Abstract:
An electrical connector includes a first housing having a first set of electrical contacts and a second housing having a second set of electrical contacts. The first and second housing are configured to be matable with one another to mate the first set of contacts with the second set of contacts. The first and second housings are movable between an initial position wherein the first and second sets of electrical contacts are unmated and a final position wherein the respective first and second sets of electrical contacts are fully mated. A lever member is rotatably mounted to the first housing and configured to engage the second housing when rotated. The lever member is configured to move the first and second housings between the initial and final positions as the lever member is rotated when the lever and the second housing are initially aligned. The lever member includes at least one blocking beam configured to separate the first and second housings as the lever member is rotated when the lever member and the second housing are initially misaligned.

Description:
BACKGROUND OF THE INVENTION 
     The invention relates generally to electrical connectors and, more particularly, to a lever assist connector with a flexible blocking feature. 
     In certain applications, electronic components require the mating of several electrical contacts, such as in automotive electrical components. The electronic component includes a connector housing that holds several electrical contacts, while a mating connector housing holds an equal number of electrical contacts. One connector housing includes male electrical contacts, while the other connector housing includes female electrical contacts. As the number of electrical contacts to be mated increases, it becomes difficult to fully join the mating connector housings because of friction between the mating electrical contacts. The connector housings are formed with a mate assist assembly that includes a lever-and-gear system to pull together the connector housings in order to overcome the frictional resistance created by the mating electrical contacts. 
     One connector with a mate assist assembly is described in U.S. Pat. No. 6,558,176. The connector includes first and second connector housings having electrical contacts, and a lever member for mating the housings together. The first connector housing is configured to be positioned inside the second connector housing. The lever includes a handle and two arms extending therefrom that may be rotated alongside side walls of the first connector housing. The lever is placed in an initial or pre-latched position and the first connector housing and second connector housing are engaged sufficiently for the gear teeth to engage, after which the lever is rotated to complete the mating operation. 
     Although it is intended that final mating of the contacts be accomplished by rotation of the lever, it is possible to put the connector housings together with the lever in other than the initial position and apply enough force to establish at least partial electrical contact. The connector could later separate in service. Thus, a need exists for a mate assist assembly that prevents electrical engagement when the connector housings are not latched in the fully mated position. 
     BRIEF DESCRIPTION OF THE INVENTION 
     In one embodiment of the invention, an electrical connector includes a first housing having a first set of electrical contacts and a second housing having a second set of electrical contacts. The first and second housing are configured to be matable with one another to mate the first set of contacts with the second set of contacts. The first and second housings are movable between an initial position wherein the first and second sets of electrical contacts are unmated and a final position wherein the respective first and second sets of electrical contacts are fully mated. A lever member is rotatably mounted to the first housing and configured to engage the second housing when rotated. The lever member is configured to move the first and second housings between the initial and final positions as the lever member is rotated when the lever and the second housing are initially aligned. The lever member includes at least one blocking beam configured to separate the first and second housings as the lever member is rotated when the lever member and the second housing are initially misaligned. 
     Optionally, the blocking beam is configured to engage a mating post within the second housing and to flex to allow the first and second housings to move from the initial position to the final position when the lever member is aligned so that a first gear surface on the lever member engages the mating post. 
     In another embodiment of the invention, an electrical connector includes a first housing that has a first set of electrical contacts, and a lever member rotatably mounted thereto that includes at least one blocking beam. A second housing having a second set of electrical contacts is configured for mating engagement with the first housing. The second housing has a mating post located therein for engagement with the lever member. The mating post includes a first engagement surface and a second engagement surface. The lever member mates the first and second sets of contacts as the lever member is rotated when the lever member engages the first engagement surface of the mating post. The blocking beam prevents mating of the first and second contacts as the lever is rotated when the lever engages the second engagement surface. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 illustrates a top perspective view of a mate assist connector assembly formed in accordance with an exemplary embodiment of the present invention. 
     FIG. 2 illustrates an exploded view of the mate assist connector assembly of FIG.  1 . 
     FIG. 3 illustrates a perspective view of the bottom portion of the harness connector of the mate assist connector assembly of FIGS. 1 and 2. 
     FIG. 4 illustrates a perspective view of an exemplary lever member according to an embodiment of the present invention. 
     FIG. 5 is a partial side view of a lever member illustrating a contact base and a blocking beam formed according to an alternative embodiment of the present invention. 
     FIG. 6 illustrates a perspective view of the module connector of the mate assist connector assembly of FIGS. 1 and 2. 
     FIG. 7 is a cross-sectional view of the mate assist connector assembly of FIG. 1, taken along line  6 — 6 , illustrating the connector assembly in a mating stage. 
     FIG. 8 is a cross-sectional view of the mate assist connector assembly of FIG. 1, taken along line  6 — 6 , illustrating the connector assembly in the final position. 
     FIG. 9 is a cross-sectional view of the mate assist connector assembly of FIG. 1, taken along line  6 — 6 , illustrating the connector assembly with the lever member improperly positioned for mating. 
     FIG. 10 is a cross-sectional view of the mate assist connector assembly of FIG. 1, taken along line  6 — 6 , illustrating the connector assembly with the blocking feature inhibiting electrical engagement. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     FIG. 1 illustrates a top perspective view of an exemplary mate assist connector assembly  10  including a flexible blocking feature according to an embodiment of the present invention. The mate assist connector assembly  10  includes a harness connector  18  having a bottom portion  16  and a top portion  20 . The bottom portion  16  is configured to receive packets that hold groups of electrical contacts while the top portion  20  covers the electrical contacts. A module connector  22  holds electrical contacts configured to mate with the electrical contacts in the harness connector  18 . As illustrated in FIG. 1, the harness connector  18  is partially inserted within the module connector  22  to an initial staging position. 
     A lever member  14  is retained on the exterior of the harness connector  18  and engages the module connector  22 . The lever member  14  is rotatable in the direction of arrow A from the initial staging position (FIG. 1) to a final position (FIG.  7 ). As the lever member  14  is rotated, it pushes the harness connector  18  downward in the direction of arrow B into the module connector  22  and fully mates the electrical contacts of the harness connector  18  and the module connector  22  with each other. If the lever member  14  is not properly positioned at the initial position, a blocking beam  28  on the lever member  14  engages the module connector  22  in a manner to move the harness connector  18  and the module connector  22  apart to inhibit the mating process. Thus, the blocking feature facilitates blocking the harness connector  18  and module connector  22  from mating to the point of electrical contact if the lever member  14  is not properly positioned at the initial staging position. 
     FIG. 2 illustrates an exploded view of the mate assist connector assembly  10  of FIG.  1 . The lever member  14  includes cam arms  26  that rotate about pivot posts  30  extending outward from the harness connector  18  along a rotational axis  36 . The lever member  14  is oriented in an unmated position with lever arms  58  aligned generally parallel to a vertical axis  24 . The module connector  22  includes large alignment posts  38  and a small alignment post  42  formed in the center of the module connector  22 . The module connector  22  also includes mating posts  46  facing each other and located alongside side walls  146 . Release posts  50  (only one of which is shown) are positioned between the mating posts  46 . 
     The top portion  20  and the bottom portion  16  of the harness connector  18  are fastened together by retention latches  56  extending from the top portion  20  and engaging latch catches  74  extending from side walls  60  of the bottom portion  16 . The harness connector  18  and the lever member  14  are removably inserted downward in the direction of arrow C into the module connector  22  to the initial staging position shown in FIG.  1 . When the harness connector  18  is in the initial staging position, each cam arm  26  is positioned between a pair of opposing mating posts  46  and above a pair of release posts  50 , and the harness connector  18  slidably receives the alignment posts  38  and  42  within alignment recesses (not shown) located inside the harness connector  18 . 
     FIG. 3 illustrates a perspective view of the bottom portion  16  of the harness connector  18  of FIGS. 1 and 2. The bottom portion  16  is box shaped and includes opposing side walls  60  and opposing end walls  62 . A perimeter around the exterior of the bottom portion  16  is smaller than an interior perimeter of the module connector  22  of FIGS. 1 and 2, in order that the harness connector  18  may be positioned within the module connector  22 . 
     Securing rails  66  and  67  extend outward from opposite ends of the side walls  60 . Double securing rails  67  are located on opposite sides at one end of the bottom portion  16  and a single securing rail  66  is located on opposite sides of an opposite end of the bottom portion  16 . The securing rails  66  and  67  are slidably received by cavities  100  (FIG. 5) within the module connector  22  so that the bottom portion  16  does not slide transversely to the securing rails  66  and  67  within the module connector  22 . The pivot posts  30  extend outward from the centers of recessed portions  70  of the side walls  60 . Each cam arm  26  (FIG. 2) encloses and rotates about a pivot post  30  along a recessed portion  70 . When the harness connector  18  is positioned within the module connector  22 , the cam arms  26  are rotatable within a chamber defined by the recessed portion  70  and the module connector  22 . The side walls  60  also include the triangular latch catches  74  that engage the retention latches  56  formed with the top portion  20 . 
     Short securing rails  68  extend outward from the end walls  62  proximate opposite corners of the end walls  62 . The short securing rails  68  are slidably received within the module connector  22  and engage end walls  150  (FIG. 5) of the module connector  22 . Each end wall  62  also includes a retention wedge  78  located between two diamond shaped retention beams  82 . The retention wedges  78  are received by retention channels  86  (FIG. 5) in the module connector  22  and engage wedge catches  90  (FIG. 5) positioned within the retention channels  86 . The retention beams  82  engage an alignment plate (not shown) positioned within the module connector  22  (shown in FIG.  1 ). As the bottom portion  16  is inserted into the module connector  22 , the retention wedges  78  and retention beams  82  slide past the wedge catches  90  and beam catches  94 , respectively, so that the bottom portion  16  is retained within the module connector  22 . 
     The bottom portion  16  includes several connector pockets  98  of varying shapes and sizes formed with walls  99  extending from the side and end walls  60  and  62 . The connector pockets  98  extend throughout the harness connector  16  from an open top section  102  to an open bottom section  106 . The connector pockets  98  hold the electrical contacts that are mated with the electrical contacts contained within the module connector  22 . Centered within the bottom portion  16  between sets of connector packets  98  is a small alignment recess  96  situated between large alignment recesses  92 . The small and large alignment recesses  96  and  92  extend through the harness connector  16  and receive and enclose the small and large alignment posts  42  and  38  (FIG. 2) mounted in the module connector  22  when the harness connector  18  is positioned within the module connector  22 . 
     FIG. 4 illustrates a perspective view of the lever member  14  in more detail. A handle  110  is formed integral with, and extends perpendicularly between, the lever arms  58 , which are in turn formed with the cam arms  26 . Circular contact bases  114  extend along the insides of the cam arms  26 , and retention apertures  118  extend through the cam arms  26  and contact bases  114 . The lever member  14  is attached to the harness connector  18  by deflecting the lever arms  58  outward away from each other so that the contact bases  114  slide along the pivot posts  30  (FIG. 2) until the pivot posts  30  are enclosed within the retention apertures  118 . The lever member  14  is then rotatable about the rotational axis  36  (FIG. 2) with the contact bases  114  slidably engaging the recessed portions  70  (FIG. 3) of the harness connector  18 . The handle  110  includes two grip surfaces  122  that an operator may use to rotate the lever member  14 . 
     Each contact base  114  includes one of the blocking beams  28 . In one embodiment, the blocking beams  28  are integrally formed in the contact base  114 . Each blocking beam  28  has a free end  29  that includes a heel portion  31  and a bevel  33  proximate the heel portion  31 . The blocking beams  28  are deflectable in the direction of arrow K during the mating process to allow fill engagement of the harness connector  18  and the module connector  22  when the lever member  14  is properly oriented at the initial staging position as will be described. 
     Each cam arm  26  includes a first notch  126  adjacent a second notch  130  along a gear tooth  132  formed in the peripheral surface of the cam arm  26 . The first notch  126  includes a first ungearing surface  134  located across from a gearing surface  138  on the gear tooth  132 . When the lever member  14  is rotated to move the mate assist connector assembly  10  from the initial staging position to the final position (as shown in FIG.  8 ), the gearing surfaces  138  engage the mating posts  46  (FIG. 2) as described below. Alternatively, when the lever member  14  is rotated to move the mate assist connector assembly  10  from the final position to the initial staging position, the first ungearing surfaces  134  engage the mating posts  46  as described below. 
     The second notch  130  of each cam arm  26  is partially defined by a second ungearing surface  142 . When the lever member  14  is rotated to move the mate assist connector assembly  10  from the final position to the initial staging position, the second ungearing surfaces  142  engage the release posts  50  (FIG. 2) situated alongside the mating posts  46 . 
     FIG. 5 is a partial side view of a lever member illustrating a contact base  214  and a blocking beam  228  formed according to an alternative embodiment of the present invention. With the exception of the contact base  214  and the blocking beam  228 , the features shown are identical to the corresponding feature of FIG.  4  and are numbered correspondingly. 
     The blocking beam  228  is formed integrally with the contact base  214 . The blocking beam  228  is deflectable in the direction of arrow K′ into a slot  235  formed in the contact base  214 . The blocking beam  228  has a heel portion  231  and a bevel  233  proximate the heel portion  231 . The blocking beam  228  is deflectable in the direction of the arrow K′ during the mating process when the lever member  14  (see FIG. 4) is properly oriented at the initial staging position as described above. 
     FIG. 6 illustrates an isometric view of the module connector  22 . The two side walls  146  are formed integral with, and are aligned perpendicular to, the end walls  150 . The side and end walls  146  and  150  are formed integral with, and extend from, a base  154 , which has a larger perimeter than a perimeter about the side and end walls  146  and  150 . The base  154  is mounted to an electronic component (not shown), such as a radio, with the side and end walls  146  and  150  extending outward from the electronic component. Several contact slots  158  of varying sizes and shapes extend through the base  154 . The electrical contacts positioned within the module connector  22  are connected to the electronic component through the contact slots  158 . The large alignment posts  38  and small alignment post  42  extend upward from the center of the base  154 . 
     The side walls  146  each include rail chambers  162  along the exteriors of the side walls  146  that define cavities  100  along the interiors of the side walls  146 . The rail chambers  162  are appropriately situated along each side wall  146  so that when the harness connector  18  is positioned within the module connector  22 , the cavities  100  receive corresponding securing rails  66  and  67  situated on the side walls  60  of the harness connector  18  (FIG.  4 ). Thus the rail chambers  162  retain the securing rails  66  and  67  and guide the harness connector  18  into the module connector  22  in the proper orientation. 
     The mating posts  46  and the release posts  50  extend inward from the side walls  146  along the base  154 . Two mating posts  46  extending from one side wall  146  face each other and are oriented opposite two mating posts  46  extending from the other side wall  146 . Similarly, two release posts  50  extend from one side wall  146  between the mating posts  46  oriented opposite two release posts  50  extending from the other side wall  146 . Each side wall  146  includes mating posts  46  and release posts  50  so that the lever member  14  and the top portion  20  (FIG. 2) of the harness connector  18  may be connected to the bottom portion  16  in either one of two orientations with each cam arm  26  still engaging a mating post  46  and a release post  50  when the harness connector  18  is inside the module connector  22 . 
     The mating posts  46  are rectangular in shape and include flat top surfaces  166 . A wedge shaped tooth  170  extends from an inside wall  174  of each mating post  46  proximate the top surface  166 . The tooth  170  includes a top portion or first engagement surface  178  that extends downward at an acute angle from the top surface  166  to a bottom portion or second engagement surface  182  that extends upward from, and at an obtuse angle to, the inside wall  174 . The top surfaces  166  include a stop edge  168  interiorly and adjacent each tooth  170 . In operation, when the cam arms  26  (FIG. 4) are rotated to move the mate assist connector assembly  10  from the initial staging position to the final position, the gearing surfaces  138  (FIG. 4) engage, and are resisted by, the bottom portions  182 , pulling the cam arms  26  downward in the direction of arrow E. The heel portion  31  of the blocking beam  28  engages the stop edge  168  of the mating post  46 , and if the lever  14  is properly positioned, the bevel  33  on the blocking beam  28  induces the blocking beam  28  to flex sufficiently to allow the mate assist connector assembly  10  to move to the final position. When the cam arms  26  are rotated to move the mate assist connector assembly  10  from the final position to the initial staging position, the first ungearing surfaces  134  (FIG. 4) engage, and are resisted by, the top portions  178 , pushing the cam arms  26  upward in the direction of arrow G. 
     The release posts  50  are rectangular in shape and include flat top surfaces  186  that slope downward in the direction of the other release post  50  along the same side wall  146 . In operation, when the cam arms  26  are rotated to move the mate assist connector assembly  10  from the final position to the initial staging position, the second ungearing surfaces  142  (FIG. 4) engage, and are resisted by, the top surfaces  186 , pushing the cam arms  26  upward in the direction of arrow G. 
     Each end wall  150  includes two guide walls  190  that extend inwardly and perpendicularly from the end wall  150  parallel to each other. The two guide walls  190  and the end wall  150  define the retention channel  86  that receives a retention wedge  78  (FIG.  3 ). The beam catches  94  extend inward from the end walls  150  alongside the guide walls  190 . The wedge catches  90  are located between the guide walls  190  within the retention channels  86  so that the retention wedges  78  slide downward past, and are retained under, the wedge catches  90  as the harness connector  18  is inserted downward into the module connector  22 . 
     With reference to FIGS. 7 through 9, the operation of the blocking feature will be described in detail. The blocking feature facilitates blocking the harness connector  18  and the module connector  22  from mating to the point of electrical contact when the lever member  14  is not positioned at the initial stage to facilitate proper engagement of the gearing surfaces  138  and  182 . 
     FIG. 7 is a cross-sectional view of the mate assist connector assembly of FIG. 1, taken along line  6 — 6 , illustrating the connector assembly in a mating stage with the gearing surface  138  engaging the bottom portion  182  of the tooth  170 . The harness connector  18  is partially drawn into the module connector  22 . From this condition, proper mating will occur. The bevel  33  at the heel portion  31  of the blocking beam  28  is engaged with the stop edge  168  of the mating post  46 . With continued rotation of the lever member  14  in the direction of arrow J, the bevel  33  induces the blocking beam  28  to deflect inwardly in the direction of arrow K, sliding off the stop edge  168  and allowing the mating process to continue. As the lever member is rotated, the gearing action between the gearing surface  138  and the bottom portion  182  of the tooth  170  urges the harness connector  18  downward in the direction of arrow E and into the module connector  22 . 
     FIG. 8 is a cross-sectional view of the mate assist connector assembly of FIG. 1, taken along line  6 — 6 , illustrating the connector assembly  10  fully mated in the final seated position. The harness connector  18  is fully seated within the module connector  22  and electrical engagement between the connectors  18  and  22  is established. 
     FIG. 9 is a cross-sectional view of the mate assist connector assembly  10  of FIG. 1, taken along line  6 — 6 , illustrating the connector assembly with the lever member improperly positioned for mating. As shown, the harness connector  18  has been inserted into the module connector  22 . However, the lever member  14  was not sufficiently vertical at the start of the operation. As a result, the gear tooth  132  along with ungearing surface  142  are engaged with the top portion  178  of the tooth  170  on the mating post  46 . In addition, the heel portion  31  of the blocking beam  28  is engaged with the stop edge  168  of the post top surface  166 . In this position, the blocking beam is not induced to flex, rather, the blocking beam is an impediment to further seating of the connectors  18  and  22 . Upon further rotation of the lever member  14  in the direction of arrow J, the heel portion  31  of the blocking beam  28  is forced against the top surface  166  of the mating post  46  so that the lever member  14  pivots about the heel portion  31  of the blocking beam  28  lifting the harness connector  18  upward in the direction of arrow G, away from the module connector  22 . 
     FIG. 10 illustrates a cutaway side view of the mate assist connector assembly  10  of FIG. 1 with the blocking feature inhibiting electrical engagement. From FIG. 9, continued rotation of the lever member  14  in the direction of arrow J results in the condition shown in FIG.  10 . Since the lever member  14  was not properly positioned at the initial stage, gearing surface  138  is not engaged with bottom portion  182  of tooth  170  such that the rotation of the lever member  14  could&#39;not achieve final mating of the harness connector  18  with the module connector  22 . Rather, the heel portion  31  of the blocking beam  28  is impacted against the top surface  166  of the mating post  46  which results in the harness connector  18  being pulled in the direction of arrow G, away from the module connector  22  with rotation of the lever member  14  in the direction of arrow J. This provides a visual and tactile indication to a technician that the connectors  18  and  22  are not properly mated, and also inhibits electrical engagement between the connectors  18  and  22 . 
     The embodiments thus described provide a mate assist connector assembly with a flexible blocking feature that provides both a visual and tactile indication when the connectors are not properly mated by urging the connectors apart instead of drawing the connectors together as the lever member is rotated. The assembly also facilitates inhibiting electrical engagement between the connectors when proper mating is not achieved, thus reducing the potential for in-service failures due to improper mating of the connectors. 
     While the invention has been described in terms of various specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the claims.