Abstract:
An electrical connector assembly is disclosed having a housing assembly, having a mating face where at least one camming slide slides relative to the housing assembly, and has a camming slot therein is cooperable with a camming lug on a mating housing. The slide comprises gear rack teeth thereon. A rotary gear is rotatable relative to the housing assembly and includes gear teeth which cooperate with the gear rack teeth. A lever is rotatable relative to the housing assembly and is profiled to rotate the rotary gear, and in turn translate the slide. The housings are drawn together and apart upon movement of the slide.

Description:
RELATED APPLICATION 
     The subject disclosure is related to Applicants file E-AV-00630 filed on even date as Ser. No. 12/386,621, the subject matter of which is incorporated herein by reference. 
     BACKGROUND OF THE INVENTION 
     The subject disclosure relates generally to an electrical connector assembly having an actuation system to effect mating engagement of two connector halves. 
     Connector arrangements may have a plug housing, a socket housing, and an actuation means for moving one of the housings into engagement with the other housing such that receptacle contacts of the socket housing are electrically connected to pluggable contacts of the plug housing. These types of plug connector arrangements are primarily used in cases where one of the housings is fixed and accessibility to the plug connector arrangement is limited. These types of conditions typically exist, for example, in the automotive sector, for example in a door-to-body application. 
     In order to save space, the moveable housing is formed so that only a small portion of the moveable housing projects from the fixed housing when the housings are engaged. This configuration causes the disengagement of the moveable housing from the fixed housing to be difficult. A problem also exists in that the plug connector arrangement has a large number of contact elements that exert a high normal contact force such that considerable force is required to plug-in and release the moveable housing from the fixed housing. 
     In order to resolve these problems, plug connector arrangements have been provided with actuation systems including actuation camming slides. The actuation slides are arranged on the movable housing and are displaceable in a direction transverse to a direction of engagement. For example, the camming slides may be provided with camming slots that engage with cam projections on the fixed housing. Movement of the movable housing toward the fixed housing can be performed by displacement of the actuation slides transversely with respect to the direction of the movement of the moveable housing toward the fixed housing. In another example, an actuation slide means may be constructed as a toothed rack wherein the displacement of the moveable housing is forced by rotary movement of a pivotal lever with a pinion region engaging in the toothed rack. Examples of such actuation slides are taught by European Patent No. 0 273 999 B1 and U.S. Pat. Nos. 5,478,251; 5,593,309; 5,618,194 and 5,660,556. The actuation slide may be actuated by a lever as shown in U.S. Pat. No. 6,960,090. 
     In some configurations, given the number of contacts and the mating force to bring the two connectors together, these actuation slides are not effective for the mating engagement. Furthermore, the slides themselves, or the levers require significant open space around them for full travel, which may be an issue with packaging, installation or operation. 
     It is therefore desirable to develop a plug connector arrangement which can be pushed together and released in a simplified and secured manner while at the same time maintaining low manufacturing costs and saving space. 
     SUMMARY OF THE INVENTION 
     The objects were accomplished by providing an electrical connector assembly comprising a housing assembly, having a mating face, and at least one slide slidably movable relative to the housing assembly. The at least one slide assembly has a first actuation member thereon cooperable with a mating housing, such that the housings are drawn together and apart upon movement of the slide. The slide further comprises a second actuation member thereon. A rotary member is rotatable relative to the housing assembly and includes a third actuation member which cooperates with the second actuation member upon rotation thereof to move the slide, and a fourth actuation member radially spaced from a center of rotation of the rotary member. A lever is rotatable relative to the housing assembly and includes a fifth actuation member, which cooperates to rotate the rotary member, and translate the slide, upon rotation of the lever. 
     In another embodiment of the invention, an electrical connector assembly comprises a housing assembly having a mating face; at least one slide slidably movable relative to the housing assembly, the at least one slide assembly having a camming slot therein cooperable with a camming lug on mating housing, such that the housings are drawn together and apart upon movement of the slide, the slide further comprising gear rack teeth thereon; a rotary gear being rotatable relative to the housing assembly and including gear teeth which cooperate with the gear rack teeth upon rotation thereof to translate the slide, and an actuation member radially spaced from a center of rotation of the rotary member; and a lever being rotatable relative to the housing assembly and profiled for engagement of the actuation member, which cooperates to rotate the rotary member, and translate the slide, upon rotation of the lever. 
     In yet another embodiment of the invention, an electrical connector assembly, comprises a housing assembly, having a mating face; at least one camming slide slidably movable relative to the housing assembly, the at least one slide assembly having an actuation member thereon cooperable with a mating housing, such that the housings are drawn together and apart upon movement of the slide; a lever being rotatable relative to the housing assembly; and a mechanical advantage multiplier between the lever and the at least one camming slide to provide a compounding of the mechanical advantage of the lever and camming slide, whereupon rotation of the lever cooperates to activate the mechanical advantage multiplier and to translate the slide. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a top perspective view of the connector assembly of the present invention; 
         FIG. 2  is a bottom perspective view of the connector assembly shown in  FIG. 1 ; 
         FIG. 3  is a perspective view showing the components of the connector assembly of  FIG. 1  exploded away from each other; 
         FIG. 4  is a bottom perspective view of the central housing shown in  FIG. 3 ; 
         FIG. 5  is a top perspective view of the central housing shown in  FIG. 3 ; 
         FIG. 6  is a cross-sectional view through lines  6 - 6  of  FIG. 4 ; 
         FIG. 7  is a cross-sectional view through lines  7 - 7  of  FIG. 5 ; 
         FIG. 8  is a rear perspective view of the front housing portion; 
         FIG. 9  is front perspective view of the front housing portion; 
         FIG. 10  is a front perspective view of the rotary gear; 
         FIG. 11  is a rear perspective view of the rotary gear; 
         FIGS. 12 and 13  show bottom perspective views of the camming slide; 
         FIG. 14  shows a perspective view of the lever; 
         FIG. 15  shows a longitudinal cross-sectional view through the connector assembly at the position of the rotary gear, with the lever in the pre-mated position; 
         FIG. 16  shows a cross-sectional view, similar to that of  FIG. 15  showing the lever being actuated; and 
         FIG. 17  shows a cross-sectional view similar to that of  FIG. 15  in the fully actuated position. 
     
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENTS 
     With reference first to  FIGS. 1-3 , an electrical connector assembly  2  is shown as comprised of a housing assembly  4 , a lever  6 , rotary gears  8 , and as best shown in  FIG. 3 , camming slides  10 . With reference now to  FIG. 3 , the various components are shown in an exploded view, where the housing assembly  4  would comprise a central housing portion  12 , a front housing portion  18 , and a retaining cap  20 . It should be appreciated that connector assembly  2  is profiled to mate with a mating connector having lugs which engage with the camming slides  10 , to draw the connector assembly  2  and the mating connector into a fully mated position. 
     With reference now to  FIGS. 4-7 , central housing portion  12  will be described in greater detail. Central housing portion  12  includes first and second sidewalls  30 ,  32  and end walls  34 ,  36 . As shown best in  FIGS. 4 and 5 , slots  40  and  42  are defined through end walls  34  and  36 , and are positionable against an inside of respective sidewalls  30  and  32 . With reference to  FIGS. 4 and 7 , the bottom edge of the sidewalls  30  and  32 , include lips  48  having a groove  50  formed therein. As shown in  FIGS. 6 and 7 , each of the sidewalls  30  and  32  also include upper bars  58  having grooves  60  formed therein. As should be appreciated, slots  40  and  42  is each profiled to receive one of the camming slides  10  ( FIG. 3 ) as will be described further herein. 
     As shown in  FIGS. 4 and 7 , lips  48  are separated to define openings at  64 . Each sidewall  30 ,  32  also includes a flexible latch  70  molded therein with a latching lug  72  aligned with one of the openings  64 . As shown in  FIG. 4 , the latching lugs align with diametrically opposed openings  64 . As shown best in  FIG. 5 , each of the side walls  30 ,  32  also includes a semi-circular recess at  68 . A recessed wall  80  is positioned inward of the grooves  50 ,  60  and spans the semicircular recess  68 . The recessed wall  80  includes an integral snap pin at  82  as described herein. Each sidewall  30 ,  32  further comprises an off-center snap pin at  88 , as shown in  FIGS. 4 and 5 . 
     With reference now to  FIGS. 8 and 9 , front housing portion  18  will be described in greater detail. Front housing portion  18  includes a housing shroud portion  100  having a skirt  102  with a plurality of latch members  104  to latchingly retain the front housing portion  18  within central housing portion  12 . Shroud  100  includes a front mating face  106  having a plurality of terminal receiving cavities  108  for latchingly receiving a plurality of electrical terminals as is known in the art. As shown best in  FIG. 8 , front housing portion  18  includes an interior  110  to receive the terminals as described above. 
     With reference now to  FIGS. 10 and 11 , rotary gear  8  includes a disk portion  120  and a pinion portion  122  having an actuation member comprised of a plurality of gear teeth  124 . Gear teeth  124  are radially disposed about a central axis opening  126 . Finally, rotary gear  8  includes a further actuation member in the form of an offset carrier pin  128  provided on the backside of disk portion  120  as will be described herein. 
     With respect now to  FIGS. 12 and 13 , camming slide  10  is shown in greater detail. Camming slide  10  is comprised of a rectangular body portion  130  having an upper edge  132  and a lower edge  134 . Upper edge  132  includes a tongue  136  and an actuation member in the form of a plurality of rack-type teeth  138  which cooperate with pinion teeth  124  as described herein. As shown best in  FIG. 13 , lower edge  134  includes a tongue  140  which cooperates with tongue  136  for translation of the slide as described herein. Lower edge  134  also includes actuation members in the form of camming slots  142 , where each camming slot includes an entry portion  144 , an angled portion at  146  and a lateral end portion  148 . 
     With reference now to  FIG. 14 , lever  6  includes lever arms  160  connected together by way of a lever handle  162 . Each of the lever arms  160  includes an aperture  164 , profiled to be snap-fitted over snap pin  88 , and an actuation member in the form of groove  166  profiled to be received over offset carrier pin  128  as described herein. With the above described elements, the assembly and operation of the connector assembly  2  will be described herein. 
     It should be appreciated that front housing portion  18  and retaining cap  20  can be snapped in place to central housing portion  12 , into the configuration shown in  FIGS. 1 and 2 . The camming slides  10  may now be received in respective slots  40  and  42  such that the camming slots  142  open downwardly and the respective tongues  136 ,  140  ( FIGS. 12 and 13 ) may be received in corresponding grooves  50 ,  60  ( FIGS. 6 and 7 ). This places the camming slides  6  on the inside of sidewalls  30 ,  32  and aligns the rack teeth  138  ( FIG. 12 ) with the circular opening  68  ( FIG. 5 ). The rotary gears  8  may now be positioned on central housing portion  12 , with disk portion  120  residing in the semi-circular recess  68 , with the central axis opening  126  ( FIG. 10 ) positioned over snap pin  82  ( FIGS. 4 and 5 ). The rotary gears  8  are assembled to the central housing portion  12  with the offset carrier pins  128  facing outwardly as best shown in  FIG. 1 . It should be appreciated that the camming slides  10  are mirror images of each other, and that rotary gears  8  are mirror images of each other. 
     Lever  6  may now be assembled to central housing portion  12  such that apertures  164  ( FIG. 14 ) are positioned over snap pins  88  as best shown in  FIG. 1 . Lever  6  is positioned onto pins  88  such that the offset carrier pins  128  are positioned within grooves  166 . Thus as should be appreciated, rotation of lever  6  causes a rotation of rotary gears  8 , which in turn causes meshing between pinion teeth  124  and rack teeth  138  causing a translation of the camming slides  10 . 
     With respect now to  FIG. 15 , it should be appreciated that rotary gears  8 , camming slides  10  and lever  6  are assembled to central housing  12  such that the pre-mated position of lever  6  coincides with the alignment of entry portions  144  of camming slots  142  and openings  64  of central housing portion  12 . The lugs incorporated on a mating connector are shown diagrammatically at  200  as being received through openings  64  and into the camming slots  142 . At this position, lever  6  may be rotated clockwise in the direction of arrow A in  FIG. 16 . This rotation causes lever arms  160  to rotate thereby causing a rotation of rotary gears  8  by way of contact between actuation groove  166  ( FIG. 2 ) and offset carrier pins  128  ( FIG. 2 ). 
     The continued rotation of rotary gears  8  in the direction of arrow A in  FIG. 16 , in turn causes a translation of the camming slides  10  to the left in the direction of arrow B as viewed in  FIG. 16 , camming the lugs upward into camming slots  142 . It should be appreciated to one of ordinary skill in the art that the movement of the lugs  200  into the camming slots  142  causes a drawing together of connector assembly  2  with the mating connector which contains the lugs  200 . It should also be appreciated that rotary gears form a mechanical advantage multiplier intermediate the lever  6  and the camming slides  10 . Continued rotation of the lever  6  in the direction of arrow A to the position of  FIG. 17  causes a full rotation of the rotary gear  8  and a full translation of camming slides  10  to the left as viewed by arrow B, moving the two connector housings into a fully mated position with lugs  200  positioned within the lateral end portions  148  of the camming slots  142 . 
     It should also be appreciated that the latches  70  on central housing portion  12  position latching lugs  72  at diametrically opposed openings  64  as best shown in  FIG. 2 . Thus when the mating connector which includes lugs  200  is positioned into the configuration of  FIG. 15 , the latching lugs  72  would engage with the lugs  200  and momentarily retain the two connectors in position, at least until lever  6  is actuated. Thus, the mating connector having lugs  200  could be inserted into the connector assembly  2  with one hand, and lever  6  could be actuated without requiring two hands to make the final connection. Latching lugs  72  also engage the entry portions  144  of cam slides  10  thereby holding the cam slides  10  in the position shown in  FIG. 15 . 
     The extreme positions of lever  6  are shown in  FIGS. 15 and 17 . In  FIG. 15 , handle  162  of lever  6  is positioned adjacent to retaining cap  20 ; and in  FIG. 17 , handle  162  of lever  6  is positioned adjacent to front mating face  106  of front housing  18 .