Abstract:
A connector has a housing and a TPA member. The housing has a base which includes a first and second sides and a top surface that extends between the sides. The base further includes a channel. The TPA member is operatively associated with the housing and has at least one hinge which extends from the top surface. The at least one hinge has top and bottom portions. The bottom portion is provided proximate to the base and the top portion has a portion thereof cutout to provide a weakened portion of the at least one hinge. The TPA member further includes a rearwardly extending L-shaped feature. Upon a force being applied to the TPA member, the at least one hinge is configured to first rotate about the weakened portion and, thereafter, is configured to rotate about the bottom portion, thereby allowing the L-shaped feature to be inserted into the channel.

Description:
RELATED APPLICATIONS 
       [0001]    This application is a continuation-in-part of U.S. patent application Ser. No. 14/779,169, filed Sep. 22, 2015, which is a national phase application of International Application No. PCT/US14/32345, filed Mar. 31, 2014, which, in turn, claims priority to U.S. Provisional Patent Application Ser. No. 61/806,593, filed Mar. 29, 2013, wherein each of the foregoing applications are incorporated herein by reference in their entireties. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present disclosure relates to field of connectors, more specifically to the field of connectors suitable for use on the end of a wire. 
       DESCRIPTION OF RELATED ART 
       [0003]    Connectors with terminal position assurance (TPA) features are known. In general, a TPA feature helps ensure that a terminal is retained in a housing. Often such TPA features are provided by separate components that must be mated to a housing after the terminals are positioned in the housing. While hinged TPAs have also been provided, existing designs don&#39;t provide the desired set of features that ensure terminals are appropriately retained and positioned with the desired levels of reliability and ease of use. Thus certain individuals would appreciate further improvements in a connector with a TPA member. 
       BRIEF SUMMARY 
       [0004]    A connector is provided that includes a housing with one more discrete insulated channels. Each channel is configured to receive a terminal in a manner that prevents over insertion of the terminal into the channel. A terminal position assurance (TPA) member is hinged to the housing. The TPA member is configured so that it can be translated from an open position to a locked positioned and in the locked position the TPA member is configured to ensure the terminals are appropriately positioned and retained in their respective channels. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0005]    The present disclosure is illustrated by way of example and not limited in the accompanying figures in which like reference numerals indicate similar elements and in which: 
           [0006]      FIG. 1A  illustrates a perspective view a first embodiment of a connector with a TPA member that is hinged to a housing with the TPA in an open position; 
           [0007]      FIG. 1B  illustrates another perspective view of the first embodiment depicted in  FIG. 1A ; 
           [0008]      FIG. 2  illustrates an elevated side view of the first embodiment depicted in  FIG. 1A ; 
           [0009]      FIG. 3  illustrates an enlarged view of the first embodiment depicted in  FIG. 1A ; 
           [0010]      FIG. 4  illustrates a perspective view of the first embodiment of a connector with a hinged TPA with the TPA in a closed position; 
           [0011]      FIG. 5  illustrates an elevated front view of the first embodiment depicted in  FIG. 4 ; 
           [0012]      FIG. 6  illustrates a perspective view of a cross-section taken along line  6 - 6  in  FIG. 4 ; 
           [0013]      FIG. 7A  illustrates a perspective view of an embodiment of a terminal; 
           [0014]      FIG. 7B  illustrates a bottom view of the embodiment depicted in  FIG. 7A ; 
           [0015]      FIG. 8  illustrates a perspective view of a cross-section taken along line  8 - 8  in  FIG. 4 ; 
           [0016]      FIG. 9  illustrates a perspective view of a cross-section taken along line  9 - 9  in  FIG. 4 ; 
           [0017]      FIG. 10  illustrates a perspective view of a simplified embodiment with a terminal and a portion of a housing; and 
           [0018]      FIGS. 11-17  illustrate side views of a second embodiment of a connector where a hinged TPA member is moved from an open position to a closed position, where  FIGS. 11 and 12  illustrate elevated side views,  FIGS. 13-15  illustrate cross-sectional side views, and  FIGS. 16 and 17  illustrate elevated front views. 
       
    
    
     DETAILED DESCRIPTION 
       [0019]    The detailed description that follows describes exemplary embodiments and is not intended to be limited to the expressly disclosed combination(s). Therefore, unless otherwise noted, features disclosed herein may be combined together to form additional combinations that were not otherwise shown for purposes of brevity. 
         [0020]      FIGS. 1A-10  illustrate features of a first embodiment of a connector with a terminal position assurance (TPA) member hinged to the housing. As can be appreciated, the benefit of connecting the TPA directly to the housing is that a single molding operation can be used to provide the housing and the TPA member, thus potentially reducing costs. Thus depicted design can be a one-piece molded design. However, one issue with such designs is that it is more challenging to provide a hinged TPA member that doesn&#39;t just retain but also helps position terminals. Certain TPA members have attempted to provided such a feature but because of the complexity of the TPA member, those TPA member were either not attached to the housing (making the use of the TPA member more challenging as care was needed to ensure it was available when need) or they attached to the housing with just two hinges that were small to help ensure flexibility. 
         [0021]    Applicants have determined that using a hinge that extends substantially a width of the base provides increased control over the position of the TPA member when it is translated into a locking position, helping to prevent misalignment during the translation of the TPA member. This in turn helps ensure the TPA member is properly positioned and has properly engaged each of the terminals. Such a design can also allow for substantial translation of the TPA member (for example, the TPA member can be rotated approximately 180 degrees). 
         [0022]    Thus, as depicted a connector  10  includes a housing  20  with a base  30  that includes one or more channels  25 . An optional and integral latch  22  can be provided as depicted. Each channel  25  extends to a nose  40  that extends from the base  30 . A terminal  80  can be positioned in the channel  25 . The nose  40  can be configured so that there is a gap (e.g., an air channel) between two adjacent noses  40  and the nose includes an interior surface  42  that defines a portion of the channel  25 . The channel  25  has a first width  28   a  in the nose  40  and a second width  28   b  in the base  30 . The base  30  has a first side  31 , a second side  32  and a top surface  33  and includes angled retention flange  36  with a sloped surface  36   a  on both the first and second sides  31 ,  32 . The base includes a wall  37  with an enlarged end  38 . 
         [0023]    A terminal position assurance (TPA) member  50  is supported by the base  30  and is connected to a top surface  33  of the base  30  via a hinge  51  that extends from a first side  31  of the base to a second side  32  of the base. The hinge  51  extends a distance  52  from the top surface  33  and provides sufficient space for the TPA member  50  to rotate more than 90 degrees, preferably about 180 degrees into a secured position. The TPA member  50  has a main wall  59  and includes a rear edge  53  that is configured to press against the base  30  and a pushing flange  55  extends from the main wall past the rear edge  53  a distance  54 , the distance  54  being less than the distance  52 . The pushing flange  55  can be u-shaped to provide additional support and to help securely hold a terminal in position. The TPA member  50  also include locking tab  56  with angled surface  56   a  and when the TPA member  50  is translated to the secured position the locking tab  56  engages angled retention flange  36  and the sloped surface  36   a  and the angled surface  56   a  aid in allowing the TPA member  50  to more easily snap into place. The TPA member  50  includes fingers  58  that are configured to engage enlarged end  38  when the TPA  50  is positioned in the secured position (as depicted in  FIG. 4 ). It should be noted that the fingers  58  (which are provided in pairs) can be curved to more securely engage the enlarged ends  38  and while it has been determined to be beneficial in providing a more robust connector, such curvature is not required or may be used intermittently such that just one or some other number of fingers  58  securely engage the enlarged ends  38  (e.g., the fingers  58  can but do not need to snap over the enlarged ends  38 ). 
         [0024]    As can be appreciated, once the TPA member  50  is in the secured position the hinge  51  is curved. As noted above, the use of a wider hinge  51  was found to provide more of a benefit then expected as it helps provide a more controlled translation of the TPA member  50   
         [0025]    The terminal  80  includes a first side  80   a , a second side  80   b , a top side  80   c  and a bottom side  80   d  and has a contact end  81 , a crimp  82  and an insulator arm  83  to help provide strain relief. It should be noted that the contact end  81  has a contact width  88   a  that is less than a crimp width  88   b  of crimp  82 . In a typical configuration, the crimp  82  will securely engage a conductor and the insulator arm  83  will engage the insulation around the conductor. A projection  84  extends above the top side  80   c  and wings  85  are provided on opposing first and second sides  80   a ,  80   b . It should be noted that while two projections  84  and two wings  85  are disclosed, the use of one of each could be used. The benefit of using both is that there is a more even distribution of force and improved retention of the terminal  80  in the housing  20 . 
         [0026]    In operation, as can be appreciated from  FIG. 8 , the pushing flange  55  engages a projection  84  on the terminal  80  and helps position and secure the terminal  80  in the desired position in the channel  25 . To provide for improved assembly process, a shoulder  44  in the interior surface  42  is provided and is configured to engage the wings  85 .  FIG. 9  illustrates the wings  85  overlapping the interior surface  42  but in practice, the wings  85  will just press against the interior surface  42  and will engage the shoulder  44  if the terminal  80  is attempted to be removed after the terminal is inserted into the channel  25 . As can be appreciated, this helps ensure the terminal  80  doesn&#39;t accidentally fall out before the TPA member  50  is translated into the secure position. To help direct the terminal  80  into the desired orientation, a tapered portion  27  can be provided. The tapered portion  27 , which necks down to a third width  28   c  that is less than the first width  28   a , helps prevent the terminal  80  from being inserted sideways into the channel  25 . 
         [0027]    As can be appreciated from  FIG. 10 , the u-shape pushing flange  55  engages two projections  84  so as to provide a secure retention of the terminals  80 . As noted above, this provides for additional reliability. Thus, the depicted connector provides for improved manufacturing due to offering a one-piece construction while providing a TPA that both helps position and also helps retain terminals in the connector. 
         [0028]      FIGS. 11-17  illustrate features of a second embodiment of a connector  110  with a terminal position assurance (TPA) member  150  hinged to the housing  120 . The connector  110  is preferably identical to the connector  10  of the first embodiment in all instances, except with regard to the configuration/operation of the hinge  51  and, therefore, for brevity purposes, further discussion regarding the structure of the connector  110  will be directed to the configuration of a hinge  151  and the operation of the connector  110  in connection with the hinge  151 . 
         [0029]    As best illustrated in  FIG. 11 , the hinge  151  connects the TPA member  150  to a top surface  133  of the base  130 . The hinge  151  extends a distance  152  between the TPA member  150  and the top surface  133  of the base  130 . The hinge  151  has a top portion  160  and a bottom portion  162 , where the top portion  160  generally comprises half of the distance  152  and the bottom portion  162  also generally comprises half of the distance  152 . A rear side  164  of the top portion  160  of the hinge  151  is generally planar, but has a cutout portion  166 . As the cutout portion  166  is provided in the top portion  160 , the cutout portion  166  is provided more proximate to the TPA member  150  than to the top surface  133  of the base  130 . As illustrated in  FIG. 11 , the cutout portion  166  is preferably crescent-shaped, but it is to be understood that the cut-out portion  166  could have other configurations. 
         [0030]    In operation, the provision of the cutout portion  166  in the top portion  160  of the hinge  151  provides benefits when the TPA member  150  is to be secured to the housing  120 . The top portion  160  of the hinge  151  with the cutout portion  166  allows for the motion of the TPA member  150  to be controlled during actuation. The hinge  151  is the weakest where the cutout portion  166  is provided, such that when force is applied to the TPA member  150 , the TPA member  150  is first forced to rotate around the axis of the cutout portion  166 , as best illustrated in  FIG. 12 . Such rotation about the axis of the cutout portion  166  puts the TPA member  150  in the best position for the remainder of the actuating motion. 
         [0031]    After the top portion  160  of the hinge  151  is rotated the approximately ninety (90) degrees, the continued actuation force causes the bottom portion  162  of the hinge  151 , proximate to the housing  120 , to rotate approximately ninety (90) degrees, as illustrated in  FIG. 13 . 
         [0032]    The unique motion of the top portion  160  of the hinge  151  rotating first followed by the rotation of the bottom portion  162  allows the L-shaped feature (the combination of the pushing flanges  155  and the portion of the main wall  159  which defines the rear edge  153 ) of the TPA member  150  to enter the channel  125  of the housing  120  while not interfering with any terminal  180  or respective wire (not shown) that is positioned within the channel  125 , as best illustrated in  FIGS. 14 and 15 . 
         [0033]      FIG. 15  shows the TPA member  150  rotated a full (approximate) one-hundred eighty (180) degrees and fully seated. The L-shaped feature of the TPA member  150  is thus in its final position directly behind the projections  184  of the terminal  180 , thus preventing the terminal  180  from being pulled or pushed out of the housing  120 . As the L-shaped feature of the TPA member  150  is inside the housing  120 , the L-shaped feature prevents the TPA member  150  from moving upwardly (when viewed as in  FIG. 15 ) which keeps the TPA member from coming loose in the event that the hinge  151  cracks and breaks loose. 
         [0034]    As illustrated in  FIG. 15 , the hinge  151  also takes on a unique, low-profile configuration. When the TPA member  150  is fully seated, the hinge  151  has a forward, generally vertical portion  170 , a rearward, generally vertical portion  172 , and a middle, generally horizontal portion  174 . The middle portion  174  is generally planar and is generally parallel to the top surface  133  (which is also generally planar) of the base  130 , such that a gap  176  is provided between the hinge  151 , the top surface  133  of the base  130 , and the TPA member  150 , where the gap  176  is generally rectangular in cross-section or in configuration when viewed from the side, as in  FIG. 15 . This configuration of the hinge  151  results in a unique, low-profile configuration of the hinge  51  as compared to other known hinged TPA members, including the hinge  51  of the first embodiment which, when the TPA member  50  is fully seated, creates a rounded or U-shaped hinge with a resultant rounded or U-shaped gap. In each case where the hinge  151  would have the same height as the hinge  51 , the connector  110  using the hinge  151  would provide for a valuable low-profile configuration as compared to the connector  10  using the hinge  51 . 
         [0035]    Thus, because of the provision of the cutout portion  166 , the TPA member  150  rotates approximately one-hundred eighty (180) degrees, but the top portion  160  of the hinge  151  is designed to rotate approximately ninety (90) degrees first, followed by an approximately ninety (90) degree rotation of the bottom portion  162  in one sequential motion. As such, the hinge  151 , in essence, only rotates approximately ninety (90) degrees, but such rotation, in essence, yields one-hundred eighty (180) degrees of motion for the TPA member  150 , which allows the L-shaped feature of the TPA member  150  to hook into position inside the housing  120 . 
         [0036]    It is to be understood that the hinge  151  of the connector  110  could be comprised of a single hinge, including one which substantially extends from the first side  131  of the housing  120  to the second side  132  of the housing  120 , as generally illustrated in  FIGS. 11-15 , or could be comprised of a plurality of hinges  151 , where adjacent hinges  151  are separated from one another by a gap  178 , as generally illustrated in  FIGS. 16 and 17 . When the connector  110  includes two hinges  151 , in order to provide proper stability, one of the hinges  151  is preferably provided proximate to the first side  131  of the housing  120  and the other one of the hinges  151  is preferably provided proximate to the second side  132  of the housing  120 , as illustrated in  FIG. 16 . When the connector  110  includes three hinges  151 , in order to provide proper stability, one of the hinges  151  is preferably provided proximate to the first side  131  of the housing  120 , another one of the hinges  151  is preferably provided proximate to the second side  132  of the housing  120 , and the last hinge  151  is preferably provided generally equidistant between the first and second sides  131 ,  132  of the housing  120 . 
         [0037]    The disclosure provided herein describes features in terms of preferred and exemplary embodiments thereof. Numerous other embodiments, modifications and variations within the scope and spirit of the appended claims will occur to persons of ordinary skill in the art from a review of this disclosure.