Connector assembly having a secondary locking system (SLS) providing engagement and warning system, and method of operation thereof

Abstract

The secondary locking system connector assembly engagement and warning system and method of operation include a connector assembly having a male connector and a female connector, the female connector having a secondary locking system (SLS) therein. The engagement or assembly process of the male and female connectors includes four stages, depending on the position of the male connector within the female connector. In the first stage, the male connector begins to move toward the female connector so that the flag member of the SLS remains concealed within the female connector. In the second stage, the male connector enters the female connector and begins to engage with the SLS, while the flag member of the SLS remains concealed within the female connector. In the third stage, the actuating member of the male connector engages with the SLS, and the male and female connectors begin to assume a partially mated, semi-mated, or provisionally locked position, while the flag member of the SLS is raised to a visual and tactile warning position outside the female assembly for viewing or observation by an operator. A spring element or spring component may be provided on the SLS to automatically or resiliently move the flag member into and out of the female connector to provide the engagement and warning system. In a fourth stage, the male and female connectors assume a fully mated or fully locked position and the flag member of the SLS returns to its concealed position on the female connector.

Description

[Technical Field]

[0001] [CROSS-REFERENCE TO RELATED APPLICATIONS] This patent application claims priority to U.S. Provisional Patent Application No. 63 / 443,237, filed February 3, 2023, the entire contents of which are incorporated herein by reference. [Background technology]

[0002] Connector assemblies (e.g., those used in vehicle high-voltage connector assemblies having male and female connectors) often require a combination of a primary and secondary locking system (SLS). This requirement for the connector assembly is independent of the use of a terminal position assurance (TPA) device and / or a connector position assurance (CPA) device. That is, the use of a TPA device, or a CAP device, or a TPA device and a CPA device with a secondary locking system is optional. In such connector assemblies, it is necessary for an operator of the connector assembly to be assured that the secondary locking system is fully mated or in the fully locked position, ensuring that the male and female connectors are fully mated and remain in the fully locked position during assembly, shipping, use, etc. Conventional connector assemblies do not provide an operator with such assurance that the male and female connectors of the conventional connector assembly are fully mated or in the fully mated position. That is, an operator of a conventional connector assembly is not provided with a visible indicator that, for example, the male and female connectors are fully mated or in a fully locked position upon operation of the secondary locking system, thereby leaving only the primary locking system engaged or locked. Such an occurrence can cause the mating portions (e.g., the male and female connectors) to disengage or separate, resulting in separation during assembly, shipping, use, etc. of the connector assembly.

[0003] Therefore, there is a need for a visible engagement and warning system for the operator, and a method of operation thereof, as in the present invention, to provide the necessary assurance to the operator that the male and female connectors are fully mated or in the fully locked position using a secondary locking system. The secondary locking system for a connector assembly, and method of operation thereof, which provides an engagement and warning system in the present invention, does not require an extra step from the operator to operate the connector assembly and eliminates the possibility that the operator may forget to fully engage the secondary locking system of the connector assembly of the present invention to ensure that the male and female connectors of the connector assembly are fully mated or in the fully locked position. Summary of the Invention [Means for solving the problem]

[0004] [Summary of the Invention] A connector assembly having a secondary locking system (SLS) providing an engagement and warning system, and a method of operating the same, includes a connector assembly having a male connector and a female connector, the female connector having the secondary locking system (SLS) of the present invention located therein. The secondary locking system of the present invention and its use or operation are independent of the use of a terminal position assurance (TPA) device and / or a connector position assurance (CPA) device. That is, the use of a TPA device, or a CAP device, or a TPA device and a CPA device having the secondary locking system of the present invention is optional. Furthermore, the secondary locking system of the present invention is generally used in conjunction with a conventional primary locking system, and / or a CPA, and / or a TPA.

[0005] When the secondary locking system of the present invention comprises or is used with a conventional primary locking system and / or a conventional CPA and / or TPA, the steps of mating the male and female connectors of the connector assembly are described herein as a first stage, a second stage, a third stage, and a fourth stage. A first-stage connector assembly has the male connector beginning to move toward the female connector so that the flag member of the secondary locking system of the present invention remains concealed within the female connector. A second-stage connector assembly has the male connector within the female connector beginning to engage with the secondary locking system of the present invention, while the flag member of the secondary locking system within the female connector continues to remain concealed. A third-stage connector assembly has the male connector within the female connector, where the actuating member of the male connector begins to engage the bottom of the secondary locking system of the present invention, and the male and female assemblies begin to assume a partially mated, semi-mated, or provisionally locked position, while the flag member of the secondary locking system is raised outside the female assembly to a visual and tactile warning position that can be seen or observed by an operator. The fourth stage connector assembly has the male connector within the female connector with the male and female assemblies in a fully mated or fully locked position while the flag member of the secondary locking system is returned to its concealed position within the female connector.

[0006] The secondary locking system of the present invention, housed within the female connector, provides a visual and tactile warning to an operator who sees or observes that the flag member of the secondary locking system has been lifted outside the female assembly in the third stage that the male connector is in a partially mated, semi-mated, or provisionally locked position with the female connector (i.e., an indication to the operator that the male and female connectors are not yet fully mated or in the fully locked position). When the flag member of the secondary locking system then returns to its concealed position within the female connector, another visual and tactile warning is provided to the user that the male connector is fully mated with the female connector or is in the fully locked position, thereby providing the operator with assurance that the male and female connectors of the connector assembly will remain fully engaged or connected during assembly, shipping, use, etc. [Brief explanation of the drawings]

[0007] [Figure 1] FIG. 1 is a side view of a first stage connector assembly in which the male connector begins to move toward the female connector so that the flag member of the secondary locking system (SLS) of the present invention remains concealed within the female connector. [Figure 2A] FIG. 2A is a top perspective view of the connector assembly in a first stage showing the male connector beginning to move toward the female connector so that the flag member of the secondary locking system of the present invention remains concealed within the female connector. [Figure 2B] FIG. 2B is an enlarged view of the flag member of the secondary locking system of the present invention, showing the flag member remaining concealed within the female connector. [Figure 3] FIG. 3 is a side view of the connector assembly in a second stage, showing the male connector within the female connector beginning to engage with the secondary locking system of the present invention while the flag member of the secondary locking system within the female connector remains concealed. [Figure 4A]FIG. 4A is a top perspective view of the connector assembly in the second stage, showing the male connector within the female connector beginning to engage with the secondary locking system of the present invention. [Figure 4B] FIG. 4B is an enlarged view of the flag member of the secondary locking system of the present invention, showing the flag member remaining concealed within the female connector. [Figure 5] FIG. 5 is a side view of the connector assembly in a third stage, showing the male connector within the female connector and the male connector engaged with the secondary locking system of the present invention, with the male and female connectors in a partially mated, semi-mated, or provisionally locked position, while the flag member of the secondary locking system is raised on the outside of the female assembly to a visual and tactile warning position that can be seen or observed by an operator. [Figure 6A] FIG. 6A is a top perspective view of the connector assembly in a third stage, showing the male connector within the female connector and the male connector engaged with the secondary locking system of the present invention, with the male and female connectors in a partially mated, semi-mated, or provisionally locked position. [Figure 6B] FIG. 6B is an enlarged view of the flag member of the secondary locking system, showing the flag member raised to a visual and tactile warning position on the outside of the female assembly that can be seen or observed by an operator. [Figure 7] FIG. 7 is a side view of the connector assembly in a fourth stage showing the male connector within the female connector with the male and female connectors in a fully mated or fully locked position while the flag member of the secondary locking system has returned to its concealed position within the female connector. [Figure 8A] FIG. 8A is a top perspective view of the connector assembly in a fourth stage showing the male connector within the female connector with the male and female connectors in a fully mated or fully locked position. [Figure 8B] FIG. 8B is a close-up view of the flag member of the secondary locking system, showing the flag member returned to its hidden position within the female connector. [Figure 9]FIG. 9 is a perspective view of a secondary locking system having a flag member showing the right outer side of the secondary locking system having a rib or ridge, with an arrow pointing in the direction the male connector of the connector assembly fits into the female connector. [Figure 10] FIG. 10 is a perspective view of a secondary locking system having a flag member showing the left inner side of the secondary locking system having a partially angled bottom with an arrow pointing in the direction that the male connector of the connector assembly enters the female connector. [Figure 11] FIG. 11 is a side view of the connector assembly in a second stage, showing the male connector within the female connector beginning to engage with the secondary locking system of the present invention while the flag member of the secondary locking system remains concealed within the female connector. [Figure 12] FIG. 12 is a cross-sectional view of the second stage connector assembly illustrated in FIG. 11 taken along section line 12-12, showing the male connector within the female connector and further illustrating that the male connector has begun to engage the secondary locking system of the present invention while the flag member of the secondary locking system remains concealed within the female connector. [Figure 13] FIG. 13 is a perspective view of the connector assembly in a third stage, showing the male connector within the female connector, and further showing the male connector engaged with the secondary locking system of the present invention such that the male and female connectors are in a partially mated, semi-mated, or provisionally locked position while the flag member of the secondary locking system is raised to a visual and tactile warning position outside the female assembly that can be seen or observed by an operator. [Figure 14]FIG. 14 is a cross-sectional view of the connector assembly in the third stage taken along section line 14-14 as illustrated in FIG. 13, showing the male connector within the female connector with the actuating member of the male connector engaged with the bottom of the secondary locking system of the present invention, with the male and female connectors in a partially mated, semi-mated, or provisionally locked position, while further showing the flag member of the secondary locking system of the present invention raised outside the female assembly to a visual and tactile warning position that can be seen or observed by an operator. [Figure 15] FIG. 15 is a perspective view of the connector assembly in a fourth stage, showing the male connector within the female connector with the flag member of the secondary locking system of the present invention returned to its concealed position within the female connector while the male and female connectors are in a fully mated or fully locked position. [Figure 16] FIG. 16 is a cross-sectional view of the connector assembly in the fourth stage taken along section line 16-16 illustrated in FIG. 15, showing the male connector within the female connector with the male and female connectors in a fully mated or fully locked position while the flag member of the secondary locking system has returned to its concealed position within the female connector. DETAILED DESCRIPTION OF THE INVENTION

[0008] A connector assembly, generally designated 1, containing the inventive secondary locking system 8 therein is intended for use with a conventional primary locking system and / or a conventional CPA (and / or TPA). In accordance with standard practice in the art, the inventive secondary locking system 8 assumes use with a primary locking system (in this case, a conventional primary locking system), regardless of the use of a conventional CPA and / or TPA. Furthermore, the inventive secondary locking system 8 and its use or operation are independent of its use with a conventional primary locking system, and are further independent of its use with a conventional CPA and / or TPA. Accordingly, only the inventive secondary locking system 8 will be described in detail herein.

[0009] The mating steps or assembly process of the male connector 3 and female connector 5 of the connector assembly using the secondary locking system (SLS) 8 of the present invention will be described herein as a first stage, a second stage, a third stage, and a fourth stage. FIG. 1 shows the connector assembly 1 in a first stage, with the male connector 3 beginning to move toward the female connector 5 so that the secondary locking system 8 of the present invention remains concealed within the female connector 5. A top perspective view of the connector assembly 1 in a first stage in FIG. 2A similarly shows the male connector 3 beginning to move toward the female connector 5 so that the secondary locking system 8 of the present invention, having a flag member 10, remains concealed within the female connector 5. A close-up view of the flag member 10 of the secondary locking system 8 of the present invention in FIG. 2B shows that the flag member 10 remains concealed within the female connector in the first stage.

[0010] The second stage of the engagement step of the connector assembly 1, illustrated in FIG. 3 , shows the male connector 3 within the female connector 5, and shows the male connector 3 beginning to engage with the secondary locking system 8 of the present invention. The term "engagement," as used herein, does not mean that the male connector 3 mates or locks with the female connector 5. Depending on how far the male connector 3 is slid or pressed toward the female connector 5, the male connector 3 is not yet mated or locked with the female connector 5 in the second stage. Also, the lift or upward movement of the flag member 10 of the secondary locking system 8 (as seen in FIGS. 3 , 4A, and 4B ) toward the outside of the female connector 3 depends on how far the male connector 3 is slid or pressed toward the female connector 5. That is, the further the male connector 3 is slid or pressed toward the female connector 5, the higher the flag member 10 of the female connector 5 extends beyond the top surface 15 of the female connector 5.

[0011] 3 also illustrates a window 20 through a side 22 of the female connector 5. Through this window 20, the operation (i.e., upward or downward movement) of the secondary locking system 8 can be viewed or observed. The further use of this window 20 through the female connector 5 when an operator wishes to remove the male connector 3 and female connector 5 from their fully engaged or fully locked positions will be further described below.

[0012] FIG. 4A further illustrates the connector assembly 1 in a second stage, showing the male connector 3 within the female connector 5 beginning to engage, but not yet mated or locked, with the secondary locking system 8 of the present invention, and FIG. 4B shows an enlarged view of the flag member 10 of the secondary locking system 8, showing the flag member 10 remaining largely concealed within the female connector 5. As noted above, depending on how far the male connector 3 is slid or pressed toward the female connector 5, the male connector 3 is not yet mated or locked with the female connector 5 in the second stage. Additionally, the lift or upward movement of the flag member 10 of the secondary locking system 8 outwardly of the female connector 3 depends on how far the male connector 3 is slid or pressed toward the female connector 5, as can be seen in FIGS. 4A and 4B . That is, the further the male connector 3 is slid or pressed toward the female connector 5, the higher the flag member 10 of the female connector 5 extends beyond the top surface 15 of the female connector 5.

[0013] In the third stage of the connector assembly 1, illustrated in FIG. 5 , the male connector 3 is partially slid or pressed into the female connector 5 to engage the secondary locking system 8 of the present invention. As noted above, the term "engagement" as used herein does not mean that the male connector 3 mates or locks with the female connector 5. Depending on how far the male connector 3 is slid or pressed into the female connector 5, the male connector is partially engaged with the female connector 5 or in a pre-locked position in the third stage. That is, in the third stage, the male connector 3 and the female connector 5 are in a partially mated, semi-mated, or pre-locked position. In the third stage of the connector assembly 1, the flag member 10 is raised above the top surface 15 of the female connector 5, allowing the operator to easily view or observe from outside the female connector 5 that the flag member 10 of the secondary locking system 8 of the present invention is in a visual and tactile warning position. In other words, the raised flag member 10 provides an important visual and tactile warning to the operator that the male connector 3 has begun to engage with the female connector 5, and that the male assembly 3 and female assembly 5 are in a partially mated, semi-mated, or provisionally locked position, while the male connector 3, partially within the female connector 5, is engaged with the secondary locking system 8 of the present invention, as shown in Figures 5, 6A, and 6A.

[0014] As shown in Figure 7, in the fourth stage, the mating step of the connector assembly 1, the male connector 3 enters the female connector 5, and the male connector 3 and female connector 5 are in a fully mated or fully locked position, while the flag member 10 of the secondary locking system 8 of the present invention has returned to its hidden position within the female connector 5. As also illustrated in the top perspective view of the connector assembly in Figure 8A, the connector assembly 1 has the male connector 3 and female connector 5 in a fully mated or fully locked position, and Figures 7, 8A, and 8B show the flag member 10 of the secondary locking system 8 of the present invention returned to its hidden position within the female connector 5.

[0015] The secondary locking system 8 is illustrated in further detail in FIG. 9 . The secondary locking system 8 includes a flag member 10 extending from a top surface 30 of the secondary locking system 8. Also shown in FIG. 9 is a right outer side 32 of the secondary locking system 8, on which a rib or ridge 35 is formed. Arrow A is shown to illustrate the direction in which the male connector 3 of the connector assembly 1 enters the female connector 5 when the secondary locking system 8 is installed therein. FIG. 9 also shows a tang or lever-like member 38 that provides a resilient feel to the secondary locking system 8 as it is manipulated or moved up and down through the top surface 15 of the female connector 5 within a cavity 75 in the top 80 of the female connector 5 (see FIGS. 12 , 14 , and 16 ). Also partially shown in FIG. 9 is a partial angled bottom 40 of the secondary locking system 8, although the angled bottom 40 of the secondary locking system 8 is more clearly shown in FIG. 10 and will be described in more detail later.

[0016] FIG. 10 illustrates a secondary locking system 8 having a flag member 10 and further illustrates a left interior side 52 of the secondary locking system 8. FIG. 10 also illustrates the partial angled bottom 40 of the secondary locking system 8. The specific function of the partial angled bottom 40 of the secondary locking system will be more fully described below in connection with the cross-sectional views shown in FIGS. 12, 14, and 16. The partial angled bottom 40 extends downwardly toward a partial flat bottom 60 of the secondary locking system 8. Also shown in FIG. 10 is another bottom 65 that extends away from the partial angled bottom 40 and the partial flat bottom 60 of the secondary locking system 8.

[0017] 10 is arrow A, which illustrates the direction in which the male connector 3 of the connector assembly 1 enters the female connector 5 when the secondary locking system 8 is installed within the female connector 5 of the connector assembly 1. As further shown in FIG. 10, the part-angled bottom 40 and part-flat bottom 60 abut or join the left inner side 52 of the secondary locking system 8, while another bottom 65 abuts or joins the right outer side 32 of the secondary locking system 8, from which the rib or ridge 35 is formed or extends, as described above in connection with FIG. 9.

[0018] FIG. 11 is a perspective view of connector assembly 1 in a second stage, showing male connector 3 partially inside female connector 5 and male connector 3 beginning to engage secondary locking system 8 of the present invention, which includes flag member 10 within female connector 5 that remains concealed within female connector 5. The engagement step of connector assembly 1 in the second stage illustrated in FIG. 11 shows male connector 3 partially within female connector 5 and male connector 3 beginning to engage secondary locking system 8. The term "engagement" as used herein does not mean that male connector 3 mates or locks with female connector 5. As will be explained in more detail in connection with FIG. 12, depending on how much male connector 3 is slid or pressed toward female connector 5, male connector 3 is not yet mated or locked with female connector 5 in the second stage. 12 , the lift or upward movement of flag member 10 of secondary locking system 8 toward the outside of female connector 3 depends on how far male connector 3 is slid or pressed toward female connector 5. In other words, the further male connector 3 is slid or pressed toward female connector 5, the higher flag member 10 of female connector 5 extends beyond top surface 15 of female connector 5. The upward or downward movement of secondary locking system 8 can be seen or observed through a window 30 passing through the right exterior side 32 of secondary locking system 8.

[0019] FIG. 12 is a cross-sectional view of the second stage connector assembly illustrated in FIG. 11 taken along section line 12-12, showing the male connector 3 entering the female connector 5 and beginning to engage the secondary locking system 8 of the present invention, while the flag member 10 of the secondary locking system 8 remains concealed within the cavity 75 in the top 80 of the female connector 5 in the second stage.

[0020] FIG. 12 further illustrates the connector assembly 1 in a second stage, showing the male connector 3 within the female connector 5 beginning to engage, but not yet mated or locked with, the secondary locking system 8 of the female connector 5, while the flag member 10 remains concealed within the female connector 5. Depending on how far the male connector 3 is slid or pressed toward the female connector 5, in the second stage the male connector 3 only engages, but is not yet mated or locked with, the secondary locking system 8. Also, the flag member 10 of the secondary locking system 8 moves up or upward through the top surface 15 of the female connector 3 and outwardly of the female connector 3, as can be seen in FIG. 12 , depending on how far the male connector 3 is slid or pressed toward the female connector 5. That is, the further the male connector 3 is slid or pressed toward the female connector 5, the higher the flag member 10 of the female connector 5 extends beyond the top surface 15 of the female connector 5.

[0021] 12 , the male connector 3 includes an actuating member 70 that engages with the angled bottom portion 40 of the secondary locking system 8. That is, as the female connector 3 is slid or pressed further into the female connector 5, the actuating member 70 of the male connector 3 slides further along the angled bottom portion 40 of the secondary locking system 8. As the actuating member 70 of the male connector 3 slides along the angled bottom portion 40 of the secondary locking system 8, the secondary locking system 8 is lifted or raised toward the top surface 15 of the female connector 5. And, as the secondary locking system 8 is lifted or raised, the flag member 10 of the secondary locking system 8 is likewise lifted or raised further past the top surface 15 of the female connector 5.

[0022] It should be noted here that, as shown in Figure 12 (and Figures 14 and 16), actuating member 70 of male connector 3 is shown with dashed lines to indicate that its shape is not limited to a rectangle. In other words, actuating member 70 may take any shape or form so long as actuating member 70 is capable of actuating secondary locking system 8 of the present invention in the manner described herein in the connector assembly engagement steps or processes further labeled from Stage 1 to Stage 4 herein.

[0023] Also shown in Figure 12 is a cavity 75 in the top 80 of the female connector 5 for receiving the secondary locking system 8 and corresponding flag member therein. Also shown in Figure 12 are several seals 76, 78 within the female connector 5.

[0024] Also illustrated in FIG. 2 is at least one spring element or spring component 100 (i.e., one or more spring elements or spring components 100) within cavity 75 near or adjacent to flag member 10 of secondary locking system 8. Spring element or spring component 100 may be one or more coil springs near or adjacent to flag member 10 of secondary locking system 8, or a coil spring that substantially surrounds flag member 10 of secondary locking system 8 within cavity 75. Alternatively, spring element or spring component 100 may be a disc spring, leaf spring, gas spring, or the like, or any component that stores and releases energy. Spring element or spring component 100 may be used, for example, to “automate” the function of secondary locking system 8, so that an operator does not need to manually lock secondary locking system 8. Such a structural element eliminates the need for an operator to manipulate or assist in moving secondary locking system 8 up or down within female connector 5.

[0025] FIG. 13 shows the connector assembly 1 in a third stage with the male connector 3 partially within the female connector 5 and engaged with the secondary locking system 8 of the present invention, such that the male connector 3 and female connector 5 are in a partially mated, semi-mated, or provisionally locked position (i.e., not yet fully mated or in a fully locked position), while the flag member 10 of the secondary locking system 8 is raised above the top surface 15 of the secondary locking system 8 and outside the cavity 75 in the top 80 of the female connector 5 to a visual and tactile warning position that can be seen or observed by an operator.

[0026] Further, in the third stage of the mating step or assembly process of connector assembly 1, as illustrated in FIG. 13 , male connector 3, partially within female connector 5, engages secondary locking system 8 while flag member 10 of secondary locking system 8 is raised above top surface 15 of secondary locking system 8 and outside cavity 75 within top portion 80 of female connector 5 to a visual and tactile warning position visible or observable by an operator.

[0027] The third engagement step or assembly process is more clearly shown in the cross-sectional view of Figure 14, which is a cross-sectional view taken along line 14-14 of Figure 13. Here, as the male connector 3 is further slid into or pressed against the female connector 5, the top surface 88 of the actuating member 70 of the male connector 3 eventually passes the partial angled bottom 40 of the secondary locking system 8 while continuing to engage with the secondary locking system 8, ultimately and specifically engaging the partial flat bottom 60 of the secondary locking system 8. As the top surface 88 of the actuating member 70 of the male connector 3 transitions from the partial angled bottom 40 to the partial flat bottom 60 of the secondary locking system 8 in its engaged state with the female connector 5, the secondary locking system 8 simultaneously moves upward within the cavity 75 located at the top 80 of the female connector 5, which then pushes its flag member 10 upward and past the top surface of the female connector 5. The flag member 10 on the exterior of the female connector 5 provides a visual and tactile warning to the operator that the male connector 5 has become partially engaged or assumes a provisionally locked position relative to the connector 5 (i.e., is not yet fully mated or is not yet in the fully locked position). The visual and tactile warning provided by the flag member 10, which is located on the exterior of the top surface 15 of the female connector 5 for viewing or observation by the operator, further indicates to the operator that further pressure is required to push the male connector 3 toward the female connector 4 to fully mate the male connector 3 and female connector 5 in the fourth stage, fully locked position, as described in more detail below.

[0028] Generally, in the fourth stage, the mating step or assembly process of connector assembly 1, as shown in the perspective view of connector assembly 1 in FIG. 15 , male connector 3 moves into female connector 5, and male connector 3 and female connector 5 are in a fully mated or fully locked position, while secondary locking system 8 including flag member 10 returns to its concealed position within female connector 5. For reasons that will be explained more fully below, rib or ridge 35 on the right outer side 32 of secondary locking system 8 is clearly visible through window 20 through side 22 of female connector 5.

[0029] 15 , in the engagement step of the fourth assembly process of connector assembly 1, male connector 3 is further slid or pressed toward female connector 5. As a result, top surface 88 of actuating member 70 of male connector 3 further crosses partial flat bottom 60 of secondary locking system 8. When top surface 88 of actuating member 70 of male connector 3 completely crosses and passes partial flat bottom 60 of secondary locking system 8, secondary locking system 8 descends or drops onto top surface 90 of male connector 3, which is lower than top surface 88 of actuating member 70 of male connector 3. As discussed above, in connection with FIG. 9 , secondary locking system 8 of the present invention includes tongue or lever-like member 38 that provides resilience to secondary locking system 8 as it moves up and down within cavity 75 and through top surface 15 of female connector 5, thereby causing secondary locking system 8 to be spring-activated. As the spring-activated secondary locking system 8 descends or drops onto the top surface 90 of the male connector 3, the flag member 10 of the secondary locking system 8 similarly descends below the top surface 15 of the female connector 5, such that the flag member 10 is again hidden or concealed within the cavity 75 in the top 89 of the female connector 5, which indicates to the operator that the male connector 3 and female connector 5 of the connector assembly 1 are in a fully mated or fully locked position. More specifically, as further shown in FIG. 16 , the secondary locking system 8 of the present invention fully blocks or locks the actuating member 70 of the male member 3 such that the secondary locking system 8 of the present invention blocks, locks, or prevents the male connector 3 from being pulled out or unlocked from the female connector 5.

[0030] In the fourth stage engagement step or assembly process of connector assembly 1, after pre-observation or visual recognition of the warning signal indicated by flag member 10 of secondary locking system 8 protruding outward from top surface 15 of female connector 5 in the third stage, the visual and tactile warning provided to the operator by flag member 10 of secondary locking system 8 is absent or removed in the fourth stage. As a result, the operator is assured that male connector 3 and female connector 5 are in a fully mated or fully locked position, thereby providing the operator with the necessary assurance that male connector 3 and female connector 5 are maintained in a fully mated or fully locked position during assembly, transportation, use, etc. of connector assembly 1.

[0031] When the male connector 3 and the female connector 5 of the connector assembly 1 are in a fully mated or fully locked position, it may be necessary for an operator to intentionally unlock or disengage the male connector 3 and the female connector 5, as illustrated in Figures 15 and 16. In such a case, the operator simply uses, for example, at least one finger of one hand (or a tool in one hand) to press upward on at least one of the ribs or protuberances 35 (see, for example, Figure 15) on the right outer side 32 of the secondary locking system 8, which then presses and moves the secondary locking system 8 of the present invention upward, thereby allowing the engagement step or assembly process of the connector assembly 1 to return from the fourth stage to the third stage (see Figures 13 and 14), and the secondary locking system 8 of the present invention unblocks the actuating member 70 of the male connector 3, thereby allowing the male connector 3 to be slid or pulled out of the female connector 5 using, for example, the operator's other hand.

[0032] The present invention is not limited to the above-described embodiment, and various design and configuration changes can be made without departing from the spirit of the present invention.

Claims

1. A connector assembly having a primary locking system, or at least a connector position assurance device (CPA device) and a terminal position assurance device (TPA device), the connector assembly comprising: a male connector having an actuation member; a female connector for accommodating a secondary locking system therein, the secondary locking system being separate from the female connector; 1. A secondary locking system for a connector assembly that provides an engagement and warning system for an operator, wherein the secondary locking system includes a flag member that is movable in and out of the female connector, thereby providing an engagement and warning system for an operator.

2. The male connector begins to enter the female connector, 2. The secondary locking system for a connector assembly providing an engagement and warning system for an operator according to claim 1, wherein said flag member of said secondary locking system remains concealed within said female connector.

3. when the male connector is slid or pressed toward the female connector, the male connector begins to engage with the secondary locking system of the female connector; 3. The secondary locking system for a connector assembly providing an engagement and warning system for an operator as recited in claim 2, wherein said flag member of said secondary locking system remains concealed within said female connector.

4. When the male connector is further slid or pressed toward the female connector, the male connector engages with the secondary locking system of the female connector; 4. The secondary locking system for a connector assembly providing an engagement and warning system for an operator as recited in claim 3, wherein the flag member of the secondary locking system is pushed outwardly of the female connector to provide a visual and tactile warning system to notify the operator that the male connector and the female connector are in a partially mated or provisionally locked position.

5. when the male connector is further slid or pressed toward the female connector, the actuation member of the male connector blocks the secondary locking system, thereby preventing the male connector from being slid off, withdrawn, or disengaged from the female connector; 5. The secondary locking system for a connector assembly providing an engagement and warning system for an operator as recited in claim 4, wherein the flag member of the secondary locking system returns to a concealed position within the female connector to provide an additional visual and tactile warning system to the operator that the male connector and the female connector are in a fully mated or fully locked position.

6. A connector assembly having a primary locking system, or at least a connector position assurance device (CPA device) and a terminal position assurance device (TPA device), the connector assembly comprising: a male connector having an actuation member; a female connector for accommodating a secondary locking system therein, the secondary locking system being separate from the female connector; the secondary locking system includes a flag member, the flag member of the secondary locking system being movable in and out of the female connector to provide an engagement and warning system for an operator; 1. A secondary locking system for a connector assembly that provides an engagement and warning system for an operator, wherein the secondary locking system further includes a partial angled bottom and a partial flat bottom.

7. The male connector begins to enter the female connector, 7. The secondary locking system for a connector assembly providing an engagement and warning system for an operator as recited in claim 6, wherein said flag member of said secondary locking system remains concealed within said female connector.

8. when the male connector is slid or pressed toward the female connector, the actuating member of the male connector begins to engage with the secondary locking system of the female connector; 8. The secondary locking system for a connector assembly providing an engagement and warning system for an operator as recited in claim 7, wherein said flag member of said secondary locking system remains concealed within said female connector.

9. when the male connector is further slid or pushed toward the female connector, the actuating member of the male connector engages with the partially angled bottom and the partially flat bottom of the secondary locking system of the female connector; 9. The secondary locking system for a connector assembly providing an engagement and warning system for an operator as recited in claim 8, wherein when the actuating member of the male connector is engaged with the partial flat portion of the secondary locking system, the flag member of the secondary locking system is pushed outwardly of the female connector to provide a visual and tactile warning system to notify the operator that the male connector and the female connector are in a partially mated or provisionally locked position.

10. when the male connector is further slid or pressed toward the female connector, the actuating member of the male connector completely crosses the partially flat bottom of the secondary locking system, thereby blocking the male connector from being slid off, pulled out, or disengaged from the female connector; 10. The secondary locking system for a connector assembly providing an engagement and warning system for an operator of claim 9, wherein the flag member of the secondary locking system returns to a concealed position within the female connector to provide an additional visual and tactile warning system to the operator that the male connector and the female connector are in a fully mated or fully locked position.

11. 2. The secondary locking system for a connector assembly providing an engagement and warning system for an operator according to claim 1, wherein the secondary locking system further includes a tongue or lever member that provides resilient movement to the secondary locking system when the secondary locking system moves within the female connector.

12. a connector assembly having a primary locking system and at least a connector position assurance device (CPA device) and a terminal position assurance device (TPA device); Initiating insertion of a male connector including an actuation member into the female connector in a mating step or a first stage of an assembly process between the male and female connectors; and maintaining a flag member of the secondary locking system of the female connector, the flag member being movable in and out of the female connector and separate from the female connector, in a concealed state within the female connector.

13. a step of sliding or pushing the male connector toward the female connector during a mating step or second stage of the assembly process, wherein the male connector begins to engage the secondary locking system of the female connector; 13. The method of operating a connector assembly having a secondary locking system that provides an engagement and warning system for an operator as recited in claim 12, further comprising the step of: maintaining said flag member of said secondary locking system concealed within said female connector.

14. In a third stage of the mating step or assembly process of the male connector and the female connector, a step of further sliding or pressing the male connector toward the female connector, the male connector engaging the secondary locking system of the female connector; 14. The method of operating a connector assembly having a secondary locking system that provides an engagement and warning system for an operator of claim 13, further comprising the step of: pushing the flag member of the secondary locking system outward from the female connector to provide a visual and tactile warning system to notify the operator that the male connector and the female connector are in a partially mated or provisionally locked position.

15. a step of further sliding or pressing the male connector into the female connector in a fourth stage of the mating step or assembly process of the male connector and the female connector, characterized in that the actuating member of the male connector blocks the secondary locking system, thereby preventing the male connector from being slid off, pulled out, or disengaged from the female connector; 15. The method of operating a connector assembly having a secondary system that provides an engagement and warning system for an operator of claim 14, further comprising the step of returning the flag member of the secondary locking system to a concealed position within the female connector to provide an additional visual and tactile warning system to the operator that the male and female connectors are in a fully mated or fully locked position.

16. 2. The secondary locking system for a connector assembly providing an engagement and warning system for an operator of claim 1, further characterized by a spring element or spring component for automatically or resiliently moving the flag member of the secondary locking system into and out of the female connector to provide the engagement and warning system for the operator.

17. 5. The secondary locking system for a connector assembly providing an engagement and warning system for an operator of claim 4, further characterized by a spring element or spring component for automatically or resiliently moving said flag member of said secondary locking system into and out of said female connector to provide said engagement and warning system for said operator.

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