Blind Mate Connector System and Method of Assembling the Same

Abstract

A connector system that uses a resilient suspension to provide mating alignment responsiveness and to provide axial compression of the two connector halves. The connector system uses a first connector half mounted to a body and a second connecting half having a fixedly attached outer housing with a resilient suspension element that suspends the inner connector housing. The outer housing can be attached to another body in such a way that the mating process of the two connector halves is not visible. The axial compression of the two connector halves keeps them securely mated.

Description

Technical Field

[0001] [Cross - Reference to Related Applications] This patent application claims the benefit of U.S. Provisional Patent Application No. 63 / 042,317, filed on Jun. 22, 2020, the entire content of which is incorporated herein by reference as part of this specification.

[0002] [Background of the Invention] The present invention relates generally to a connector system that uses an elastic suspension to provide responsiveness to mating alignment and to provide axial compressive force between two connector half - members.

Summary of the Invention

Means for Solving the Problems

[0003] The present invention generally relates to a connector system composed of a first connector half - member including a female connector and a second connector half - member including a male connector. The male connector includes a male outer housing, a suspension, and a male inner housing.

[0004] When the connector system is in its assembled state, the suspension is within the male outer housing. The male inner housing is suspended by the suspension. The male outer housing may be attached to a first body, and the female connector may be fastened to a second body.

[0005] The outer housing can also be attached to the first body in such a way that the mating process of the two connector half - members is not visible, and thus it is named a blind - mate connector. The axial compressive force of the two connector half - members keeps them firmly mated and eliminates relative movement between them.

[0006] Further features, effects, and embodiments of the present invention will become apparent by considering the following detailed description, drawings, and claims. Further, it should be understood that both the above summary of the invention and the following detailed description are merely exemplary and are not intended to limit the scope of the invention described in the claims without limitation.

Brief Description of the Drawings

[0007]

Figure 1A

Figure 1B

Figure 1C

Figure 1D

Figure 1E

Figure 1F

Figure 1G

Figure 1H

Figure 1I

Figure 1J

Figure 2A

Figure 2B

Figure 2C

Figure 2D

Figure 2E

Figure 2F

Figure 2G

Figure 2H

Figure 2I

Figure 3A

Figure 3B

Figure 3C

Figure 3D

Figure 3E

Figure 3F

Figure 3G

Figure 3H

Figure 3I

Figure 4A

Figure 4B

Figure 4C

Figure 4D

Figure 5A

Figure 5B

Figure 5C

Figure 5D

Figure 6

Figure 7

Figure 8A

Figure 8B

Figure 9

Figure 10

Figure 11

Figure 12

Embodiments for Carrying Out the Invention

[0008] Figure 1A is a perspective view of an assembled connector system according to the principles of the present invention, showing a female connector and a male connector. Figure 1A shows a female connector 100 and a male connector 200 including a male inner housing 200, a suspension 300, and a male outer housing 400. The suspension 300 shown in Figure 1A is a first embodiment. The suspension 300A shown in Figures 11 and 12 is a second embodiment.

[0009] Figure 1B shows a perspective view of the assembled connector system of Figure 1A. Figure 1C is a cross-sectional view taken along line 1C-1C of Figure 1B. Figure 1C shows the female connector 100, the male inner housing 200, the suspension 300, and the male outer housing 400, and also shows a female terminal position assurance (TPA) member 110 inserted into the female connector 100, a conducting wire 120 within the female connector 100, a female terminal box 125, a male terminal position assurance (TPA) member 210 inserted into the male inner housing 200, a conducting wire 220 within the male inner housing 200, and a male terminal box 225.

[0010] Figure 1D is a top elevation view of the assembled connector system of Figure 1A. Figure 1E is a bottom elevation view of the assembled connector system of Figure 1A. Figure 1F is a front view of the assembled connector system of Figure 1A. Figure 1G is a rear view of the assembled connector system of Figure 1A. Figure 1H is a right side elevation view of the assembled connector system of Figure 1A. Figure 1I is a left side elevation view of a portion of the assembled connector system of Figure 1A.

[0011] Figure 1J is a left elevation view of the suspension 300, the male inner housing 200, and the components of the male inner housing 200 in accordance with the principles of the present invention. Figure 1J shows the male inner housing 200 combined with the suspension 300 prior to being combined with the male outer housing 400 and the female connector 100. The cutout region 215A of the male inner housing 200 is shown in a region extending beyond the suspension 300. When the male outer housing 400 is combined with the male inner housing 200 and the suspension 300, the cutout region 215A accommodates the overhang portion 440 of the male outer housing 400. The cutout region 215A is near the lower part of the male inner housing 200. The overhang portion 440 is shown, for example, in Figure 5B.

[0012] Figure 2A is a perspective view of the female connector in accordance with the principles of the present invention, showing the front end and the lower end of the female connector. Figures 2A and show that the female connector 100 has openings 140, 142, 144 at each corner of its lower end. The openings 140, 142, 144 can be referred to as fork receiving openings. The lower end of the female connector 100 can be referred to as the first end of the female connector 100, or alternatively, as the lower part of the female connector 100. The lower part of the female connector 100 can also be regarded as a mating end, but it has a lower inclined edge 182 on its outer periphery. The lower inclined edge 182 is inclined so as to narrow from each side surface of the female connector 100, narrows towards the lower surface 102 of the female connector 100, and also terminates. The lower inclined edge 182 assists in the insertion and mating of the female connector 100 with the male inner housing 200, and the lower inclined edge 182 may also interact with the inclined introduction portion 202 of the male inner housing 200 (see Figure 11). More specifically, as shown in Figure 2E, each of the openings 140, 142, 144, 146 is also formed at the corner portion of the lower inclined edge 182.

[0013] Figure 2E also shows the fork receptacle openings 146. The fork receptacle openings 140, 142, 144, 126 are for receiving the fork-shaped protrusions 240, 242, 244, 246 of the male inner housing 200 (as shown, for example, in Figure 3E) when the female connector 100 is fully combined and fitted into the male inner housing 200.

[0014] As shown in Figure 2A, the lower surface 102 of the female connector 100 also includes the openings 150, 152, 154, 156.

[0015] Figure 2A shows that the front portion of the female connector 100 has a fork-shaped protrusion 130. The fork-shaped protrusion 130 is to be received in the fork receptacle opening 230 of the male inner housing 200 (as shown, for example, in Figure 3E) when the female connector 100 is combined with the male inner housing 200.

[0016] Figure 2A shows that the left side surface of the female connector 100 has a fork-shaped protrusion 132. The fork-shaped protrusion 132 is to be received in the fork receptacle opening 232 of the male inner housing 200 (as shown, for example, in Figure 3E) when the female connector 100 is combined with the male inner housing 200.

[0017] Figure 2B is a perspective view of the female connector of Figure 2A, showing the rear end and the lower end of the female connector. The rear part of the female connector 100 has an opening 160 for receiving the female TPA member, and this opening 160 extends into the female connector 100 and is located at the center of one of its sides. The female connector 100 is inclined so as to narrow from three of its four sides, and also has an inclined edge 161 that narrows towards the lower surface 102 of the female connector 100. The inclined edge 161 is located further towards the lower surface 102 side than the opening 160. Further, as shown in Figure 8B, when the female connector 100 is combined with the male inner housing 200, the inclined edge 161 is substantially at the same height as a part of the inclined introduction part 202 of the male inner housing and has an inclination angle that allows it to be received.

[0018] Figure 2B shows that the rear part of the female connector 100 has a fork-shaped protrusion 134. The fork-shaped protrusion 134 will be received in the fork receiving opening 234 of the male inner housing 200 (shown in Figure 3E for example) when the female connector 100 is combined with the male inner housing 200. The fork-shaped protrusion 134 is formed by extending from a part of the inclined edge 161 of each side of the female connector 100 having the opening 160, and extends in the direction towards the lower surface 102 of the female connector 100 as shown in Figure 2B.

[0019] Figure 2B shows that the right side surface of the female connector 100 has fork-shaped protrusions 132, 136. The fork-shaped protrusions 132, 136 are formed by extending from two opposing parts of the inclined edges 161 of two opposing sides of the female connector 100, and the part of the inclined edge 161 having the fork-shaped protrusion 134 is between them. The protrusions 132, 136 extend in the direction towards the lower surface 102 of the female connector 100. The fork-shaped protrusion 136 will be received in the fork receiving opening 236 of the male inner housing 200 (shown in Figure 3E for example) when the female connector 100 is combined with the male inner housing 200.

[0020] Figure 2B shows the fork receiving openings 144 and 146 at the lower corners of the female connector 100. Alignment protrusions 164 and 166 are shown at the rear of the female connector 100, extending from the inclined edge 161 to the lower surface 102 of the female connector 100.

[0021] Figure 2C is a front elevation view of the female connector of Figure 2A. Figure 2D is a rear elevation view of the female connector of Figure 2A. Figure 2E is a bottom elevation view of the female connector of Figure 2A. Figure 2F is a top elevation view of the female connector of Figure 2A. Figure 2F shows the wire routing groove 162.

[0022] Figure 2G is an exploded perspective view of the female connector of Figure 2A and its components according to the principles of the present invention. Figure 2G shows the opening 105 near the upper part of the female connector 100 and also shows the female TPA 110. The wire 120 for the female connector 100, the electrical crimp terminal 122 for the female connector 100, and the terminal box 125 for the female connector 100 are additionally shown in Figure 2G.

[0023] Figures 2F and 2G show the configuration near the upper part of the female connector 100 and include fastening clips. One or more of these configurations can be used to fasten the female connector 100 to a body (not shown).

[0024] Figure 2H is a perspective view of the female connector of Figure 2A and its components according to the principles of the present invention. Figure 2I is a bottom elevation view of the female connector of Figure 2A and its components according to the principles of the present invention.

[0025] Figure 3A is a perspective view of the male inner housing according to the principles of the present invention. Figure 3A shows the opening 205 at the upper part of the male inner housing 200 for receiving the lower part of the female connector 100, and also shows the fork-shaped protrusions 244 and the fork receiving openings 232, 234.

[0026] The male inner housing 200 has a rear inner wall having a fork receiving opening 234 for receiving the fork-shaped protrusion 134 of the female connector 100. The rear inner wall of the male inner housing 200 receives the lower surface 102 of the female connector 100 as a whole, and when fully inserted, the lower surface 102 abuts against the rear inner wall of the male inner housing 200, fits at the same height, and contacts completely uniformly (see FIGS. 8B and 12). The rear inner wall also has an alignment groove 264 for receiving the alignment protrusion 164 of the female connector 100 and an alignment groove 266 for receiving the alignment protrusion 166 of the female connector 100. The alignment grooves 264, 266 and the alignment protrusions 164, 166 help to ensure proper insertion of the female connector 100 into the male inner housing 200 in the correct orientation and arrangement.

[0027] FIG. 3A shows the inclined ramps 270 and 276 near the lower part of the male inner housing 200. FIG. 3A also shows a notch 215 for receiving the overhanging portion 440 of the male outer housing 400. The notch 215 is near the lower part of the male inner housing 200. The overhanging portion 440 is shown, for example, in FIGS. 5B and 5C.

[0028] FIG. 3B is a perspective view of the male inner housing of FIG. 3A. FIG. 3B shows the inclined ramps 270, 272, 276, the fork receiving openings 230, 323, 234, 236, and the fork-shaped protrusions 244, 246. FIG. 3C is a front elevation view of the male inner housing of FIG. 3A.

[0029] FIG. 3D is a rear elevation view of the male inner housing of FIG. 3A. FIG. 3D shows that the rear part of the male inner housing 200 has an opening 260 for receiving the male terminal position assurance (TPA) member 210. As shown in FIG. 3D, the lower part of the male inner housing 200 has a platform 218 directly below the notch 215. The platform 218 is wider than the notch 215 as shown in FIG. 3D. The lower part of the male inner housing 200 can be referred to as the lower end of the male inner housing 200.

[0030] Figure 3E is a top elevation view of the male inner housing of Figure 3A. As shown in Figure 3E, the male inner housing 200 includes fork-shaped protrusions 240, 242, 244, 246. The male inner housing 200 also has fork receiving openings 230 in the front inner wall, fork receiving openings 232 in the left inner wall, fork receiving openings 234 in the rear inner wall, and fork receiving openings 236 in the right inner wall. Openings 250, 252, 254, 256 are at the lower part of the male inner housing 200. Alignment grooves 264, 266 are in the rear inner wall.

[0031] Figure 3F is a bottom elevation view of the male inner housing of Figure 3A. Figure 3F shows the inclined ramps 270, 272, 274, 276 of the male inner housing 200. The inclined ramps 270, 272, 274, 276 are near the lower part of the male inner housing 200.

[0032] The platform 218 is at the lower part of the male inner housing 200. Each side of the platform 218 has one of the inclined ramps 270, 272, 274, 276 respectively. As shown in Figure 3F, each of the inclined ramps 270, 272, 274, 276 is disposed at the substantial center of the side of the platform 218.

[0033] Figure 3G is an exploded perspective view of the male inner housing of Figure 3A and its components according to the principles of the present invention. Electric conductors 220, electrical crimp terminals 222, terminal box 225, and blades 228 are shown in Figure 3G. Figure 3H is a perspective view of the male inner housing of Figure 3A and its components according to the principles of the present invention.

[0034] When the male inner housing 200 is coupled or fitted to the female connector 100, the lower part of the female connector 100 penetrates the opening 205 and the blade 228 penetrates the terminal box 125. When the blade 228 penetrates the terminal box 125, an electrical connection is established between the male inner housing 200 and the female connector 100.

[0035] Figure 3I is a bottom elevation view of the male inner housing and its components in FIG. 3A in accordance with the principles of the present invention.

[0036] FIG. 4A is a perspective view of a suspension in accordance with the principles of the first embodiment of the present invention. FIG. 4A shows a suspension 300 having flexibility and elasticity. The suspension 300 is elastomeric and can be produced by a synthetic material, a natural material, or a combination of a synthetic material and a natural material. Here, the suspension 300 is formed of silicone rubber, but the embodiment shown herein is an integrally molded piece having two regions, namely an upper region 301 and a lower region 303.

[0037] The suspension 300 utilizes the elastic force of the lower portion 303 and the buffer elastic element 336 to elastically bias the male inner housing 200 in all angular degrees of freedom. The male inner housing 200 is biased to remain positioned such that the central axis of the male inner housing 200 coincides with the central axis of the male outer housing 400. Also, when the male inner housing 200 is pushed and the central axis of the male inner housing 200 is temporarily displaced from the central axis of the male outer housing 400, the suspension 300 biases the male inner housing 200 to move such that the central axis of the male inner housing coincides again with the central axis of the male outer housing 400.

[0038] The central axis of the male inner housing 200 extends through the male inner housing 200 along, for example, the left-right longitudinal direction when viewing FIG. 8B. The central axis of the male outer housing 400 extends through the male outer housing 400 along, for example, the left-right longitudinal direction when viewing FIG. 8B. The central axis of the connector system extends through the female connector 100, the male inner housing 200, the suspension 300, and the male outer housing along, for example, the left-right direction when viewing FIG. 8B.

[0039] For example, while attempting to couple the female connector 100 and the male inner housing 200, the male inner housing 200 may be pushed such that the central axis of the male inner housing 200 is temporarily displaced from the central axis of the male outer housing 400. That is, the user moving the lower portion of the female connector 100 toward the opening 205 may inadvertently push a portion of the male inner housing 200 laterally instead of inserting the lower portion of the female connector 100 directly straight into the opening 205 without any contact that would cause lateral movement of the male inner housing 200 (see FIGS. 1C and 11). In other words, the user attempts to insert the lower portion of the female connector 100 downward into the opening 205 of the male inner housing 200 (see FIGS. 1C and 11), but if the user does not perfectly aim or align the female connector 100, the lower portion of the female connector 100 may not be initially correctly aligned with the opening 205 of the male inner housing 200, and thus may push the male inner housing 200 such that the central axis of the male inner housing 200 is temporarily displaced from the central axis of the male outer housing 400. In such a situation, while attempting to couple the female connector 100 and the male inner housing 200, the flexibility of the suspension 300 allows the male inner housing 200 to move such that the central axis of the male inner housing 200 is temporarily displaced from the central axis of the male outer housing 400, but the introduction portion 202 of the inclined shape redirects the female member additionally toward the central axis of the male inner housing when contact occurs with a portion of the introduction portion 202 of the inclined shape. Also, due to the elasticity of the suspension 300, one of the following occurs to the male inner housing 200. (1) After the opening 205 is coupled with the lower portion of the female connector 100, the central axis of the male inner housing 200 moves back to a position where it again coincides with the central axis of the male outer housing 400, or (2) after the coupling of the opening 205 with the lower portion of the female connector 100 is completed, the male inner housing 200 is biased to move back to a position where the central axis of the male inner housing 200 coincides with the central axis of the male outer housing 400.

[0040] The shape of the suspension 300, the shape of the inclined introduction part at the upper part of the male inner housing 200, and the shape of the opening 205 are useful for the user to quickly and easily insert the lower part of the female connector 100 and further insert it into the opening 205, even when the user cannot visually confirm the exact position of the opening 205.

[0041] When the user pushes the lower part of the female connector 100 into the opening 205 with excessive force, or when longitudinal and vertical forces impact the fully assembled female connector 100 and male inner housing 200 in a state where the male inner housing 200 is suspended by the suspension 300, the suspension 300 can act as a shock absorber. That is, the suspension 300 and the suspension 300A allow the male inner housing 200 to move downward by the lower part of the female connector 100 while maintaining the male outer housing 400 substantially immobile. Refer to FIGS. 11, 12 and the following description for the relative movement of the female connector 100, the male inner housing 200, and the male outer housing 400 during the assembly of the connector system.

[0042] Referring to FIGS. 1C, 11 and 12, due to the elasticity of the suspension 300 and the suspension 300A, any of the following occurs to the male inner housing 200. (1) After the connection between the opening 205 and the female connector 100 is completed and the lower surface 102 abuts against the rear inner wall of the male inner housing 200, (with the male outer housing 400 remaining substantially immobile), it moves upward toward the upper part of the female connector 100, or (2) after the connection between the opening 205 and the female connector 100 is completed and the lower surface 102 abuts against the rear inner wall of the male inner housing 200, (with the male outer housing 400 remaining substantially immobile), it is biased to move upward toward the upper part of the female connector 100. This biasing is brought about by a spring-like force realized by the upper edge 330, the main body 332, and the lower edge 334, as will be described below.

[0043] Figure 4B is a cross-sectional view taken along line 4B-4B of Figure 4A. Figure 4B shows the upper part 310 and the lower part 320 of the suspension 300. Inside the suspension 300, there is an inclined part having an upper edge 330, a main body 332, and a lower edge 334. When the connector system is assembled, at least a part of the upper edge 330 abuts against the upper surface 216 of the notch 215 of the male inner housing 200. The upper surface 216 of the notch 215 is acted upon by the upper edge 330 of the suspensions 300, 300A when the suspensions 300, 300A act as a spring-like device during operation. Figure 4C is an elevation view of the upper end of the suspension of Figure 4A. Figure 4D is an elevation view of the lower end of the suspension of Figure 4A.

[0044] When the user presses the female connector 100 such that the lower part of the female connector 100 fully enters into the opening 205, the upper surface 216 of the notch 215 of the male inner housing 200 can engage with the upper edge 330 of the suspension 300 (alternatively, with the upper edge 330 of the suspension 300A in the second embodiment). Due to the elasticity of the upper edge 330, the male inner housing 200 can move further downward and pass through the male outer housing 400, while the male outer housing 400 remains in a relatively non-moving state. The upper edge 330 provides an elastic force against this movement and acts as a spring-like force in cooperation with the main body 332 and the lower edge 334, and brings it about. The angled part of the main body 332 formed with the lower edge 334 and the upper edge 330 creates a substantially Z-shaped structure.

[0045] As shown in Figures 4B, 4C, and 4D, the suspension 300 forms a through-hole in the central region of the suspension 300. As shown in Figures 4B, 4C, and 4D, the through-hole in the central region of the suspension 300 has a wider opening near the upper part of the suspension 300 and a narrower opening defined by the upper edge 330 of the inclined path near the lower part of the suspension 300. The wider opening near the upper part of the suspension 300 can be called the upper opening of the suspension 300. The narrower opening near the lower part of the suspension 300 can be called the lower opening of the suspension 300.

[0046] The suspension 300 can be made as a single, integrated, unitary component, one at a time, as shown, for example, in FIGS. 4A and 4B. However, in different embodiments, instead of a single component 300, it is possible to use two or more separate components that are cut and separated by the dashed line C.

[0047] The lower region 303 of the suspension 300 can also be replaced by a conventional coil spring or the like in any combination of the upper components of the upper region 301 of the suspension 300, provided that the upper components have a surface against which the coil spring abuts during use.

[0048] For example, the suspension 300 may be replaceable by the following: (1) the upper components of the upper region 301 of the suspension 300 that extend from directly above the upper edge 330 through the upper portion 310 and are of the same size, shape, and material as in the first and second embodiments of the present invention with reference to FIG. 4B, and (2) the lower components of the lower region 303 of the suspension 300 that include the upper edge 330 and extend from the upper edge through the lower portion 320 and are of the same size, shape, and material as in the first and second embodiments of the present invention with reference to FIG. 4B.

[0049] Also, the suspension 300 may be replaceable by the following: (1) the upper components of the upper region 301 of the suspension 300 that extend from directly above the upper edge 330 through the upper portion 310 and are of the same size, shape, and material as in the first and second embodiments of the present invention with reference to FIG. 4B, and (2) the lower components of the lower region 303 of the suspension 300 that include the upper edge 330 and extend from the upper edge through the lower portion 320 and are of different sizes, shapes, and materials.

[0050] Also, the suspension 300 may be replaceable as follows. (1) Upper components of the upper region 301 of the suspension 300 that extend from directly above the upper edge 330 through the upper portion 310 with different sizes, shapes, and materials, and (2) Lower components of the lower region 303 of the suspension 300 that include the upper edge 330 and extend from the upper edge through the lower portion 320 with the same size, shape, and material as in the first and second embodiments of the present invention with reference to FIG. 4B.

[0051] FIG. 5A is a perspective view of the male outer housing according to the principles of the present invention. FIG. 5B is a cross-sectional view taken along line 5B-5B of FIG. 5A. The male outer housing 400 has an upper portion 410 and a lower portion 420. FIG. 5C is a front elevation view of the upper end of the male outer housing of FIG. 5A. FIG. 5D is a front elevation view of the lower end of the male outer housing of FIG. 5A.

[0052] As shown in FIGS. 5B, 5C, and 5D, the male outer housing 400 has a through hole formed in the central region of the male outer housing 400. As shown in FIGS. 5B, 5C, and 5D, the through hole at the center of the male outer housing 400 has a wider opening near the upper portion of the male outer housing 400 and a narrower opening near the lower portion of the male outer housing 400. The wider opening near the upper portion of the male outer housing 400 can be referred to as the upper opening of the male outer housing 400. The narrower opening near the lower portion of the male outer housing 400 can be referred to as the lower opening of the male outer housing 400.

[0053] FIGS. 5C and 5D show that the through hole at the center of the male outer housing 400 has a rounded rectangular shape. FIGS. 5C and 5D also show that the male outer housing 400 has two circular openings near the edge of the male outer housing 400. The circular openings are used to attach the male outer housing 400 to a body (not shown).

[0054] Figure 6 is a perspective view of a female terminal and its components according to the principles of the present invention. The female terminal is disposed in the female connector 100. The female terminal includes an electrical conductor 120, an electrical crimp terminal 122, and a terminal box 125. The terminal box 125 includes a locking projection 126 having an inclined ramp 127.

[0055] Figure 7 is a perspective view of a male terminal and its components according to the principles of the present invention. The male terminal is disposed in the male inner housing 200. The male terminal includes an electrical conductor 220, an electrical crimp terminal 222, and a terminal box 225. The terminal box 225 includes a locking projection 226 having an inclined ramp 227, and a blade 228.

[0056] Figure 8A is a view of the connector system in the assembled state of FIG. 1A. Figure 8B is a cross-sectional view taken along line 8B-8B of FIG. 8A. Inside the female connector 100, there is a locking projection 180 with an inclined ramp. The locking projection 180 is engaged with the locking projection 126 to hold the female terminal in the correct position.

[0057] Inside the male inner housing 200, there is a locking projection 280 with an inclined ramp. The locking projection 280 is formed on the locking projection 226 to hold the male terminal in the correct position.

[0058] Figure 9 is a perspective view of a male terminal position assurance (TPA) member according to the principles of the present invention. The male TPA member 210 has an inclined edge 211. The inclined edge 211 accommodates a portion of the male terminal and verifies the correct position of the male terminal, as shown in FIG. 8B.

[0059] After the male TPA member 210 is properly inserted into the opening 260 at the rear of the male inner housing 200, the upper portion 213 of the male TPA member 210 faces the upper portion of the male inner housing 200, as shown in FIG. 8B. Also, as shown in FIG. 8B, the upper portion 213 of the male TPA member 210 faces the female connector 110. As shown in FIG. 8B, the front portion 214 of the male TPA member 210 faces downward.

[0060] Figure 10 is a perspective view of the female terminal position guarantee member according to the principle of the present invention. The female TPA member 110 has an inclined edge 111. The inclined edge 111 accommodates a part of the female terminal and verifies the correct position of the female terminal as shown in FIG. 8B.

[0061] After the female TPA member 110 is properly inserted into the opening 160 at the rear part of the female connector 100, the lower part 113 of the female TPA member 110 faces the lower part of the female connector 100 as shown in FIG. 8B. Also, as shown in FIG. 8B, the lower part 113 of the female TPA member 110 faces the suspension 300. As shown in FIG. 8B, the front part 114 of the female TPA member 110 faces downward.

[0062] When comparing the male TPA member 210 and the female TPA member 110, the following information should be considered. In the male TPA member 210, the inclined edge 211 extends by a first distance and connects the front part 214 to the lower part 212. In the female TPA member 110, the inclined edge 111 extends by a second distance and connects the front part 114 to the upper part 112. As can be seen by comparing FIGS. 9 and 10, the second distance is larger than the first distance.

[0063] Figure 11 is a cross-sectional view of a part of the connector system according to the principle of the second embodiment of the present invention, showing the female connector and the male connector. Figure 11 shows the suspension 300A (second embodiment), the lower part of the female connector 100, the male inner housing 200, and the male outer housing 400. Figure 11 shows the downward movement of the female connector 100 into the opening 205 of the male inner housing during assembly, and also shows a slight expansion of the opening 205 when penetrated by the lower part of the female connector 100.

[0064] As shown in FIG. 11, it is shown that the suspension 300A has a buffer elastic element 336 that horizontally surrounds the upper region of the suspension 300A above the upper edge 330. The buffer elastic elements 336 are substantially parallel to each other and are also parallel to the male inner housing 200 when the male inner housing 200 is inserted into the suspensions 300 and 300A.

[0065] The suspension 300A (second embodiment) is different from the suspension 300 (first embodiment) at least due to the orientation of the plurality of buffer elastic elements 336. In the suspension 300A, the buffer elastic elements 336 are horizontally oriented (see FIGS. 11 and 12). In the suspension 300, the buffer elastic elements 336 are oriented to extend vertically between the upper part 310 and the upper edge 330 (see FIGS. 4A, 4B, 4C, 4D, and 8B). When the buffer elastic elements 336 are not compressed by the male inner housing 200, they are recessed inward toward the openings 000 of the suspensions 300 and 300A.

[0066] The lower part of the female connector 100 fits snugly into the opening 205 at the upper part of the male inner housing 200. FIG. 11 shows that when the female connector 100 moves downward into the opening 205 of the male inner housing 200 and also during the assembly of the connector, the upper region of the male inner housing 200 (near the opening 205) is also pushed slightly outward to accommodate the lower part of the female connector 100. The lower part of the female connector 100 fits snugly into the opening 205. See FIG. 11. Also shown is an inclined introduction part 202 that can provide surfaces that interact with the lower surface 102, the lower inclined edge 182, and the side surfaces of the female connector 100 while entering the opening 205. The inclined introduction part 202 is substantially funnel-shaped and protrudes outward and away from the central axis of the male inner housing 200 and the opening 205 (see FIG. 11).

[0067] FIG. 12 is a cross-sectional view of a part of a connector system according to the principle of the second embodiment of the present invention, showing the female connector and the male connector.

[0068] Figure 12 shows that when the connection is completed, the suspension 300A is displaced, the buffer elastic element 336 is compressed, and the male inner housing 200 is pushed downward and pushed into the male outer housing 400.

[0069] FIG. 12 shows the suspension 300A (second embodiment), the lower part of the female connector 100, the male inner housing 200, and the male outer housing 400. FIG. 1 shows the downward movement of the male inner housing 200 relative to the male outer housing 400 under the following conditions: (1) First, as shown in FIG. 12, it is understood that the female connector 100 is pushed downward by a first distance such that the lower part of the female connector 100 is inserted into the opening 205 of the male inner housing 200. (2) Subsequently, the female connector 100 is pushed further downward by an additional distance, and the lower part of the female connector 100 moves deeper into the opening 205 to ensure complete insertion. And (3), since the lower part of the female connector 100 is already fully inserted into the opening 205, the lower part of the female connector 100 cannot move deeper into the opening 205. Therefore, when the female connector 100 is continuously pushed downward by an additional distance, the upper surface 216 of the notch 215 of the male inner housing 200 compresses the upper edge 330 portion of the suspension 300A, enabling the platform 218 of the male inner housing 200 to move further downward below the lower part of the male outer housing 400. The suspension 300A, like a spring, provides an elastic force opposite to the downward force of the male inner housing 200 during operation and also provides an upward force to the female connector 100. Similarly, preferably, the additional embodiments described above can utilize a coil spring or the like to replace the lower part 303 of the suspensions 300, 300A. Essentially, the male inner housing 200 is vertically suspended by the lower part 303. The lower part 303 spring force elastically biases the male inner housing 200 towards the female housing 100 and prevents further downward movement towards the male outer housing 400. This also acts as a kind of shock absorption when a longitudinal, vertical force impacts the fully assembled female connector 100 and the male inner housing 200 while the male inner housing 200 is suspended by the suspension 300 during operation.

[0070] The suspension 300 (first embodiment) functions in the same manner as the suspension 300A (second embodiment). The suspensions 300 and 300A have elasticity. The suspensions 300 and 300A have flexibility. The suspensions 300 and 300A are relatively more flexible than the inner male housing 200. The suspensions 300 and 300A are relatively more flexible than the outer male housing 400. The suspensions 300 and 300A are relatively more flexible than the female connector 100. The inner male housing 200, the outer male housing 400, and the female connector 100 are substantially inflexible. The flexibility of the suspension is not limited to the above comparison, but the suspensions 300 and 300A are flexible such that during use and operation, the movement of the lower part of the suspensions 300 and 300A is flexible and provides sufficient elasticity and spring-like force for the tight fit between the female connector 100 and the inner male housing 200.

[0071] The female connector 100 and its components can include at least the female TPA member 110, the conductive wire 120, the electrical crimp terminal 122, the terminal box 125, and other features described herein. The male connector and its components can include at least the inner male housing 200, the suspension 300, the outer male housing 400, the male TPA member 210, the conductive wire 220, the electrical crimp terminal 222, the terminal box, and other features described herein.

[0072] When the lower opening 405 of the male outer housing 400 is penetrated by the platform 218 during assembly, the lower opening of the male outer housing can be temporarily expanded slightly by one or more of the inclined ramps 270, 272, 274, 276. When the lower opening 405 of the male outer housing 400 is penetrated by the platform 218 during assembly, the platform 218 and the inclined ramps 270, 272, 274, 276 can be temporarily compressed inward by the side surface of the lower opening of the male outer housing 400. Each side surface of the platform 218 has one opening 270a, 272a, 274a, 276a respectively on the platform 218 to provide a space for the side surface of the platform 218 to be compressed inward when the inclined ramps 270, 272, 274, 276 are temporarily compressed inward by the side surface of the lower opening 405 of the male outer housing 400 as described above. Each of the respective inclined ramp openings 270a, 272a, 274a, 276a is disposed substantially at the center of each side surface of the platform 218 as shown in FIG. 3F.

[0073] After the lower opening of the male outer housing 400 is penetrated by the platform 218 moving downward, the shape and size of the inclined ramps 270, 272, 274, 276 prevent the platform 218 from passing through the lower opening 405 of the male outer housing 400 and returning upward. (See FIG. 8B).

[0074] The fork-shaped protrusions 130, 132, 134, 136, 240, 242, 246 can be called mating protrusions. The fork receiving openings 140, 142, 144, 146, 230, 232, 234, 236 can be called mating openings. The fork-shaped protrusions and the fork receiving openings help to reduce vibration and can be called a vibration damping function. The fork-shaped protrusions and the fork receiving openings fit snugly together.

[0075] The female connector 100 can be called the first connector 100. The male connector includes a male inner housing 200, a suspension 300, and a male outer housing 400. The male connector can be called the second connector and is composed of an inner housing and an outer housing. The male inner housing 200 can be called the inner housing 200. The male outer housing 400 can be called the outer housing 400.

[0076] The lower part of the first connector 100 can be called the first end of the first connector 100. The lower part of the male inner housing 200 can be called the first end of the male inner housing 200.

[0077] The above includes descriptions of the conductor 220, the electrical crimp terminal 222, the terminal box 225, and the blade 228 within the male inner housing 200, and also includes descriptions of the conductor 120, the electrical crimp terminal 122, and the terminal box 125 within the female connector 100. When the male inner housing 200 is coupled or mated to the female connector 100, the lower part of the female connector 100 penetrates the opening 205, and the blade 228 penetrates the terminal box 125. When the blade 228 penetrates the terminal box 125, an electrical connection is established between the male inner housing 200 and the female connector 100. However, the conductor 220, the electrical crimp terminal 222, the terminal box 225, the blade 228, the conductor 120, the electrical crimp terminal 122, and the terminal box 125 are not necessarily required. The suspension 300 and other features of the connector system of the present application still provide benefits even when there is no electrical connection between the female connector 100 and the male inner housing 200.

[0078] As described herein, the blind mate connector system can be wire-to-wire or device-to-device. The blind mate connector system uses an elastic suspension (e.g., such that the first connector half member includes the female connector 100 and the second connector half member includes the male inner housing 200, the suspension 300, and the male outer housing 400) to provide responsiveness in mating alignment and to provide axial compression force between the two connector half members. The features of this blind mate connector system are a first connector half member (female) fixedly installed on a large body (such as a transmission housing cover), and a second connection half member (male) having a fixedly attached outer housing with an elastic suspension element that suspends the inner connector housing. The outer housing can be attached to another body (such as a transmission housing) in such a way that the mating process of the two connector half members is not visible. The axial compression force between the two connector half members keeps the two contacted housings firmly mated and eliminates relative movement between them. The means for attaching and fixing the connector system half members to their respective bodies is not limited to the illustrated configuration of the present invention.

[0079] It should be noted that the above description relates to a preferred embodiment of the present invention, but other modifications and changes will be apparent to those skilled in the art, and it is possible to implement them without departing from the spirit of the present invention. Furthermore, the features described in connection with one embodiment of the present invention can be adopted with other embodiments even if not explicitly described above.

Description of Reference Numerals

[0080] 100 Female connector (first connector) 102 Bottom surface 105 Opening near the upper side of the female connector 110 Female terminal position assurance (TPA) member 111 Inclined edge 112 Upper part of the body of the female TPA member Lower part of the body of the female TPA member Front part of the body of the female TPA member Electrical conducting wire of the female connector Electrical crimping terminal Female terminal box Lock protrusion in the female terminal box Inclined ramp on the lock protrusion Fork-shaped protrusion (fitting protrusion) at the front part Fork-shaped protrusion (fitting protrusion) on the left side surface Fork-shaped protrusion (fitting protrusion) at the rear part Fork-shaped protrusion (fitting protrusion) on the right side surface Fork receptacle opening (fitting opening) Fork receptacle opening (fitting opening) Fork receptacle opening (fitting opening) Fork receptacle opening (fitting opening) Opening at the lower part Opening at the lower part Opening at the lower part Opening at the lower part Opening at the rear part of the female connector for accommodating the female TPA member Inclined edge of the female housing Conducting wire routing groove Alignment protrusion Alignment protrusion Lock protrusion (with inclined ramp) inside the female connector Lower inclined edge Male inner housing (inner housing) Inclined introduction part Opening near the upper side of the male inner housing Male terminal position assurance (TPA) member Inclined edge Lower part of the body of the male TPA member Upper part of the male TPA member Front part of the body of the male TPA member Notch for accommodating the protruding portion 440 of the male outer housing 400 Notch area of the male inner housing in the region extending beyond the suspension Upper surface of the notch Platform at the lower part of the male inner housing Electrical conducting wire inside the male inner housing Electrical crimping terminal Male terminal box Lock protrusion in the male terminal box Inclined ramp on the lock protrusion Blade Fork receiving opening (fitting opening) on the front inner wall Fork receiving opening (fitting opening) on the left inner wall Fork receiving opening (fitting opening) on the rear inner wall Fork receiving opening (fitting opening) on the right inner wall Fork-shaped protrusion (fitting protrusion) Fork-shaped protrusion (fitting protrusion) Fork-shaped protrusion (fitting protrusion) Fork-shaped protrusion (fitting protrusion) Opening Opening Opening Opening Opening at the rear part of the male inner housing for accommodating the male TPA member Alignment groove Alignment groove Inclined ramp on the first side surface of the platform Inclined ramp on the second side surface of the platform Inclined ramp on the third side surface of the platform Inclined ramp on the fourth side surface of the platform Opening Opening Opening 276a opening 280 Lock projection (with inclined ramp) in the male inner housing 300 Suspension (first embodiment) 300A Suspension (second embodiment) 301 Upper part of the suspension 303 Lower part of the suspension 310 Upper portion of the suspension 320 Lower portion of the suspension 330 Upper edge of the inclined ramp 332 Body of the inclined ramp 334 Lower edge of the inclined ramp 336 Buffer elastic element 400 Male outer housing (outer housing) 405 Lower opening of the male outer housing 410 Upper part of the male outer housing 420 Lower part of the male outer housing 440 Protrusion C Separation line

Claims

1. A first connector having a first end and forming a plurality of fitting protrusions and fitting openings, and a second connector, characterized in that the second connector includes an inner housing forming a first opening, a notch, and a plurality of fitting protrusions and a plurality of fitting openings; a suspension having a through hole for receiving the inner housing and having an inclined portion inside with at least a first edge and a main body, and at least a part of the first edge of the inclined portion being configured to be received in the notch, the suspension being flexible; an outer housing provided on the suspension, the first end of the first connector being received in the first opening of the inner housing, each one of the fitting protrusions provided on the first connector being respectively received in one of the fitting openings of the inner housing, and the notch accommodating an overhanging portion of the outer housing, a connector system.

2. The connector system according to claim 1, characterized in that each one of the fitting protrusions provided on the inner housing is respectively received in one of the fitting openings of the first connector.

3. The connector system according to claim 1, characterized in that the suspension has a buffer elastic element surrounding a first region of the suspension.

4. The connector system according to claim 1, characterized in that the first connector, the inner housing, and the outer housing are substantially non-flexible.

5. The connector system according to claim 1, characterized in that the inclined portion has a second edge.

6. The connector system according to claim 5, characterized in that an angled portion of the main body of the inclined portion where the first edge and the second edge are formed forms a Z-shaped structure.

7. Inserting an inner housing forming a notch and a plurality of fitting protrusions and a plurality of fitting openings into a first opening of a suspension, inserting a first end of the inner housing into a first opening of an outer housing, inserting a fitting end of a first connector forming a plurality of fitting protrusions and a plurality of fitting openings into the first opening of the inner housing. One of each of the fitting protrusions provided on the first connector is respectively received in one of the fitting openings of the inner housing, and the suspension has flexibility and has an inclined portion having at least a first edge and a main body inside, and at least a part of the first edge of the inclined portion is received in the notch, and the notch accommodates the overhanging portion of the outer housing. A method for assembling a connector system, characterized in that.

8. The method according to claim 7, characterized in that the suspension has a buffer elastic element surrounding a first region of the suspension.

9. The method according to claim 7, characterized in that the suspension is formed of a synthetic material.

10. The method according to claim 7, characterized in that the inclined portion has a second edge.

11. The method according to claim 10, characterized in that an angled portion of the main body of the inclined portion in which the first edge and the second edge are formed forms a Z-shaped structure.

12. The method according to claim 11, characterized in that the suspension has a first region including a buffer elastic element and a second region including the main body of the inclined portion, the first edge of the inclined portion, and the second edge.

13. Coupling the outer housing to the first body, and Coupling the first connector to the second body. The method according to claim 7, further characterized by.

14. A first connector having a lower end and a first opening, and forming a plurality of fitting protrusions and fitting openings; A notch, an inner housing forming a first opening and a second opening, and forming a plurality of fitting protrusions and a plurality of fitting openings; A suspension having a through hole for receiving the inner housing and having an inclined portion having at least a first edge and a main body inside, and at least a part of the first edge being configured to be received in the notch and having flexibility; An outer housing provided on the suspension, characterized by comprising: A first end of the first connector is received in the first opening of the inner housing, A connector system, characterized in that one of each of the fitting protrusions provided on the first connector is respectively received in one of the fitting openings of the inner housing.

15. The connector system according to claim 14, wherein the first terminal position guarantee member is received in the first opening of the first connector.

16. The connector system according to claim 15, wherein the second terminal position guarantee member is received in the second opening of the inner housing.

17. The connector system according to claim 14, wherein when the first end of the first connector is received in the first opening of the inner housing, the inner housing can move within the outer housing due to the flexibility of the suspension.

18. The connector system according to claim 14, wherein each one of the fitting protrusions provided on the inner housing is received in one of the fitting openings of the first connector.

Images