ADJUSTABLE CPA FOR ELECTRICAL CONNECTORS

Abstract

An electrical connector has a connector housing that can be connected to a second electrical connector. The electrical connector has a CPA lever assembly comprising a pair of pivot arms and a CPA element, with each pair of pivot arms pivotally mounted on pivot projections. The pair of pivot arms has CPA guide channels, and the CPA element has a pair of telescopic arms mounted in guide channels and a transverse element connected between the arms. The CPA element is selectively pivotable when in an extended position to draw the second electrical connector into engagement with it, and the CPA element has a CPA locking element that engages with the CPA guide element when the electrical connector is fully engaged with the second electrical connector and the telescopic arms are moved into the retracted position.

Description

AREA

[0001] This invention relates to an electrical connector, in particular to an electrical connector with an adjustable connector position locking (CPA) assembly. STATE OF THE ART

[0002] Electrical connector pairs are known to provide convenient and quick electrical connections. Some electrical connector pairs have a mechanism that assists in engaging the connector pair (plug and socket) and locking them together (Connector Position Assurance, CPA). With such electrical connector pairs, it is desirable to reduce the forces required for assembly and to ensure that the connector pair is fully assembled when the CPA is engaged.

[0003] DE102022118993A1 relates to a housing arrangement for an electrical connector with a plugging aid, for example, but not exclusively, for automotive applications. Furthermore, the present invention relates to an electrical connector with such a housing arrangement and to a connector arrangement with such an electrical connector.

[0004] DE102021112898A1 relates to a plug for mating with a mating plug and a plug set. JP2010146950A relates to a lever connector. EP4542784A1 describes an electrical connector with lever locking. The connector comprises a first housing section configured to receive a second housing section in a seated orientation. The object of the invention is to engage and lock a pair of electrical connectors via a mechanism. Embodiments suitable for this purpose are described below. SUMMARY

[0005] According to one aspect, an embodiment provides an electrical connector comprising: a connector housing with a connector opening configured to be connected to a second electrical connector, a pair of pivot projections extending from it on opposite sides of the connector housing, and a CPA retaining element extending from the connector housing; and a CPA lever assembly comprising a pair of pivot arms and a CPA element, wherein the pair of pivot arms is each pivotably attached to one of the respective pivot projections, and wherein the pair of pivot arms each has a CPA guide channel;and the CPA element comprises a pair of telescopic arms and a transverse element connected between the arms, each of the telescopic arms being mounted in one of the respective CPA guide channels and being selectively telescopically displaceable therein between a retracted position and an extended position, the CPA element being configured to be selectively pivotable when in the extended position to engage the second electrical connector, and the CPA element having a CPA locking element extending from it and being configured to engage the CPA guide element when the electrical connector is fully engaged with the second electrical connector and the telescopic arms are moved into the retracted position.

[0006] According to one embodiment, the electrical socket can be shipped and stored with a connector position lock (CPA) that holds it in a compact position for assembly with an electrical plug.

[0007] According to one embodiment, a CPA element of a CPA lever assembly can be extended telescopically during an assembly process of the electrical connector assembly, but cannot be retracted telescopically (without tools) after extension until the electrical plug and socket are fully engaged.

[0008] According to one embodiment, a CPA lever assembly can only be pivoted relative to a socket housing when an electrical plug is partially engaged with an electrical socket. Pivoting the CPA lever assembly causes a cam to pull the electrical plug into full engagement with the electrical socket.

[0009] According to one embodiment, once a CPA lever assembly is pivoted into a position in which the plug and socket are fully engaged, a CPA element is released to slide telescopically into a position to engage with the CPA, thereby preventing the CPA lever assembly from pivoting out of the position for full engagement of the connector until a process for disconnecting the electrical connectors is initiated.

[0010] A further understanding of these examples can be gained from reviewing the detailed description below and the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS Fig. Figure 1 is a schematic, perspective view of an electrical socket with a CPA lever assembly, shown in a delivery locking position. Fig. Figure 2 is a schematic view similar to Fig. 1, however with the CPA lever assembly in a pre-locked position, ready to receive an electrical plug. Fig. Figure 3 is a schematic view similar to Fig. 2, but viewed from a different perspective. Fig. Figure 4 is a schematic, perspective view of a section of the electrical socket with the CPA lever assembly in a connector engagement position and a CPA release position, with a pivot arm partially cut away to show a second telescopic control projection in contact with a CPA release flange. Fig. Figure 5 is a schematic view similar to Fig. 4, but viewed from a different perspective. Fig. Figure 6 is a schematic, perspective view of the electrical socket with the CPA lever assembly in a connector engagement position and a locked CPA state (shown without the plug attached to the socket to better illustrate some elements of the electrical socket). Fig. Figure 7 is a schematic top view of a plug. Fig. Figure 8 is a schematic top view of the assembled plug and socket with the CPA in the locked position. DETAILED DESCRIPTION

[0011] The following detailed description and the accompanying drawings describe and illustrate various exemplary embodiments of an electrical connector. The description and illustration of these examples are provided to enable those skilled in the art to manufacture and use an electrical connector according to the present invention. They are not intended to limit the scope of the claims in any way.

[0012] With reference now made to the drawings, in the Fig. 1, Fig. 2, Fig. 3, Fig. 4, Fig. 5 to Fig. Figure 6 illustrates an example of an electrical socket 20, which has a socket housing 22 from which electrical wires 24 extend. At an end of the socket housing 22 opposite the end of the electrical wires 24, there is a connector opening 26 in which wire connectors 28 are arranged. The socket housing 22 has a pair of release slots 30 extending from the connector opening 26 on opposite sides of the socket housing 22. Adjacent to each of the release slots 30 is a corresponding pivot projection 32 extending outward from the socket housing 22. Adjacent to each of the pivot projections 32 is a corresponding pivot stop flange 34 extending outward from the socket housing 22. From each pivot stop flange 34 extends a corresponding CPA release flange 36.Each anti-rotation feature 38 extends outwards from the bushing housing 22 adjacent to each CPA release flange 36. Although both sides of the bushing housing 22 are not illustrated, the features described above can be essentially symmetrical and thus have the same position, shape, and function as the features shown in the figures.

[0013] A pair of delivery position flanges 40 extends outwards from the socket housing 22, adjacent to the connector opening 26. A delivery position stop flange 42 extends outwards from the socket housing 22, adjacent to the pair of delivery position flanges 40. A CPA retaining tab 44 extends along the socket housing 22 and defines a locking tab recess 46.

[0014] A CPA lever assembly 49 comprises pivot arms 48, each having a channel 50 pivotably attached to a corresponding pivot projection 32, release tabs 51, an arm cam 52, and a CPA guide channel 54. The release tabs 51 are each configured to be selectively secured in one of the release slots 30. The CPA guide channels 54 each have a first wall 56 comprising a first insertion opening 58 and a first extension opening 60; a second wall 62 comprising a retention slot 64; and a third wall 66 comprising a second insertion opening 68 and a second extension opening.

[0015] The CPA lever assembly 49 has a generally U-shaped CPA element 72 with telescopic arms 74 connected by a transverse element 76. Each telescopic arm 74 is slidably received in a respective CPA guide channel 54 and has a first flexible arm 77, from which a first telescopic control projection 78 projects and which can be selectively aligned with the first insertion opening 58 and the first extension opening 60; a second flexible arm 79, from which a second telescopic control projection 80 projects and which can be selectively aligned with the second insertion opening 68 and the second extension opening 70; and a third flexible arm 81, from which a CPA mounting flange 82 projects and which can be selectively aligned with the retaining slot 64. Each of the telescopic arms 74 has a guide slot 83 extending along its length. The first telescopic control approaches 78 each have inclined surfaces 84 (i.e., at an angle other than perpendicular to the first flexible arm 77, for example, about forty-five degrees), wherein the inclined surfaces 84 point in the direction in which the CPA element 72 slides telescopically with respect to the pivot arms 48. The second telescopic control attachments 80 each have a first inclined surface 86 (i.e., at an angle other than perpendicular to the second flexible arm 79, for example, at an angle of about forty-five degrees) facing away from the respective channel 50, and a second perpendicular surface 88 facing the respective channel 50 and being substantially perpendicular to the second flexible arm 79. Each of the CPA mounting flanges 82 has an inclined insertion surface 90 (i.e.,, at an angle other than perpendicular to the third flexible arm 81 (for example, at an angle of approximately forty-five degrees) which faces the respective channel 50, as well as a perpendicular retaining surface 92 which faces away from the respective channel 50 and is essentially perpendicular to the third flexible arm 81. When the term "flexible" is used herein, it refers to components that are generally elastically flexible, i.e., they bend when a force is applied and return to their original shape when the force is removed.

[0016] The transverse element 76 of the CPA element 72 has a CPA locking tab 94 extending from it and generally centered between the telescopic arms 74. The CPA locking tab 94 is dimensioned and arranged to selectively engage the delivery position flanges 40 and the delivery position stop flange 42 and to selectively engage the CPA retaining tab 44 in the locking tab recess 46.

[0017] With reference to the following Fig. Figure 7 shows an example of an electrical plug 100 that can be joined with the electrical socket 20 (as in Fig. (8 illustrated). The electrical connector 100 has a connector housing 102 from which electrical wires 104 extend. A pair of pivot-arm release projections 106 extends from opposite sides of the connector housing 102, each pivot-arm release projection 106 being dimensioned and arranged to be aligned with one of the release slots 30 ( Fig. 1 to Fig. 2) A pair of cam projections 108 extends from opposite sides of the connector housing 102, each adjacent to the respective pivot arm release projections 106, and is dimensioned and arranged to engage in each of the arm cams 52.

[0018] With reference to the following Fig. 8 is referred to in the Fig. 1, Fig. 2, Fig. 3, Fig. 4, Fig. 5, Fig. 6 to Fig. 7 discusses an example of assembling the electrical socket 20 with the electrical plug 100. Fig. Figure 1 illustrates the CPA lever assembly 49 in a delivery locking position at the electrical socket 20. In the delivery locking position, the release tabs 51 are engaged in their respective release slots 30, and the CPA locking tab 94 is held between the delivery position flanges 40 and the delivery position stop flange 42, thus retaining the CPA lever assembly 49 in this position. In the delivery locking position, the CPA element 72 is also held telescopically retracted into the CPA guide channel 54 by holding the first telescopic control projections 78 in their respective first insertion openings 58 and the second telescopic control projections 80 in their respective second insertion openings 68. Thus, the CPA lever assembly 49 is held in this configuration, for example, during transport or storage, ready for assembly.

[0019] Fig. 2 and Fig. Figure 3 illustrates the CPA lever assembly 49 shortly before the electrical connectors 20 and 100 are connected. To remove the CPA element 72 from the in Fig. Position 1 shown in the position of the Fig. 2 and Fig. To move 3, a force is exerted on the CPA element 72 in a direction away from the socket housing 22, thereby pulling the CPA element away from the electrical socket housing 22. The applied force should be sufficient to cause the inclined surfaces 84 of the first telescopic control arms 78 to bend the first flexible arm 77, thus releasing the first telescopic control arms 78 from the first insertion openings 58, and sufficient to cause the first inclined surfaces 86 of the second telescopic control arms 80 to bend the second flexible arm 79, thus releasing the second telescopic control arms 80 from the second insertion openings 68. The telescopic arms 74 of the CPA element 72 are now free to slide telescopically outwards in the respective CPA guide channels 54.The telescopic movement is stopped when the CPA mounting flanges 82 reach the respective ends of the retaining slots 64; at this point, the third flexible arms 81 press the respective vertical retaining surfaces 92 of the CPA mounting flanges 82 into engagement with the ends of the retaining slots 64. The vertical retaining surfaces 92, which are generally perpendicular to the end surfaces of the retaining slots 64, prevent the CPA element 72 from being completely withdrawn from the pivot arms 48. When the CPA mounting flanges 82 reach their stop positions, the first telescopic control arms 78 and the second telescopic control arms 80 align with their corresponding first extension openings 60 and second extension openings 70, with the corresponding first flexible arms 77 and second flexible arms 79 pressing the respective arms into the aligned openings.With the CPA element 72 in this fully extended position, the second vertical surfaces 88 of the second telescopic control projections 80, which are generally perpendicular to and engage with the edges of the second extension openings 70, prevent the CPA element 72 from being telescopically retracted into the pivot arms 48. Accordingly, the CPA element 72 is locked in the extended position until the electrical plug 100 is assembled with the electrical socket 20, as explained below.

[0020] If the CPA lever assembly 49 is in the Fig. 2 and Fig. When the electrical plug 100 is in the position shown in Figure 3, it is aligned with the electrical socket 20 and partially engaged with it. As the electrical plug 100 moves towards the electrical socket 20, the pivot arm release projections 106 are pushed into their respective release slots 30 until they engage and push the release tabs 51 out of their respective release slots 30. This releases the pivot arms 48 to pivot relative to the socket housing 22. As the electrical plug 100 moves towards the electrical socket 20, the cam projections slide into the respective openings in the respective arm cams 52. The electrical plug 100 is now partially engaged with the electrical socket 20, but the CPA element 72 cannot yet be extended inwards towards the socket housing 22.Preventing the CPA element 72 from extending inwards while the electrical connectors 20, 100 are only partially engaged provides a visual indication that the connection is not complete.

[0021] To move the CPA lever assembly 49 from its position into the Fig. 2 and Fig. 3 into position in the Fig. 4 and Fig. To move 5, a force is exerted on the CPA element 72 in a direction that causes the CPA lever assembly 49 to pivot about the pivot projections 32 of the socket housing 22. The CPA lever assembly 49 pivots until the third walls 66 of the pivot arms 48 contact the respective pivot stop flanges 34. While the force is exerted on the CPA element 72, the pivoting of the CPA lever assembly 49 causes the cam projections 108 to slide into the arm cams 52. The sliding of the cam projections 108 into the arm cams 52 pulls the electrical plug 100 toward the electrical socket 20 and into full engagement with it. While the third walls 66 of the swivel arms 48 are moved into contact with the respective swivel stop flanges 34, the second telescopic control attachments 80 are pressed against the respective CPA release flanges 36 (ideally in the section shown in Fig. (see Figure 4). The CPA release flanges 36 thus press against the second telescopic control arms 80, causing the second flexible arms 79 to bend and the second telescopic control arms 80 to move out of their respective second extension openings 70. The CPA element 72 is now no longer prevented from sliding into the pivot arms 48. As the third walls 66 of the pivot arms 48 move into contact with the respective pivot stop flanges, the guide slots 83 on the CPA element 72 align with the respective anti-rotation attachments 38 on the bushing housing 22.

[0022] As soon as the CPA lever assembly 49 is in the Fig. 4 and Fig. In the position illustrated in section 5, the CPA element 72 can now be telescopically inserted into the Fig. 6 and Fig. The position shown in section 8 can be moved (although in Fig.(Figure 6, the electrical plug 100 is not shown to allow a better view of the elements on the electrical socket 20.) The CPA lever assembly 49 is prevented from being moved into this final position without the engagement of the electrical plug and socket 20, 100 (as explained above). When force is applied to telescopically extend the CPA element 72 into the pivot arms 48, the second telescopic control projections 78 are already released from the second extension openings 68, the inclined surface 84 of the first telescopic control projections 78 bends the first flexible arms 77, thereby releasing the first telescopic control projections 78 from the first extension openings 60, and the inclined insertion surfaces 90 bend the third flexible arms 81, allowing the CPA mounting flanges 82 to slide along the respective retaining slots 64. The applied force then causes the telescopic arms 74 to slide into the CPA guide channels 54.As the telescopic arms 74 are pushed into the CPA guide channels 54, the guide slots 83 slide over the respective anti-rotation lugs 38, and the CPA locking tab 94 slides into the locking tab recess 46 below the CPA retaining tab 44, thus preventing the CPA lever assembly 49 from pivoting relative to the socket housing 22. When the CPA element 72 is fully telescopically inserted into the pivot arms 48, the first telescopic control lugs 78 are held in the first insertion openings 58 and the second telescopic control lugs 80 are held in the second insertion openings 68, ensuring that the CPA element 72 remains fully inserted into the pivot arms 48. Accordingly, the connector position lock (CPA) ensures that the electrical plug 100 remains fully engaged with the electrical socket 20.

[0023] The electrical plug 100 can be disconnected from the electrical socket 20 by reversing the procedure described above.

[0024] A person skilled in the art will recognize that various modifications and alternatives to the described and illustrated embodiments can be developed in light of the general teaching of the disclosure, and that the various elements and features of one example described and illustrated herein can be combined with various elements and features of another example without departing from the scope of the invention. Accordingly, the specific examples disclosed herein were selected by the inventor(s) merely to describe and illustrate examples of the invention and are not intended to limit the scope of the invention in any way. The scope of protection is defined by the full scope of the appended claims and all equivalents thereof.

Claims

[1] Electrical connector (20), comprising: a connector housing (22) with a connector opening (26) configured to be connected to a second electrical connector (100), a pair of pivot projections (32) extending from it on opposite sides of the connector housing (22), and a CPA retaining element extending from the connector housing (22); and a CPA lever assembly (49) comprising a pair of pivot arms (48) and a CPA element (72), wherein the pair of pivot arms (48) is each pivotably mounted on one of the respective pivot projections (32), wherein the pair of pivot arms (48) each has a CPA guide channel (54); and the CPA element (72) comprising a pair of telescopic arms (74) and a transverse element (76) connected between the arms (74), each of the telescopic arms (74) being mounted in one of the respective CPA guide channels (54) and being selectively telescopically displaceable therein between a retracted position and an extended position, the CPA element (72) being configured to be selectively pivotable when in the extended position to engage the second electrical connector (100) with the electrical connector (20), and the CPA element (72) comprising a CPA locking element extending therefrom and being configuredto engage with the CPA retaining element when the electrical connector (20) is fully engaged with the second electrical connector (100) and the telescopic arms (74) are moved into the retracted position, characterized in that the connector housing (22) has a pair of pivot stop flanges (34) extending from opposite sides of the connector housing (22) and configured to stop the pivoting of the CPA lever assembly (49) when the CPA lever assembly (49) is in a position for full engagement of the second electrical connector (100) with the electrical connector (20). [2] Electrical connector (20) according to claim 1, further comprising feed flanges extending from the connector housing (22) and configured to prevent the CPA lever assembly (49) from pivoting relative to the connector housing (22) when the CPA element (72) is in the retracted position. [3] Electrical connector (20) according to claim 1, wherein the connector housing (22) has a pair of release slots (30), each of the release slots (30) extending from the connector opening (26) towards one of the respective pivot projections (32) and each of the pivot arms (48) having a release tab (51) which is biased into one of the respective release slots (30) and is configured to prevent pivoting of the CPA lever assembly (49) before the second electrical connector (100) engages at least partially with the electrical connector (20). [4] Electrical connector (20) according to claim 1, wherein the CPA element (72) is configured such that, as soon as the CPA element (72) is moved from the retracted position to the extended position with respect to the pivot arms (48), the CPA element (72) is prevented from moving back to the retracted position until the second electrical connector (100) is fully engaged with the electrical connector (20). [5] Electrical connector (20) according to claim 1, wherein the CPA retaining element is a CPA retaining tab (44) extending from the connector housing (22) to define a locking tab recess (46), and the CPA locking element is a flange extending from the CPA element (72) and configured to be received in the locking tab recess (46) to prevent pivoting of the CPA lever assembly (49) relative to the connector housing (22) when the second electrical connector (100) is fully engaged with the electrical connector (20) and the CPA element (72) is in the retracted position. [6] Electrical connector (20) according to claim 1, wherein the CPA retaining element is a pair of rotary locking projections extending from opposite sides of the connector housing (22), and the CPA locking element is a pair of guide slots (83), each of the guide slots (83) being recessed in one of the telescopic arms (74) and configured to engage with one of the rotary locking projections when the second electrical connector (100) is fully engaged with the electrical connector (20) and the CPA element (72) is in the extended position. [7] Electrical connector (20) according to claim 1, wherein each of the pair of telescopic arms (74) has a CPA fastening element configured to prevent the pair of telescopic arms (74) from being removed from each of the CPA guide channels (54). [8] Electrical connector (20) according to claim 1, wherein each of the pair of pivot arms (48) has an arm cam (52) configured to engage with cam projections (108) extending from the second electrical connector (100) and to draw the second electrical connector (100) into full engagement with the electrical connector (20) when the CPA lever assembly (49) is pivoted into a position of full engagement. [9] Electrical connector (20) according to claim 1, wherein each of the CPA guide channels (54) has an insertion opening (58, 68) and an extension opening (60, 70), each of the pair of telescopic arms (74) has a control projection (78, 80) that can be selectively engaged with corresponding insertion openings (58, 68) when the CPA element (72) is in the retracted position, and can be engaged with the extension openings (60, 70) when the CPA element (72) is in the extended position, and the connector housing (22) has a pair of CPA release flanges (36) each extending from corresponding pivot stop flanges (34), the pair of CPA release flanges (36) being configured to allow the control projections (78, 80) to be directed away from the respective extension openings (60,70) to release,when the CPA lever assembly (49) is in a position for full engagement of the second electrical connector (100) with the electrical connector (20) to allow the CPA element (72) to be moved from the extended position to the retracted position. [10] Electrical connector (20) according to claim 9, wherein each of the control projections (78, 80) has an inclined surface (84) which is at an angle other than perpendicular to a direction of movement of the telescopic arms (74) with respect to the respective CPA guide channels (54) and points away from the respective pivot projections (32), and a vertical surface (88) which is generally perpendicular to the direction of movement of the telescopic arms (74) with respect to the respective CPA guide channels (54) and faces the respective pivot projections (32), wherein the vertical surfaces are configured to prevent the CPA element (72) from moving from the extended position to the retracted position unless the CPA release flanges (36) push the control projections (78, 80) out of the respective extension openings (60, 70). [11] Electrical connector (20) according to claim 10, wherein each of the control attachments (78, 80) is attached to a respective flexible arm (77, 79, 81) of the telescopic arms (74), wherein the flexible arms (77, 79, 81) are arranged to allow elastic bending in order to release the control attachments (78, 80) from the respective insertion openings (58, 68) and extension openings (60, 70). [12] Electrical connector (20) according to claim 1, wherein the pair of pivot arms (48) each has a retention slot (64) and each of the pair of telescopic arms (74) has a CPA fastening element having an inclined insertion surface (90) facing the respective pivot projections (32) and a vertical retention surface (92) facing away from the respective pivot projections (32), wherein the vertical retention surface (92) selectively engages in the respective retention slots (64) to prevent the pair of telescopic arms (74) from being removed from the respective CPA guide channels (54). [13] Electrical connector (20) according to claim 12, wherein each of the CPA fastening elements extends from a respective flexible arm (77, 79, 81) of the telescopic arms (74), wherein the flexible arms (77, 79, 81) are configured to allow elastic bending to enable the insertion of the telescopic arms (74) into the respective CPA guide channels (54).

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