CONNECTOR SYSTEM

Description

BACKGROUND OF THE INVENTION

[0001] The present invention generally relates to a connector system provided with a position assurance device for assuring the engagement of a male housing with a female housing. The connector system includes the connector position assurance device, the male housing and the female housing. The female housing receives the connector position assurance device to assure the male and female housings are engaged with each other. The female housing can receive an optional terminal position assurance device, regarding connections of at least one terminal for one or more electrical wires and / or electrical connections. The male housing can receive an optional terminal position assurance device, regarding connections of at least one terminal for one or more electrical wires and / or electrical connections.

[0002] US 2009 / 023325 A1 shows a conventional connector position assurance device having two flexible members. The two flexible members are configured to flex in the same directions. US 8 016 606 B1 shows another conventional connector position assurance (CPA) device for ensuring mating of a male header connector with a female housing which includes a body portion, a first arm, and a second arm. The first arm is attached to the body portion, extended from the body portion, and includes a locking groove proximate a distal end thereof. The second arm, which includes a locking latch, is spaced apart from the first arm, attached to the body portion, and extended from the body portion. When the CPA device is guided along the female housing, the locking groove and the locking latch lock onto complementary protrusions on the female housing in a pre-lock position, only to be dislodged upon contact of a sloped surface at the distal end of the first arm with the male header connector during insertion of the male header connector into the female housing to proceed to a final-lock position.SUMMARY OF THE INVENTION

[0003] A connector system according to the present invention is set out in independent claim 1. Further advantageous developments of the present invention are set out in the dependent claims.

[0004] A connector position assurance (CPA) device is inserted into a female housing before the female housing is coupled with a male housing, such that the CPA device is at a pre-lock position. The CPA device serves to assure the engagement of the male housing with the female housing. If the male housing and female housing are engaged together, the engagement thereof is assured when the CPA device is placed at the full-lock position.

[0005] If an optional terminal position assurance (TPA) device is being used for the female housing, the TPA device can be inserted into the female housing before the female housing is coupled with the male housing, such that the TPA device is at a pre-lock position. The use of the TPA is not part of the claimed invention.

[0006] When the TPA device is in the pre-lock position, it is not possible to easily insert the female housing into the male housing, because the TPA device extends out from the body of the female housing to cause an outer dimension of the female housing / TPA device combination to be too large to fit into the male housing. When the female housing is to be inserted into the male housing, the TPA device must be inserted further into the female housing, such that the TPA device is at a full-lock position. When the TPA device is at the full-lock position, the female housing can be inserted all the way into the male housing.

[0007] When the female housing is inserted all the way into the male housing, the CPA device can be inserted further into the female housing, such that the CPA device is at a full-lock position.

[0008] At least one terminal, for one or more electrical wires and / or electrical connections, is provided into the female housing when the TPA device is at a pre-lock position. The at least one terminal provided into the female housing is secured thereto when the TPA device is moved to the full-lock position.

[0009] With the TPA device being at the full-lock position, the female housing can enter the inside of the male housing, and both the male and female housings can be fully engaged together with the CPA device. The full engagement of the male housing with the female housing is assured when the CPA device is at a full-lock position.

[0010] Additional features, advantages, and embodiments of the invention are set forth or apparent from consideration of the following detailed description, drawings and claims. Moreover, it is to be understood that both the foregoing summary of the invention and the following detailed description are exemplary and intended to provide further explanations without limiting the scope of the invention as claimed.BRIEF DESCRIPTION OF THE DRAWINGS

[0011] FIG. 1 is an exploded perspective view of the connector system of the present invention, showing a male housing, a female housing, a connector position assurance (CPA) device, and an optional terminal position assurance (TPA) device, illustrating a first embodiment of the present invention. FIG. 2A is a first perspective view of the female housing of FIG. 1. FIG. 2B is a second perspective view of the female housing of FIG. 1. FIG. 2C is a third perspective view of the female housing of FIG. 1. FIG. 3A is a first perspective view of the CPA device of FIG. 1. FIG. 3B is a second perspective view of the CPA device of FIG. 1. FIG. 3C is a third perspective view of the CPA device of FIG. 1. FIG. 3D is an elevational view of the CPA device of FIG. 1. FIG. 4 is a perspective view of the TPA device of FIG. 1. FIG. 5A is a perspective view of the male housing of FIG. 1. FIG. 5B is an elevational view of the male housing of FIG. 1. FIG. 6A is a first perspective view of the female housing of FIG. 1, with the TPA device of FIG. 1 at a pre-lock position in the female housing, and with the CPA device of FIG. 1 at a pre-lock position in the female housing. FIG. 6B is a second perspective view of the female housing of FIG. 1, with the TPA device of FIG. 1 at a pre-lock position in the female housing, and with the CPA device of FIG. 1 at a pre-lock position in the female housing. FIG. 6C is a perspective view of the female housing of FIG. 1, with the TPA device of FIG. 1 at a full-lock position in the female housing, and with the CPA device of FIG. 1 at a pre-lock position in the female housing. FIG. 7A is a cross-sectional view, taken along line 7A-7A in FIG. 6B, showing the TPA device at a pre-lock position in the female housing. FIG. 7B is a cross-sectional view, taken along line 7B-7B in FIG. 6C, showing the TPA device at a full-lock position in the female housing. FIG. 8A is a first perspective view of the female housing, male housing, and CPA device shown in FIG. 1, with the female housing coupled with the male housing, and with the CPA device inserted into the female housing at a pre-lock position. FIG. 8B is a second perspective view of the female housing, male housing, and CPA device shown in FIG. 1, with the female housing coupled with the male housing, and with the CPA device inserted into the female housing at a pre-lock position. FIG. 9A is a cross-sectional view, taken along line 9A-9A in FIG. 8A. FIG. 9B is a cross-sectional view, taken along line 9B-9B in FIG. 8A. FIG. 9C is a cross-sectional view, taken along line 9C-9C in FIG. 8A. FIG. 9D is a cross-sectional view, taken along line 9D-9D in FIG. 8A. FIG. 10 is a perspective view of the female housing, male housing, and CPA device shown in FIG. 1, with the female housing coupled with the male housing, and with the CPA device inserted into the female housing at a full-lock position. FIG. 11A is a cross-sectional view, taken along line 11A-11A in FIG. 10. FIG. 11B is a cross-sectional view, taken along line 11B-11B in FIG. 10. FIG. 11C is a cross-sectional view, taken along line 11C-11C in FIG. 10. FIG. 11D is a cross-sectional view, taken along line 11D-11D in FIG. 10. FIG. 12 is a cross-sectional view, taken along line 12-12 in FIG. 10. FIG. 13 is an exploded perspective view of the connector system of the present invention, showing a male housing, a female housing, a connector position assurance (CPA) device, and an optional terminal position assurance (TPA) device, illustrating a second embodiment of the present invention. FIG. 14A is a first perspective view of the female housing of FIG. 13. FIG. 14B is a second perspective view of the female housing of FIG. 13. FIG. 14C is a third perspective view of the female housing of FIG. 13. FIG. 15 is a perspective view of the TPA device of FIG. 13. FIG. 16A is a perspective view of the male housing of FIG. 13. FIG. 16B is an elevational view of the male housing of FIG. 13. FIG. 17A is a first perspective view of the female housing of FIG. 13, with the TPA device of FIG. 13 at a pre-lock position in the female housing, and with the CPA device of FIG. 13 at a pre-lock position in the female housing. FIG. 17B is a second perspective view of the female housing of FIG. 13, with the TPA device of FIG. 13 at a pre-lock position in the female housing, and with the CPA device of FIG. 13 at a pre-lock position in the female housing. FIG. 17C is a perspective view of the female housing of FIG. 13, with the TPA device of FIG. 13 at a full-lock position in the female housing, and with the CPA device of FIG. 13 at a pre-lock position in the female housing. FIG. 18A is a cross-sectional view, taken along line 18A-18A in FIG. 17B, showing the TPA device in a pre-lock position in the female housing. FIG. 18B is a cross-sectional view, taken along line 18B-18B in FIG. 17C, showing the TPA device in a full-lock position in the female housing. FIG. 19A is a first perspective view of the female housing, male housing, and CPA device shown in FIG. 13, with the female housing coupled with the male housing, and with the CPA device inserted into the female housing at a pre-lock position. FIG. 19B is a second perspective view of the female housing, male housing, and CPA device shown in FIG. 13, with the female housing coupled with the male housing, and with the CPA device inserted into the female housing at a pre-lock position. FIG. 20A is a cross-sectional view, taken along line 20A-20A in FIG. 19A. FIG. 20B is a cross-sectional view, taken along line 20B-20B in FIG. 19A. FIG. 20C is a cross-sectional view, taken along line 20C-20C in FIG. 19A. FIG. 20D is a cross-sectional view, taken along line 20D-20D in FIG. 19A. FIG. 21 is a perspective view of the female housing, male housing, and CPA device shown in FIG. 13, with the female housing coupled with the male housing, and with the CPA device inserted into the female housing at a full-lock position. FIG. 22A is a cross-sectional view, taken along line 22A-22A in FIG. 21. FIG. 22B is a cross-sectional view, taken along line 22B-22B in FIG. 21. FIG. 22C is a cross-sectional view, taken along line 22C-22C in FIG. 21. FIG. 22D is a cross-sectional view, taken along line 22D-22D in FIG. 21. FIG. 23 is a cross-sectional view, taken along line 23-23 in FIG. 21. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0012] FIG. 1 is an exploded perspective view of the connector system of the present invention, showing a male housing, a female housing and a connector position assurance device (CPA) illustrating a first embodiment of the present invention. FIG. 1 also ilustrates an optional terminal position assurance (TPA) device which is not part of the claimed invention.

[0013] The first embodiment, shown in FIG. 1, illustrates a three-pin configuration wherein a male housing and a female housing have apertures and features accommodating three pins or three terminals for electrical wires and / or electrical connections.

[0014] As shown in FIG. 1, the connector system is generally referred to by reference number 1, and includes a female housing 3, a male housing 5, a connector position assurance (CPA) device 8, and an optional terminal position assurance (TPA) device 6.

[0015] FIG. 2A is a first perspective view of the female housing of FIG. 1. FIG. 2B is a second perspective view of the female housing of FIG. 1. FIG. 2C is a third perspective view of the female housing of FIG. 1.

[0016] The female housing 3 has an upper side 18, a lower side 20, a first side 22, a second side 24, a front end side 26, and a back end side 28. A side slot 13 is located on the first side 22 of the female housing 3. A top slot 15 is located on the upper side 18 of the female housing 3. A protrusion 23 is located on the first side 22 of the female housing 3. An exterior bridge member 30 is located at a position adjacent to the top slot 15. A groove 31 is located on a lower side 20 of the female housing 3. Three terminal slots 33 are located on the back end side 28.

[0017] Three terminal slots 34 are located on the front end side 26. A flexible member 35 or flexible arm 35 is located on the female housing, as shown in FIG. 2B. The flexible member 35 has a front end 40. Two protruding members 43 are formed on the flexible member 35. The front side 26 of the female housing 3 forms an opening 42. A substantially U-shaped member 45 is on the female housing 3. In the female housing 3, there is a ramp-like member 46 which has an end portion 50.

[0018] A first window 55 and a second window 57 are formed in the lower side 20 of the female housing 3, as shown in FIG. 2C. An interior bridge member 60 is located in the female housing 3, as shown in FIG. 2C. The first window 55 is adjacent to the interior bridge member 60. The second window 57 is also adjacent to the interior bridge member 60. The interior bridge member 60 is disposed between the first window 55 and the second window 57.

[0019] As explained later, the side slot 13 may receive the optional TPA device 6. The exterior bridge member 30 is located between the side slot 13 and the top slot 15.

[0020] FIG. 2B shows the flexible member 35 extending along the second side 24 of the female housing 3, such that the front end 40 of the flexible member 35 extends to a position near the substantially U-shaped member 45. The protruding members 43 extend from the flexible member 35 at an intermediate area of the flexible member 35. FIG. 2C shows an engaging member 61 on an interior of the female housing 3.

[0021] FIG. 3A is a first perspective view of the CPA device of FIG. 1. FIG. 3B is a second perspective view of the CPA device of FIG. 1. FIG. 3C is a third perspective view of the CPA device of FIG. 1. FIG. 3D is an elevational view of the CPA device of FIG. 1.

[0022] FIG. 3A illustrates the CPA device 8 shown in FIG. 1. The CPA device 8 has an upper side 73, lower side 74, side ledges 75, a first flexible side member 70, a second flexible side member 77, and an end portion 85. The first flexible side member 70 has a side end portion 72 and an opening 92.

[0023] As shown in FIG. 3A, the second flexible side member 77 has a lower side with a front ledge 81, a wedge-like member 80, a cut-out portion 82 next to the wedge-like member 80, and a back ledge 83. As shown in FIG. 3C, the second flexible side member 77 has an upper side with a ramp-like member 88 and end portion 90.

[0024] The CPA device 8 locks the female housing 3 and the male housing 5 together. The ramp-like member 88 provides a spring-like action or a resilience property for the second flexible side member 77, as will be later discussed. The opening 92 passes through an inner portion of the first flexible side member 70.

[0025] The back ledge 83, in combination with the wedge-like member 80, forms a substantially U-shaped portion on the lower side of the second flexible side member 77.

[0026] As shown in FIG. 3D, the side end portion 72 of the first flexible side member 70 is able to flex in a first direction upward away from the second flexible side member 77 and in a second direction opposite to the first direction. As shown in FIG. 3C, the wedge-like member 80 of the second flexible side member 77 is able to flex in a third direction toward the upper side 73 and in a fourth direction opposite to the third direction.

[0027] FIG. 4 is a perspective view of the TPA device of FIG. 1, which is not part of the claimed invention. As shown in FIG. 4, the TPA device 6 is substantially L-shaped. However, the general shape of the TPA device 6 is not limited to such a configuration. A first elongated member 100 and a second elongated member 102 extend from a top portion 98 of the TPA device 6.

[0028] FIG. 5A is a perspective view of the male housing of FIG. 1. FIG. 5B is an elevational view of the male housing of FIG. 1. The male housing 5 is shown in a generic form in FIGS. 1, 5A, and 5B, for example, such that some details of the male housing 5 are not illustrated. The male housing 5 has a first end portion 105, a second end portion 107, a first side 109, a second side 111, an opening 110, a guide groove 112, and a guide protrusion 114. An elongated slot 108 is formed in the second side 111. Also, the male housing 5 has three terminal apertures 106.

[0029] As shown in FIG. 5B, the space 103 is the region where the optional TPA device 6 is located, if the TPA device 6 is inserted to a full-lock position in the female housing 3 and then the female housing 3 is inserted into the opening 110 of the male housing 5.

[0030] When the female housing 3 is inserted into the opening 110 of the male housing 5, the protrusion 23 is received by the guide groove 112.

[0031] FIG. 6A is a first perspective view of the female housing of FIG. 1, with the TPA device of FIG. 1 at a pre-lock position in the female housing, and with the CPA device of FIG. 1 at a pre-lock position in the female housing. FIG. 6B is a second perspective view of the female housing of FIG. 1, with the TPA device of FIG. 1 at a pre-lock position in the female housing, and with the CPA device of FIG. 1 at a pre-lock position in the female housing.

[0032] As shown in FIG. 6A, the TPA device 6 is inserted into the side slot 13 of the female housing 3 such that the first elongated member 100 passes beneath the exterior bridge member 30 and becomes positioned within the top slot 15 of the female housing 3, the TPA device 6 being in a pre-lock position. As shown in FIGS. 6A and 6B, the CPA device 8 is at a pre-lock position with the female housing 3, while the TPA device 6 is similarly at a pre-lock position.

[0033] With the TPA device 6 and CPA device 8 at pre-lock positions, the female housing 3 and the two devices 6, 8 are in a stable configuration and are ready to be transported.

[0034] With the CPA device 8 at a pre-lock position inside the female housing 3 (and the TPA device 6 now at a pre-lock position inside the female housing 3), the female housing 3 is ready to be transported to a location where the female housing 3 can be engaged with the male housing 5.

[0035] FIG. 6C is a perspective view of the female housing of FIG. 1, with the TPA device of FIG. 1 at a full-lock position in the female housing, and with the CPA device of FIG. 1 at a pre-lock position in the female housing. After a set of terminals (not shown) is inserted through the set of terminal slots 33 of the female housing 3, the TPA device 6 is pushed further inward into the side slot 13. At this time, the second elongated member 102 of the TPA device 6 is pushed past the exterior bridge member 30 of the female housing 3, and thus the second elongated member 102 arrives into the top slot 15 of the female housing 3. The TPA device 6 is then at a full-lock position, as shown in FIG. 6C.

[0036] FIG. 7A is a cross-sectional view, taken along line 7A-7A in FIG. 6B, showing the TPA device at a pre-lock position in the female housing. FIG. 7B is a cross-sectional view, taken along line 7B-7B in FIG. 6C, showing the TPA device at a full-lock position in the female housing.

[0037] As shown in FIG. 7A, the TPA device 6 is at a pre-lock position, when the first elongated member 100 of the TPA device 6 has been pushed into side slot 13 so that the first elongated member 100 proceeds past the exterior bridge member 30, wherein the first elongated member 100 is located in the top slot 15 and the second elongated member 102 is not in the top slot 15.

[0038] As shown in FIG. 7B, the TPA device 6 is at a full-lock position, when the first elongated member 100 and the second elongated member 102 of the TPA device 6 have both been pushed into side slot 13 so that the first elongated member 100 and the second elongated member 102 both proceed past the exterior bridge member 30, wherein the first elongated member 100 and the second elongated member 102 are both located in the top slot 15.

[0039] As shown in FIG. 7B, the TPA device 6 is fully inserted into the female housing 3 so that no part of the TPA device 6 extends beyond the exterior edge of the first side 22 of the female housing 3. When the TPA device 6 is at a full-lock position within the female housing 3, the TPA device 6 has secured the set of terminals (not shown) intended to be joined with the female housing 3, and the female housing 3 is ready to be inserted into, and coupled with, the male housing 5. Thus, no part of the TPA device 6 extends beyond the exterior edge of the first side 22 of the female housing 3. When the TPA device 6 is at a full-lock position in the female housing 3, the female housing 3 is able to fully enter, unimpeded, into the opening 110 and guide groove 112 of the male housing 5. After the female housing 3, with the TPA device 6 at a full-lock position therein, has been fully inserted into the male housing 5, the CPA device 8 can be moved from a pre-lock position to a full-lock position by inserting the CPA device 8 further into the female housing 3. After the female housing 3 is inserted into the male housing 5, the movement of the CPA device 8 to a full-lock position provides assurance that the female housing 3 and male housing 5 are fully and properly engaged.

[0040] If the female housing 3 is to utilize the optional TPA device 6 (shown in FIG. 4), it is preferable that, first, the female housing 3 have its TPA device 6 at a pre-lock position therein and also have the CPA device 8 at a pre-lock position therein, and then, second, the female housing 3 be transported to an assembly destination with the devices 6 and 8 at pre-lock positions therein during such transport.

[0041] If the female housing 3 is not to utilize a TPA device, it is preferable that, first, the female housing 3 initially have the CPA device 8 at a pre-lock position therein, and then, second, the female housing 3 be transported to an assembly destination with the device 8 at a pre-lock position therein during such transport.

[0042] If the male housing 5 is to utilize a TPA device (not shown), it is preferable that, first, the male housing 5 have its TPA device at a pre-lock position therein, and then, second, the male housing 5 be transported to an assembly destination with its TPA device at a pre-lock position therein during such transport.

[0043] FIG. 8A is a first perspective view of the female housing, male housing, and CPA device shown in FIG. 1, with the female housing coupled with the male housing, and with the CPA device inserted into the female housing at a pre-lock position. FIG. 8B is a second perspective view of the female housing, male housing, and CPA device shown in FIG. 1, with the female housing coupled with the male housing, and with the CPA device inserted into the female housing at a pre-lock position.

[0044] FIG. 9A is a cross-sectional view, taken along line 9A-9A in FIG. 8A. FIG. 9B is a cross-sectional view, taken along line 9B-9B in FIG. 8A. FIG. 9C is a cross-sectional view, taken along line 9C-9C in FIG. 8A. FIG. 9D is a cross-sectional view, taken along line 9D-9D in FIG. 8A.

[0045] FIGS. 8A, 8B, 9A, 9B, 9C, and 9D illustrate the female housing 3 and the male housing 5 being engaged, while the CPA device 8 is at a pre-lock position, and while the TPA device 6 (visible in FIG. 9A, for example), is at a full-lock position.

[0046] As shown in FIGS. 8A, 9A, and 9B, the protruding members 43 have entered the elongated slot 108 of the male housing 5.

[0047] As shown in FIG. 9B, wherein the CPA device is at a pre-lock position, the CPA device 8 has its wedge-like member 80 in a position adjacent to the interior bridge member 60. As depicted in FIG. 9B, the wedge-like member 80 is in a position corresponding to the first window 55 (shown in FIG. 2C) of the female housing 3.

[0048] FIG. 9B shows the engaging member 61 on an interior of the female housing 3. The cut-out portion 82 of the CPA device 8 engages with the engaging member 61 of the female housing 3, when the CPA device 8 is at a pre-lock position.

[0049] To signify completed entry of the wedge-like member 80 into the first window 55, a sound (preferably, a clicking sound or the like) may be heard.

[0050] To facilitate the wedge-like member 80 first moving into the first window 55, second traversing the interior bridge member 60, and third moving into the second window 57, the front face of the wedge-like member 80 is preferably formed to have an inclined shape (see FIGS. 3A, 9D, and 11D, for example). The front face of the wedge-like member 80 is a face of the wedge-like member 80 disposed toward the front ledge 81.

[0051] The wedge-like member 80 is on the second flexible side member 77, which provides a spring-like action or resilience property.

[0052] At a pre-lock position (as illustrated in FIGS. 9A, 9B, and 9C, for example), the side end portion 72 of the CPA device 8 has traversed the ramp-like member 46 of the female housing 3 and has passed beyond the end portion 50. When the side end portion 72 passes beyond the end portion 50, a sound (preferably a clicking sound or the like) may be heard. When the side end portion 72 passes beyond the end portion 50, the end portion 50 penetrates the opening 92.

[0053] At this time, the wedge-like member 80 is fitted inside the first window 55 and is in contact with the interior bridge member 60, and the wedge-like member 80 is held in place, at least partly, by the resiliency of the second flexible side member 77, and thus the CPA device 8 is prevented from easily moving further forward into the female housing 3. Also, at this time, the end portion 50 is penetrating the opening 92, and the side end portion 72 is held in place, at least partly, by the resiliency of the first flexible side member 70, and thus the CPA device 8 is prevented from easily moving backward out from the female housing 3.

[0054] FIG. 10 is a perspective view of the female housing, male housing, and CPA device shown in FIG. 1, with the female housing coupled with the male housing, and with the CPA device inserted into the female housing at a full-lock position.

[0055] FIG. 11A is a cross-sectional view, taken along line 11A-11A in FIG. 10. FIG. 11B is a cross-sectional view, taken along line 11B-11B in FIG. 10. FIG. 11C is a cross-sectional view, taken along line 11C-11C in FIG. 10. FIG. 11D is a cross-sectional view, taken along line 11D-11D in FIG. 10. FIG. 12 is a cross-sectional view, taken along line 12-12 in FIG. 10.

[0056] The manner in which the CPA device 8 is placed at a full-lock position with the female housing 3 shall now be described, with reference to FIGS. 10, 11A, 11B, 11C, 11D, and 12. When the CPA device 8 is at a full-lock position, this can provide assurance that the female housing 3 is fully and properly engaged, coupled, and locked with the male housing 5.

[0057] When the female housing 3 enters the opening 110 of the male housing 5, the protruding members 43 of the female housing 3 enter the elongated slot 108 of the male housing 5. When the CPA device 8 is at a pre-lock position, the flexible member 35 may be pushed downward toward an interior of female housing 3, permitting the protruding members 43 to go downward, which could facilitate the female housing 3 being pulled away from the male housing 5 if desired.

[0058] However, when the CPA device 8 is at a full-lock position, as shown in FIGS. 10, 11A, 11B, 11C, 11D, and 12, the side ledges 75 of the CPA device 8 will prevent the flexible member 35 of the female housing 3 from being pushed downward toward an interior of female housing 3, and thus the protruding members 43 cannot go downward. Thus, the female housing 3 cannot be pulled away from the male housing 5.

[0059] The CPA device 8 is moved to a full-lock position in the female housing 3 when the CPA device 8 is pushed deeper into the female housing 3, from a pre-lock position to a full-lock position. When the CPA device 8 moves from a pre-lock position to a full-lock position, the wedge-like member 80 of the CPA device 8 moves out from the first window 55, traverses the interior bridge member 60 between the first window 55 and the second window 57, and moves into the second window 57. See FIGS. 11B and 11D.

[0060] Upon entry of the wedge-like member 80 into the second window 57, a sound (preferably a clicking sound or the like) may be heard. When, or approximately when, the wedge-like member 80 enters the second window 57, as shown in FIGS. 11B and 11D, the side end portion 72 of the first flexible side member 70 moves deeper into the female housing 3 while the end portion 50 is penetrating the opening 92. In addition, when the CPA device 8 is at a full-lock position, the side ledges 75 of the CPA device 8 are positioned beneath the flexible member 35, as shown in FIG. 12, and thus, the flexible member 35 cannot be pushed downward toward an interior of the female housing 3, and consequently, the protruding members 43 of the flexible member 35 cannot go downward to try to move out from the elongated slot 108 of the male housing 5. Thus, when the CPA device 8 is at a full-lock position, the female housing 3 cannot be pulled away from the male housing 5, and this serves to assure that the female housing 3 and the male housing 5, when engaged, remain fully locked together.

[0061] FIG. 13 is an exploded perspective view of the connector system of the present invention, showing a male housing, a female housing and a connector position assurance (CPA) device, illustrating a second embodiment of the present invention. An optional terminal position assurance (TPA) device is also shown but it is not part of the claimed invention.

[0062] The second embodiment, shown in FIG. 13, illustrates a four-pin configuration wherein a male housing and a female housing have apertures and features accommodating four pins or four terminals for electrical wires and / or electrical connections.

[0063] As shown in FIG. 13, the connector system is generally referred to by reference number 200, and includes a female housing 203, a male housing 205, a connector position assurance (CPA) device 8, and an optional terminal position assurance (TPA) device 206.

[0064] FIG. 14A is a first perspective view of the female housing of FIG. 13. FIG. 14B is a second perspective view of the female housing of FIG. 13. FIG. 14C is a third perspective view of the female housing of FIG. 13.

[0065] The female housing 203 has an upper side 218, a lower side 220, a first side 222, a second side 224, a front end side 226, and a back end side 228. A side slot 213 is located on the first side 222 of the female housing 203. A top slot 215 is located on the upper side 218 of the female housing 203. A protrusion 223 is located on the first side 222 of the female housing 203. An exterior bridge member 230 is located at a position adjacent to the top slot 215. A groove 231 is located on a lower side 220 of the female housing 203. Four terminal slots 233 are located on the back end side 228.

[0066] Four terminal slots 234 are located on the front end side 226. A flexible member 235 is located on the female housing, as shown in FIG. 14B. The flexible member 235 has a front end 240. Two protruding members 243 are formed on the flexible member 235. The front side 226 of the female housing 203 forms an opening 242. A substantially U-shaped member 245 is on the female housing 203. In the female housing 203, there is a ramp-like member 246 which has an end portion 250.

[0067] A first window 255 and a second window 257 are formed in the lower side 220 of the female housing 203, as shown in FIG. 14C. An interior bridge member 260 is located in the female housing 203, as shown in FIG. 14C. The first window 255 is adjacent to the interior bridge member 260. The second window 257 is also adjacent to the interior bridge member 260. The interior bridge member 260 is disposed between the first window 255 and the second window 257.

[0068] As explained later, the side slot 213 may receive the optional TPA device 206. The exterior bridge member 230 is located between the side slot 213 and the top slot 215.

[0069] FIG. 14B shows the flexible member 235 extending along the second side 224 of the female housing 203, such that the front end 240 of the flexible member 235 extends to a position near the substantially U-shaped member 245. The protruding members 243 extend from the flexible member 235 at an intermediate area of the flexible member 235.

[0070] FIG. 15 is a perspective view of the TPA device of FIG. 13, not being part of the claimed invention. As shown in FIG 15, the TPA device 206 is substantially L-shaped. However, the general shape of the TPA device 206 is not limited to such a configuration. A first elongated member 300 and a second elongated member 302 extend from a top portion 298 of the TPA device 206.

[0071] FIG. 16A is a perspective view of the male housing of FIG. 13. FIG. 16B is an elevational view of the male housing of FIG. 13. The male housing 205 is shown in a generic form in FIGS. 13, 16A, and 16B, for example, such that some details of the male housing 205 are not illustrated. The male housing 205 has a first end portion 305, a second end portion 307, a first side 309, a second side 311, an opening 310, a guide groove 312, a first guide protrusion 314, and a second guide protrusion 316. An elongated slot 308 is formed in the second side 311. Also, the male housing 205 has four terminal apertures 306.

[0072] As shown in FIG. 16B, the space 303 is the region where the optional TPA device 206 is located, if the TPA device 206 is inserted to a full-lock position in the female housing 203 and then the female housing 203 is inserted into the opening 310 of the male housing 205.

[0073] When the female housing 203 is inserted into the opening 310 of the male housing 205, the protrusion 223 is received by the guide groove 312.

[0074] FIG. 17A is a first perspective view of the female housing of FIG. 13, with the TPA device of FIG. 13 at a pre-lock position in the female housing, and with the CPA device of FIG. 13 at a pre-lock position in the female housing. FIG. 17B is a second perspective view of the female housing of FIG. 13, with the TPA device of FIG. 13 at a pre-lock position in the female housing, and with the CPA device of FIG. 13 at a pre-lock position in the female housing.

[0075] As shown in FIG. 17A, the TPA device 206 is inserted into the side slot 213 of the female housing 203 such that the first elongated member 300 passes beneath the exterior bridge member 230 and becomes positioned within the top slot 215 of the female housing 203, the TPA device 206 being in a pre-lock position. As shown in FIGS. 17A and 17B, the CPA device 8 is at a pre-lock position with the female housing 203, while the TPA device 206 is similarly at a pre-lock position.

[0076] With the TPA device 206 and CPA device 8 at pre-lock positions, the female housing 203 and the two devices 206, 8 are in a stable configuration and are ready to be transported.

[0077] With the CPA device 8 at a pre-lock position inside the female housing 203 (and the TPA device 206 now at a pre-lock position inside the female housing 203), the female housing 203 is ready to be transported to a location where the female housing 203 can be engaged with the male housing 205.

[0078] FIG. 17C is a perspective view of the female housing of FIG. 13, with the TPA device of FIG. 13 at a full-lock position in the female housing, and with the CPA device of FIG. 13 at a pre-lock position in the female housing. After a set of terminals (not shown) is inserted through the set of terminal slots 233 of the female housing 203, the TPA device 206 is pushed further inward into the side slot 213. At this time, the second elongated member 302 of the TPA device 206 is pushed past the exterior bridge member 230 of the female housing 203, and thus the second elongated member 302 arrives into the top slot 215 of the female housing 203. The TPA device 206 is then at a full-lock position, as shown in FIG. 17C.

[0079] FIG. 18A is a cross-sectional view, taken along line 18A-18A in FIG. 17B, showing the TPA device at a pre-lock position in the female housing. FIG. 18B is a cross-sectional view, taken along line 18B-18B in FIG. 17C, showing the TPA device at a full-lock position in the female housing.

[0080] As shown in FIG. 18A, the TPA device 206 is at a pre-lock position, when the first elongated member 300 of the TPA device 206 has been pushed into side slot 213 so that the first elongated member 300 proceeds past the exterior bridge member 230, wherein the first elongated member 300 is located in the top slot 215 and the second elongated member 302 is not in the top slot 215.

[0081] As shown in FIG. 18B, the TPA device 206 is at a full-lock position, when the first elongated member 300 and the second elongated member 302 of the TPA device 206 have both been pushed into side slot 213 so that the first elongated member 300 and the second elongated member 302 both proceed past the exterior bridge member 230, wherein the first elongated member 300 and the second elongated member 302 are both located in the top slot 215.

[0082] As shown in FIG. 18B, the TPA device 206 is fully inserted into the female housing 203 so that no part of the TPA device 206 extends beyond the exterior edge of the first side 222 of the female housing 203. When the TPA device 206 is at a full-lock position within the female housing 203, the TPA device 206 has secured the set of terminals (not shown) intended to be joined with the female housing 203, and the female housing 203 is ready to be inserted into, and coupled with, the male housing 205. Thus, no part of the TPA device 206 extends beyond the exterior edge of the first side 222 of the female housing 203. When the TPA device 206 is at a full-lock position in the female housing 203, the female housing 203 is able to fully enter, unimpeded, into the opening 310 and guide groove 312 of the male housing 205. After the female housing 203, with the TPA device 206 at a full-lock position therein, has been fully inserted into the male housing 205, the CPA device 8 can be moved from a pre-lock position to a full-lock position by inserting the CPA device 8 further into the female housing 203. After the female housing 203 is inserted into the male housing 205, the movement of the CPA device 8 to a full-lock position provides assurance that the female housing 203 and male housing 205 are fully and properly engaged.

[0083] If the female housing 203 is to utilize the optional TPA device 206 (shown in FIG. 15), it is preferable that, first, the female housing 203 have its TPA device 206 at a pre-lock position therein and also have the CPA device 8 at a pre-lock position therein, and then, second, the female housing 203 be transported to an assembly destination with the devices 206 and 8 at pre-lock positions therein during such transport.

[0084] If the female housing 203 is not to utilize a TPA device, it is preferable that, first, the female housing 203 initially have the CPA device 8 at a pre-lock position therein, and then, second, the female housing 203 be transported to an assembly destination with the device 8 at a pre-lock position therein during such transport.

[0085] If the male housing 205 is to utilize a TPA device (not shown), it is preferable that, first, the male housing 205 have its TPA device at a pre-lock position therein, and then, second, the male housing 205 be transported to an assembly destination with its TPA device at a pre-lock position therein during such transport.

[0086] FIG. 19A is a first perspective view of the female housing, male housing, and CPA device shown in FIG. 13, with the female housing coupled with the male housing, and with the CPA device inserted into the female housing at a pre-lock position. FIG. 19B is a second perspective view of the female housing, male housing, and CPA device shown in FIG. 13, with the female housing coupled with the male housing, and with the CPA device inserted into the female housing at a pre-lock position.

[0087] FIG. 20A is a cross-sectional view, taken along line 20A-20A in FIG. 19A. FIG. 20B is a cross-sectional view, taken along line 20B-20B in FIG. 19A. FIG. 20C is a cross-sectional view, taken along line 20C-20C in FIG. 19A. FIG. 20D is a cross-sectional view, taken along line 20D-20D in FIG. 19A.

[0088] FIGS. 19A, 19B, 20A, 20B, 20C, and 20D illustrate the female housing 203 and the male housing 205 being engaged, while the CPA device 8 is at a pre-lock position, and while the TPA device 206 (visible in FIG. 20A, for example), is at a full-lock position.

[0089] As shown in FIGS. 19A, 20A, and 20B, the protruding members 243 have entered the elongated slot 308 of the male housing 205.

[0090] As shown in FIG. 20B, wherein the CPA device is at a pre-lock position, the CPA device 8 has its wedge-like member 80 in a position adjacent to the interior bridge member 260. As depicted in FIG. 20B, the wedge-like member 80 is in a position corresponding to the first window 255 (shown in FIG. 14C) of the female housing 203.

[0091] FIG. 20B shows an engaging member 261 on an interior of the female housing 203. The cut-out portion 82 of the CPA device 8 engages with the engaging member 261 of the female housing 203, when the CPA device 8 is at a pre-lock position.

[0092] To signify completed entry of the wedge-like member 80 into the first window 255, a sound (preferably, a clicking sound or the like) may be heard.

[0093] To facilitate the wedge-like member 80 first moving into the first window 255, second traversing the interior bridge member 260, and third moving into the second window 257, the front face of the wedge-like member 80 is preferably formed to have an inclined shape (see FIGS. 3A, 20D, and 22D, for example). The front face of the wedge-like member 80 is a face of the wedge-like member 80 disposed toward the front ledge 81.

[0094] The wedge-like member 80 is on the second flexible side member 77, which provides a spring-like action or resilience property.

[0095] At a pre-lock position, the side end portion 72 of the CPA device 8 has traversed the ramp-like member 246 of the female housing 203 and has passed beyond the end portion 250. When the side end portion 72 passes beyond the end portion 250, a sound (preferably a clicking sound or the like) may be heard. When the side end portion 72 passes beyond the end portion 250, the end portion 250 penetrates the opening 92.

[0096] At this time, the wedge-like member 80 is fitted inside the first window 255 and is in contact with the interior bridge member 260, and the wedge-like member 80 is held in place, at least partly, by the resiliency of the second flexible side member 77, and thus the CPA device 8 is prevented from easily moving further forward into the female housing 203. Also, at this time, the end portion 250 is penetrating the opening 92, and the side end portion 72 is held in place, at least partly, by the resiliency of the first flexible side member 70, and thus the CPA device 8 is prevented from easily moving backward out from the female housing 203.

[0097] FIG. 21 is a perspective view of the female housing, male housing, and CPA device shown in FIG. 13, with the female housing coupled with the male housing, and with the CPA device inserted into the female housing at a full-lock position.

[0098] FIG. 22A is a cross-sectional view, taken along line 22A-22A in FIG. 21. FIG. 22B is a cross-sectional view, taken along line 22B-22B in FIG. 21. FIG. 22C is a cross-sectional view, taken along line 22C-22C in FIG. 21. FIG. 22D is a cross-sectional view, taken along line 22D-22D in FIG. 21. FIG. 23 is a cross-sectional view, taken along line 23-23 in FIG. 21.

[0099] The manner in which the CPA device 8 is placed at a full-lock position with the female housing 203 shall now be described. When the CPA device 8 is at a full-lock position, this can provide assurance that the female housing 203 is fully and properly engaged, coupled, and locked with the male housing 205.

[0100] When the female housing 203 enters the opening 310 of the male housing 205, the protruding members 243 of the female housing 203 enter the elongated slot 308 of the male housing 205. When the CPA device 8 is at a pre-lock position, the flexible member 235 may be pushed downward toward an interior of female housing 203, permitting the protruding members 243 to go downward, which could facilitate the female housing 203 being pulled away from the male housing 205 if desired.

[0101] However, when the CPA device 8 is at a full-lock position, the side ledges 75 of the CPA device 8 will prevent the flexible member 235 of the female housing 203 from being pushed downward toward an interior of female housing 203, and thus the protruding members 243 cannot go downward. Thus, the female housing 203 cannot be pulled away from the male housing 205.

[0102] The CPA device 8 is moved to a full-lock position in the female housing 203 when the CPA device 8 is pushed deeper into the female housing 203, from a pre-lock position to a full-lock position. When the CPA device 8 moves from a pre-lock position to a full-lock position, the wedge-like member 80 of the CPA device 8 moves out from the first window 255, traverses the interior bridge member 260 between the first window 255 and the second window 257, and moves into the second window 257.

[0103] Upon entry of the wedge-like member 80 into the second window 257, a sound (preferably a clicking sound or the like) may be heard. When, or approximately when, the wedge-like member 80 enters the second window 257, the side end portion 72 of the first flexible side member 70 moves deeper into the female housing 203 while the end portion 250 is penetrating the opening 92. In addition, when the CPA device 8 is at a full-lock position, the side ledges 75 of the CPA device 8 are positioned beneath the flexible member 235, as shown in FIG. 23, and thus, the flexible member 235 cannot be pushed downward toward an interior of the female housing 203, and consequently, the protruding members 243 of the flexible member 235 cannot go downward to try to move out from the elongated slot 308 of the male housing 205. Thus, when the CPA device 8 is at a full-lock position, the female housing 203 cannot be pulled away from the male housing 205, and this serves to assure that the female housing 203 and the male housing 205, when engaged, remain fully locked together.

[0104] The female housing 203 forms terminal slots 233, terminal apertures 233, or terminal openings 233, intended to have therein electrically-conductive terminals, wires, or conductors. The male housing 205 forms terminal apertures 306, terminal slots 306, or terminal openings 306, intended to have installed therein electrically-conductive terminals, wires, or conductors. Thus, in view of the above, terminals or conductors of the female housing 203 can be electrically connected with terminals or conductors of the male housing 205.List of reference numerals

[0105] 1Connector system for 3-pin embodiment or 3-terminal embodiment 3Female housing for 3-pin embodiment 5Male housing for 3-pin embodiment 6Terminal position assurance (TPA) device for female housing 3 8Connector position assurance (CPA) device 13Side slot on female housing 3 15Top slot on female housing 3 18Upper side of female housing 3 20Lower side of female housing 3 22First side of female housing 3 23Protrusion on first side of female housing 3 24Second side of female housing 3 26Front end side of female housing 3 28Back end side of female housing 3 30Exterior bridge member on female housing 3 31Groove on lower side of female housing 3 33Terminal slots on back end side 28 34Terminal slots on front end side 26 35Flexible member or flexible arm on female housing 3 40Front end of flexible member 35 42Opening on front end side 26 43Protruding members on flexible member 35 45Substantially U-shaped member on female housing 3 46Ramp-like member on female housing 3 50End portion of ramp-like member 46 55First window on lower side of female housing 3 57Second window on lower side of female housing 3 60Interior bridge member in female housing 3 61Engaging member on interior of female housing 3 70First flexible side member on CPA 8 72Side end portion of first flexible side member 70 73Upper side of CPA 8 74Lower side of CPA 8 75Side ledges on CPA 8 77Second flexible side member on CPA 8 80Wedge-like member on lower side of second flexible side member 77 81Front ledge on second flexible side member 77 82Cut-out portion next to wedge-like member 80 83Back ledge on second flexible side member 77 85End portion of CPA 8 88Ramp-like member on upper side of second flexible side member 77 90End portion of ramp-like member 88 92Opening or slot in first flexible side member 70 98Top portion of TPA 6 100First elongated member on TPA 6 102Second elongated member on TPA 6 103Space in male housing 5, for accommodating TPA 6 105First end portion of male housing 5 106Terminal apertures in male housing 5 107Second end portion of male housing 5 108Elongated slot on second side of male housing 5 109First side of male housing 5 110Opening in male housing 5 111Second side of male housing 5 112Guide groove in male housing 5 114Guide protrusion in opening 110 200Connector system for 4-pin embodiment or 4-terminal embodiment 203Female housing for 4-pin embodiment 205Male housing for 4-pin embodiment 206Terminal position assurance (TPA) device for female housing 203 213Side slot on female housing 203 215Top slot on female housing 203 218Upper side of female housing 203 220Lower side of female housing 203 222First side of female housing 203 223Protrusion on first side of female housing 203 224Second side of female housing 203 226Front end side of female housing 203 228Back end side of female housing 203 230Exterior bridge member on female housing 203 231Groove on lower side of female housing 203 232Groove on upper side of female housing 203 233Terminal slots on back end side 228 234Terminal slots on front end side 226 235Flexible member on female housing 203 240Front end of flexible member 235 242Opening on front end side 226 243Protruding members on flexible member 235 245Substantially U-shaped member on female housing 203 246Ramp-like member on female housing 203 250End portion of ramp-like member 246 255First window on lower side of female housing 203 257Second window on lower side of female housing 203 260Interior bridge member in female housing 203 261Engaging member on interior of female housing 203 298Top portion of TPA 206 300First elongated member on TPA 206 302Second elongated member on TPA 206 303Space in male housing 205, for accommodating TPA 206 305First end portion of male housing 205 306Terminal apertures in male housing 205 307Second end portion of male housing 205 308Elongated slot on second side of male housing 205 309First side of male housing 205 310Opening in male housing 205 311Second side of male housing 205 312Guide groove in male housing 205 314First guide protrusion in opening 110 316Second guide protrusion in opening 110

Claims

1. : A connector system, comprising: a female housing (3, 203) having at least a flexible arm (35, 235) with two protruding members (43, 243); an opening (42, 242) at the front side (26, 226) of the female housing (3, 203) and extending along a fitting direction; a ramp-like member (46, 246) disposed at the opening (42, 242) and having an end portion (50, 250); an engaging member (61); and a first window (55, 255) and second window (57, 257) separated by an interior bridge member (60, 260) and being formed through a lower side (20, 220) of the female housing (3, 203) disposed transversally to the opening (42, 242); a connector position assurance device (8) to be received in the opening (42, 242) of the female housing (3, 203), comprising: a first flexible member (70) having a first surface extending along the opening (42, 242) of the female housing (3, 203) with a side end portion (72), and forming an opening (92) passing through an inner portion of the first flexible member (70); a lower side (74) and an upper side (73) opposite the lower side in a thickness direction transverse to the first surface a second flexible member (77) having a lower side disposed in a thickness direction transverse to the first surface of the first flexible member (70) and forming a wedge-like member (80), a front ledge (81), a cut-out portion (82) next to the wedge-like member (80), and a back ledge (83), and an upper side opposite the lower side and forming a ramp-like member (88) and an end portion (90) of the ramp-like member (88), wherein the wedge-like member (80) and the cut-out portion (82) are disposed between the front ledge (81) and the back ledge (83); at least a first ledge (75) being formed on the first surface of the first flexible member (70), wherein the first flexible member (70) is disposed between the first ledge (75) and the second flexible member (77); and an end portion (85) being in contact with the first flexible member (70), the second flexible member (77), and the first ledge (75), wherein the first flexible member (70) extends a first distance from the end portion (85), the second flexible member (77) extends a second distance from the end portion (85), and the ramp-like member (88) is located a third distance from the end portion (85), the second distance being less than the first distance, the third distance being less than the second distance, the first flexible member (70) is configured to flex in a first direction upward away from the second flexible member (77) and in a second direction opposite to the first direction, the second flexible member (77) is configured to flex in a third direction towards the upper side and in a fourth direction opposite to the third direction, the third direction is different from the first and second directions, the opening (92) is a rectangular-shaped slot passing through the inner portion of the first flexible member (70) at a first position located less than the second distance from the end portion (85) and passing through the inner portion of the first flexible member (70) at a second position located more than the second distance from the end portion (85) and less than the first distance from the end portion (85), in a thickness direction transverse to the first surface, the upper side (73) of the first flexible member (70) lies above the upper side of the second flexible member (77), and in the thickness direction transverse to the first surface, the lower side (74) of the first flexible member (70) lies below the lower side of the second flexible member (77), and a male housing (5, 205) forming an opening (110, 210) to receive the female housing (3, 203), an elongated slot (118, 218) and an end portion (105), wherein the connector position assurance device (8) moves from a pre-lock position, wherein the side end portion (72) traverses the ramp-like member (46, 246) beyond the end portion (50,250) and the end portion (50,250) penetrates the opening (92), the cutout portion (82) engages the engaging member (61), and the wedge-like member (80) penetrates the first window (55, 255), to a full-lock position when the female housing (3, 203) and the male housing (5, 205) are coupled, the elongated slot (108, 208) receives the protruding members (43, 243), the side end portion (72) of the first flexible side member (70) moves deeper into the female housing (3) while the end portion 50 is penetrating the opening (92), and wherein the wedge-like member (80) traverses the interior bridge member (60, 260) and moves into the second window (57, 257), and the side ledges (75) of the connector position assurance device (8) are positioned under the flexible member (35, 235).

2. : The connector system according to claim 1, wherein the back ledge (83), in combination with the wedge-like member (80), forms a substantially U-shaped portion on the lower side of the second flexible member (77).

3. : The connector system according to claim 1, further comprising a second ledge (75) being formed on the first surface of the first flexible member (70), wherein the second ledge (75) is spaced apart from the first ledge (75).

4. : The connector system according to claim 1, wherein the wedge-like member (80) extends in a widthwise direction of the second flexible member (77) less than the width of the second flexible member (77).

5. : The connector system according to claim 4, wherein the cut-out portion (82) extends in the widthwise direction of the second flexible member (77) less than the width of the second flexible member (77).

6. : The connector system according to claim 5, wherein the wedge-like member (80) in combination with the cut-out portion (82) extend in the widthwise direction of the second flexible member (77) the width of the second flexible member (77).