal to the first and second shoulders.In another embodiment of any of the above, the securing step includes snapping housing locking elements together.In another embodiment of any of the above, the method includes a step of installing a second connector having a second terminal into the connector. The installing step includes electrically coupling the second terminal to the terminal and engaging the second connector with the gasket.In another embodiment of any of the above, the method includes a step of rotating a lever to lock the connector and the second connector together.In another exemplary embodiment, an electrical connector includes first and second housing portions that are secured together and each provide an aperture and a hole. The aperture is configured to receive a terminal of a wire. The hole is configured to receive the wire. The first housing portion includes a surface configured to mate with another connector that carries another terminal engageable with the terminal. A secondary lock is carried by the first housing portion. The secondary lock is slidable between unlocked and locked positions. The secondary stop is configured to abut the port in the locked position and is configured to allow insertion of the port into the aperture in the unlocked position.In another embodiment of any of the above, secondary lock retaining members attach the secondary lock to the first housing portion to provide a subassembly. The first housing part includes a guide wall forming a pocket that receives the second housing part. The guide wall encloses at least a part of the second housing part. The secondary lock retaining elements are provided by a clip on the guide wall and a tab on a rim of the secondary lock. The tab is slidable relative to the clip between the locked and unlocked positions. The first housing and the secondary lock include first and second protrusions, respectively. In the unlocked position, the second protrusion is disposed on a side of the first protrusion. In the locked position, the second protrusion is disposed on an opposite side of the one side.The disclosure may be further understood by reference to the following detailed description when considered in connection with the accompanying drawings, in which:FIGS. 1A and 1B illustrate perspective views of the first and second connectors secured together to provide an electrical connection. FIG. 2 is an exploded perspective view of the first connector shown in FIGS. 1A and 1B. FIG. 3 is an enlarged exploded view of the first housing part and a secondary lock illustrated in FIG. 2. FIG. 4 is an end view of the secondary lock retained in the first housing portion and positioned in an unlocked position. FIG. 5A is a cross-sectional view taken through the first housing portion and the secondary lock along line 5A- 5A of FIG. 4. FIG. 5B is a cross-sectional view taken through the first housing portion and the secondary lock along line 5B- 5B of FIG. 4. FIG. 6 is a perspective cross-sectional view of the first and second housing portions secured together about the secondary lock. FIG. 7 is an enlarged view of a portion of FIG. 6 illustrating housing locking members. FIG. 8 is an end view of the assembled first connector with the secondary lock in an unlocked position. FIG. 9 is an end view of the first housing portion with a tool inserted into an opening to move the secondary lock from the unlocked position to a locked position. FIG. 10 is an end view of the first connector with the secondary lock in the locked position. FIG. 11 is an end view illustrating the secondary latch in the locked position with the second housing portion removed. FIG. 12 is a schematic cross-sectional view of the first and second connectors being secured together to make an electrical connection between a terminal and a second terminal with the secondary latch in the latched position. FIG. 13 is a cross-sectional view through the first connector shown in FIG. 10 taken along line 13-13. FIG. 14 is a cross-sectional view through the first connector shown in FIG. 10 taken along line 14- 14.FIGS. 15A and 15B are enlarged broken-away cross-sectional views illustrating the seal captured between the first and second housing portions.The embodiments, examples and alternatives of the preceding paragraphs, the claims or the following description and drawings, including any of their various aspects or their respective individual features, may be used independently or in any combination. Features described in connection with an embodiment are applicable to all embodiments, provided such features are not incompatible. Like reference numerals and designations in the various drawings indicate like elements.Referring now to FIGS. 1A and 1B, a connector assembly 10 is shown having first and second connectors 12, 14 that provide a secure electrical connection between a plurality of wires. In the example, the first connector 12 includes a lever 16 having an arcuate slot 20 that receives a pin 18 provided on the second connector. When the first and second connectors 12, 14 are fully placed, the lever 16 may be rotated capturing the pin 18 within the slot 20.Referring to FIGS. 2 and 3, the first connector 12 includes first and second housing portions 22, 24. the first housing portion 22 includes a surface 23 having a plurality of first apertures 30 in which wire terminals (68 in FIG. 12 ) are disposed. A secondary lock 28 is carried by the first housing portion 22 and, when assembled, is captured between the first and second housing portions 22, 24. A seal 26 is also captured between the first and second housing portions 22, 24 and engages the second connector 14 when assembled with the first connector 12.The first housing portion 22 includes a guide wall 37 that defines a pocket 36 that receives the second housing portion 24. In the assembled state, the guide wall 37 encircles at least a portion of the second housing portion 24 (best shown in FIG. 6 ), for example at least 50%, and, in another example, at least 70%, such that the guide wall 37 engages a corresponding portion of the seal 26 (FIG. 10 ).Referring to FIGS. 3-5B, the secondary barrier 28 includes second apertures 32 that are aligned with the first apertures 30. Secondary lock retaining members 42 secure the secondary lock 28 to the first housing portion 22 to provide a subassembly. In the example, the secondary lock retaining members 42 are provided by hooks 44 provided on the guide wall 37. A skirt 40 of the secondary lock 28 includes tabs 46 that cooperate with the hooks 44. The tabs 46 are slidable between unlocked (FIG. 4 ) and locked (FIG. 11 ) positions relative to the hooks 44. In the example embodiment, there are four sets of hooks 44 and tabs 46.Referring to FIGS. 6 and 7, housing locking members 47 secure the first and second housing portions 22, 24 together in a snap-fit relationship. The housing locking elements 47 are provided by a clip 48 on the second housing part 24 that extend through gaps 49 in the guide wall 37 (FIGS. 2, 4, 7). The clip 48 includes a window 50 that receives a tab 52 in the first housing portion 22. Ribs 38 extending inwardly from the guide wall 37 as shown in FIG. 4 help guide the second housing portion 24 into the pocket 36. In the example embodiment, there are four sets of clips 48 and tabs 52. The ribs 38 on the guide wall 37 form a tight fit with the second housing portion 24 preventing the first housing portion 22 from floating about.Referring to FIGS. 8-11, the first housing portion 22 includes an opening 60 that provides access to an arm 61 extending from the secondary lock 28. A tool 62, as shown in Fig. 9, can be inserted into the opening 60 to cooperate with the arm 61. By pushing the arm 61 to the left as shown in the figures, the secondary lock 28 can be moved from the unlocked position (FIG. 8 ) to the locked position (FIG. 10 ). Secondary lock locking elements 54 are provided by first and second protrusions 56, 58 cooperating with each other. In the locked position, a first set of protrusions 56 on the secondary lock 28 moves from one side of the second protrusions 58, as shown in FIG. 4, to the other side of the second protrusions 58, as shown in FIG. 11. In the locked position, lips 64 associated with each aperture 30 of secondary lock 28 abut and block an end wall 66 of a port 68 to provide port position assurance as shown in Fig. 12.Referring to FIGS. 14, 15A and 15B, the first and second housing portions 22, 24 provide first and second shoulders 70, 72, respectively, that abut the seal 26. Positive contact with the first and second shoulders 70, 72 prevents rollover of the seal 26.In operation, the electrical connector 10 is assembled by inserting the secondary lock 28 into the first housing portion 22 to provide a subassembly. The secondary lock retainers 42 are snapped together and the secondary lock 28 is left in the unlocked position. The seal 26 is arranged on a second housing part 24.The first and second housing portions 22, 24 are secured to each other and around the secondary barrier 28 capturing the secondary barrier 28. During this step, the second housing part 24 is accommodated in the pocket 36 provided by the guide wall 37. The housing locking members 47 are snapped together, capturing the seal 26 between the first and second housing portions 22, 24.A terminal 68 is inserted through each of the first and second apertures 30, 32 and the holes 34 such that the terminals 68 are fully placed in their respective first aperture 30. Insulated wiring extends from the holes 34 at a rear side 25 of the second case 24 (FIG. 3 ). At this point, the tool 62 may be inserted into the opening 60 to urge the arm 61 toward one side to push the secondary barrier 28 from the unlocked position to the locked position to prevent the terminals 68 with the lips 64 of the secondary barrier 28 from passing the second aperture 32. When moving to the locked position, the second protrusions 58 slide past the first protrusions 56.The second connector 14 is installed on the first connector 12, electrically coupling the second terminals 74 to the terminals 68 and engaging the second connector 14 with the gasket 26. The first shoulder 70 and the second shoulder 72 abut and catch the seal 26, preventing rollover of the seal. The lever 16 is rotated to lock the first and second connectors 12, 14 together.It should be understood that although a particular component arrangement is disclosed in the illustrated embodiment, other arrangements may benefit therefrom. Although particular step sequences are shown, described, and claimed, it should be understood that unless otherwise indicated, steps may be performed in any order, separately or in combination, and will still benefit from the present invention.Although the various examples in the illustrations have specific components, embodiments of this invention are not limited to those specific combinations. It is possible to use some of the components or features of one of the examples in combination with features or components of another of the examples.

Claims

An electrical connector (12) comprising: a first housing portion (22) and a second housing portion (24) secured together, the first housing portion (22) providing an aperture (30) configured to receive a terminal (68) of a wire, the second housing portion (24) providing a hole (34) configured to receive the wire, the first housing portion (22) including a surface (23) configured to mate with another connector (14) that carries another terminal (74) engageable with the terminal (68), the first housing portion (22) further including a guide wall (37) that forms a pocket (36) that receives the second housing portion (24); a seal (26) captured between the first and second housing portions (22, 24) and configured to engage the other connector (14); and a secondary lock (28) carried by the first housing portion (22), the secondary lock (28) being slidable between an unlocked position and a locked position, wherein secondary lock retaining elements (42) are provided by a hook (44) on the guide wall (37) and a first tab (46) on a rim of the secondary lock (28), the first tab (46) being slidable relative to the hook (44) between the locked position and the unlocked position.The connector (12) of claim 1, wherein the guide wall (37) encircles at least a portion of the second housing portion (24).The connector (12) of claim 1 or 2, wherein the first and second housing portions (22, 24) include complementary housing locking members (47) that secure the first and second housing portions (22, 24) together in a snap-fit relationship.The connector (12) of claim 3, wherein the housing locking members (47) are provided by a clip (48) having a window (50) on one of the first and second housing parts (22, 24) and a second tab (52) on the other of the first and second housing parts (22, 24) receivable within the window (50).The connector (12) of claim 4, wherein the guide wall (37) includes a gap (49) configured to receive the clip (48), and the second tab (52) is provided on the first housing part (22).The connector (12) of any preceding claim, wherein the secondary catch (28) is configured to abut the terminal (68) in the locked position and is configured to allow insertion of the terminal (68) into the aperture (30) in the unlocked position.The connector (12) of claim 6, wherein the secondary lock retaining members (42) secure the secondary lock (28) to the first housing portion (22) to provide a subassembly.The connector (12) of any preceding claim, wherein the first housing portion (22) includes a first protrusion (56), the secondary catch (28) includes a second protrusion (58), the second protrusion (58) being disposed on a first side of the first protrusion (56) in the unlocked position, and the second protrusion (58) being disposed on a second side of the first protrusion (56) opposite the first side in the locked position.The connector (12) of any preceding claim, comprising the port (68) disposed in the aperture (30), the aperture (30) being a first aperture and the secondary barrier (28) including an opening (60), the secondary barrier (28) including a second aperture (32) providing a lip (64), the opening (60) configured to receive a tool (62) with which the secondary barrier (28) is movable from the unlocked position to the locked position, the lip (64) blocking the port (68) in the locked position.A method of assembling an electrical connector (12) including a first housing portion (22) and a second housing portion (24), the first housing portion (22) further including a guide wall (37) forming a pocket (36) for receiving the second housing portion (24), the method comprising: inserting a secondary lock (28) into a first housing portion (22) to provide a subassembly, the secondary lock (28) being secured to the first housing portion (22) by secondary lock retaining elements (42) provided by a hook (44) on the guide wall (37) and a first tab (46) on a rim of the secondary lock (28); disposing a seal (26) on the second housing portion (24); securing the first and second housing portions (22, 24) together and around the secondary lock (28); and capturing the seal (26) between the first and second housing portions (22, 24) in response to the attaching step.The method of claim 10, wherein the connector (12) has a first aperture (30) and the secondary barrier (28) has a second aperture (32), the first aperture (30) and the second aperture (32) being aligned with each other, wherein the first housing portion (22) has a terminal (68) disposed in the first aperture (30), and wherein the method further comprises a step of displacing the secondary barrier (28) from an unlocked position to a locked position to prevent the terminal (68) with the secondary barrier (28) from passing the second aperture (32).The method of claim 10 or 11, wherein the displacing step includes displacing a second protrusion (58) of the secondary lock (28) past a first protrusion (56) of the first housing part (22) to the locked position.The method of any of claims 10 to 12, wherein the inserting step includes snapping the secondary lock retaining members (42) together.The method of any of claims 10 to 13, wherein the securing step comprises receiving the second housing portion (24) into the pocket (36) provided by the guide wall (37) of the first housing portion (22), the guide wall (37) providing a first shoulder (70) and the second housing portion (24) providing a second shoulder (72), wherein the capturing step comprises engaging the seal (26) against the first and second shoulders (70, 72).

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