Abstract:
An electrical housing assembly is provided having a connector with an outer enclosure and a mating opening. The assembly further includes a header having a mating portion to engage the mating opening of the connector. A latch assist member is mounted to one of the header and connector and is movable between open and closed positions relative to the outer enclosure. The latch assist member includes passage ways receiving slide assist members that are mounted on the other of the header and connector. The passage ways and slide assist members cooperate to forcibly draw the header and connector into a fully mated position when the latch assist member moves to the closed position relative to the outer enclosure. A connector position assurance device (CPA) is slidably mounted to one of the connector and header and movable between locked and unlocked positions. The CPA secures the latch assist member in the closed position when the CPA is moved to its locked position.

Description:
BACKGROUND OF THE INVENTION 
     The preferred embodiments of the present invention generally relate to a connector assembly with an engagement assist member that facilitates connection of a header and plug housing with one another while operating in combination with a connector position assurance device. 
     In the past, connector assemblies have been proposed having headers connectable to plug housings that are used to interconnect a plurality of male and female electrical contacts. In many applications, the header and plug may appear connected with one another, but yet in fact may not be fully engaged. Thus, features have been added to connectors that help to ensure that the header and plug housing (and thus the contacts) are fully engaged with one another. One feature added to connectors is a connector position assurance device (CPA) which has been combined with connector assemblies in a manner that requires the header and plug to be fully engaged before the CPA device may be moved to its closed position. CPAs enable visual inspection of a connector assembly to confirm that a header and plug are fully engaged with one another. 
     With improvements in technology and the miniaturization of components, header and plug combinations are being formed with an increasing larger number of contacts arranged in a relatively small cross-sectional area of the connector assembly. Male and female contacts frictionally engage one another, and thus require a certain amount of force to be connected. As the number of contacts increases in a given cross-sectional area, the force needed to join the header and plug increases. In addition, the overall size of connector assemblies continues to be reduced. Consequently, it has become more difficult to fully join headers and plugs given the increased engaging forces that must be applied to smaller and smaller components. 
     A need exists for a self-contained connector assembly offering a user assistance in moving the header and plug to the final engaged position even when substantial mating forces may be needed while retaining the features afforded by a CPA. 
     BRIEF SUMMARY OF THE INVENTION 
     A preferred embodiment of the present invention is provided with an electrical connector housing assembly comprising a connector housing, a header, a latch assist member and a connector position assurance device (CPA). The connector housing includes an outer enclosure and a mating opening. The header includes a mating portion that engages the mating opening on the connector housing. The latch assist member is mounted to one of the header and the connector housing and is moveable between open and closed positions relative to the outer enclosure. The latch assist member passage ways receive slide assist members on the other of the header and connector. The passage ways and slide assist members cooperate to forcibly draw the header and connector into a fully mated position when the latch assist member moves to the closed position relative to the outer enclosure. The CPA is slidably mounted to one of the connector and header and is moveable between locked and unlocked positions. The CPA secures the latch assist member in its closed position when the CPA is moved to its locked position. 
     In accordance with at least one alternative embodiment, the latch assist member includes upper and lower beams connected to one another through a cross bar located proximate one end of the upper and lower beams. The upper and lower beams slidably engage the connector and header. The latch assist member may optionally include one arm containing a slot cut therein. The header may include at least one post on a parameter thereof. The slot may receive the post when the header is inserted into the connector. 
     In accordance with at least one alternative embodiment, the latch assist member includes a channel formed in an interior surface of one side thereof. The channel extends backward from a leading edge of the latch assist member at an acute angle to a front edge of the latch assist member. The header may include a slide mating member received in the channel and drawn rearward by the slide mate assist connector during the mating operation. The latch assist member may include means for engaging the header and means for pulling the header into the connector housing. Optionally, the latch assist member may include a pair of slide arms extending parallel to one another, at least one of which includes a latch beam projecting outward from a periphery of the slide arm. The latch beam engages the connector to hold the latch assist member open until the connector and header are moved to a pre-mated position. Optionally, the latch assist member may include a latch beam engaging a projection on the connector to prevent the latch assist member from prematurely closing. The header may include a boss member projecting outward therefrom and aligned to contact and deflect the latch beam in order to disengage the latch beam from the projection. 
     In accordance with at least one alternative embodiment, the connector may include a slide retention projection engaging the latch assist member to hold the latch assist member in a pre-mated position on the connector. In accordance with at least one alternative embodiment, a method is provided for electrically connecting a plug and header through use of a lever assist member. The plug and header have contact mating faces that move in a direction orthogonal to the contact mating faces until abutting against one another when the plug and header are moved to a fully mated position. According to the method, the lever assist member is located in a pre-staged position with respect to the plug. The plug and header are then inserted into one another to an initial pre-mated position. When the plug and header are inserted to the pre-mated position, drive elements on the header and lever assist member are aligned with one another. The lever assist member is then pushed from the pre-stated position to a final closed position such that the drive elements draw the contact mating faces into abutment with one another when the lever assist lever moves to the final closed position. 
     In accordance with at least one alternative embodiment, once the lever assist member is moved to the final closed position, a connector position assurance device (CPA) is moved to the closed position. During the pushing step the lever assist member is moved in a direction substantially parallel to the contact mating faces. Optionally, during the pushing step, the lever assist member is moved in a direction other than the direction orthogonal to the contact mating faces in order to cause the drive elements to pull the plug and header toward one another along the orthogonal position. As a further alternative, a blocking step may be performed during the method, whereby movement of the lever assist member is blocked to prevent movement from the pre-staged position until the header and plug are inserted into the initial pre-mated position. Optionally, the method may include locking the lever assist member in the pre-staged position and unlocking the lever assist member when the plug and header are initially joined. Alternatively, the CPA may be blocked in the preset position until the header and connector are fully mated. Movement of the CPA from the preset position may be blocked by adding a feature on the header that engages the CPA until the header and connector are fully mated. Alternatively, the CPA may be blocked in the preset position by the slide which prevents the CPA from moving to the locked position until the slide is fully closed. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The foregoing summary, as well as the following detailed description of the preferred embodiments of the invention, will be better understood when read in conjunction with the appended drawings. For the purpose of illustrating the present invention, there is shown in the drawings, embodiments that are presently preferred. It should be understood, however, that the present invention is not limited to the precise arrangements and instrumentality shown in the attached drawings. 
     FIG. 1 illustrates and exploded view of a connector assembly formed in accordance with a preferred embodiment of the present invention. 
     FIG. 2 illustrates an isometric view of a cover formed in accordance with a preferred embodiment of the present invention. 
     FIG. 3 illustrates an isometric view of a connector position assurance device formed in accordance with a preferred embodiment of the present invention. 
     FIG. 4 illustrates an isometric view of a connector mating assist member formed in accordance with a preferred embodiment of the present invention. 
     FIG. 5 illustrates the top plan view of the connector assembly while in a premated position in accordance with a preferred embodiment of the present invention. 
     FIG. 6 illustrates an end portion of a connector mating assist member operating in accordance with a preferred embodiment of the present invention. 
     FIG. 7 illustrates a top plan view of a cover, CPA and connector mating assist member located in a pre-mated position in accordance with a preferred embodiment the present invention. 
     FIG. 8 illustrates a cover, CPA and connector mating assist member located in a fully engaged position formed in accordance with a preferred embodiment of the present invention 
     FIG. 9 illustrates a cross-sectional view taken along line  9 — 9  in FIG. 7 in accordance with a preferred embodiment of the present invention. 
     FIG. 10 illustrates a cross-sectional view taken along line  10 — 10  in FIG. 8 in accordance with a preferred embodiment of the present invention. 
     FIG. 11 illustrates a top plan view of a connector assembly formed in accordance with a preferred embodiment of the present invention with the connector mate assist member in the fully engaged position. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     FIG. 1 illustrates an exploded view of a connector assembly  10 . The connector assembly  10  includes a header  12 , a plug assembly  14 , a cover  16 , a wire shield  18 , a sliding latch  20  and a connector position assurance device (CPA)  22 . The plug assembly  14  includes a plug housing  24 , a peripheral seal  26 , a terminal position assurance device (TPA)  28 , and a or wire seal  30 . The plug housing  24  is divided into front and rear portions  32  and  34 , respectively, with a dividing ledge  36  formed therebetween and extending about a perimeter of the plug housing  24 . The dividing ledge  36  receives and frictionally retains the peripheral seal  26 . The front portion  32  of the plug housing  24  includes notched regions  38  located on opposite ends thereof. Each notched region  38  includes a latching beam  40  having one end formed integral with the plug housing  24  and the opposite end extending toward a front face  42  of the plug housing  24 . Each latching beam  40  includes a lateral rib  41  extending along the outer end thereof. The latching beams  40  are deflectable toward the base of the notched regions  38 . The front face  42  includes a cavity that holds a matrix of female contact terminals  44 . The contact terminals  44 , in the example of FIG. 1, are aligned in two rows, with each row including  30  connector terminals  44 . 
     The peripheral seal  26  includes a smooth inner surface  46  and a ribbed outer surface  48 . The TPA  28  includes a front face  50 , top and bottom surfaces  51  and  52 , and end walls  54 . The front face  50  includes a plurality of contact channels  53  aligned in a matrix. At least one of the top and bottom surfaces  51  and  52 , and/or the end walls  54  include notches  56  extending from the front face  50  in a direction substantially perpendicular to the front face  50 . In the example of FIG. 1, the TPA top surface  51  includes two rectangular cutouts  58 . The notches  56  and cutouts  58  cooperate with corresponding features located on the interior of the header  12  to ensure proper alignment and functional coordination between the TPA  28  and header  12 . 
     The header  12  is divided into front and rear portions  60  and  62 , respectively, divided by a peripheral plate  64 . The header rear portion  62  includes top and bottom surfaces  66  and  68  and end walls  70 . The end walls  70  include projections  72  having ramped front and rear surfaces  74  and  76 , respectively. The end walls  70  further include two knuckles  78  that function to ensure proper orientation of the header  12  in the cover  16 . The top surface  66  includes at least one boss  80  extending upward therefrom. Optionally, the bottom surface  68  may also include one or more bosses  80 . As explained below in more detail, the bosses  80  are actively engaged by the sliding latch  20  to draw the header  12  and plug housing  24  into firm engagement with one another thereby overcoming any mating forces created between the contacts and contact receptacles and sealing forces (if present). The header  12  includes a header front face  82  having a matrix of pin openings  84  therein. A pair of brackets  86  are mounted to the front face  82 . The brackets  86  include pins  88  extending downward therefrom for engagement with a connector support structure (not shown). A pin organize may be located between brackets  86  to hold pins (not shown). 
     The rear portion  34  of the plug housing  24  includes top and bottom surfaces  90  and  92 , respectively, and end walls  94 . Both end walls  94  include a projection  96  are latches to secure the plug housing  24  to the cover  16 . The top surface  90  include a plurality of ribs  98  having latching ramps  100  formed on the rear ends thereof. The latching ramps  100  securely retain the cover  16  to the plug assembly  14 . The ribs  98  ensure proper orientation of the cover  16 . The rear portion  34  of the plug housing  24  includes a cavity that sealably receives the mating seal  30 . The outer perimeter of the mating seal  30  includes peripheral ribs  102  that form a seal with the interior of the rear portion  34 . The mating seal  30  includes a matrix of contact openings  104  therein. The contact openings  104 , contact terminals  44 , contact channels  53 , and pin openings  84  align with one another and cooperate to securely retain contacts and terminals therein. 
     The cover  16  includes top and bottom walls  106  and  108 , respectively, and end walls  110  and  112 . The end wall  112  include slots  114  that receive the sliding latch  20 . A front edge  116  of the cover  16  includes a plurality of flanges  118  formed thereon. The flanges  118  extend upward from the front edge  116  of the bottom wall  108 , and downward from the front edge  116  of the top wall  106 . The flanges  118  are also formed along the rear edge  120  of the cover  16 . The flanges  118  on the front and rear edges  116  and  120  define upper and lower channels that receive the sliding latch  20 . The flanges  118  are spaced from one another to define notches  122  therebetween. The notches  122  have different shapes and some are aligned to receive corresponding features. The end wall  112  of the cover  16  includes a CPA retention assembly  124  located between the slots  114 . 
     As shown more clearly in FIG. 2, the end wall  112  includes brackets  126  formed thereon proximate the slots  114 . The brackets  126  include outer surfaces  128  that are aligned with the slots  114  to assist in alignment of the sliding latch  20  with the cover  16 . The brackets  126  include inwardly extending beams  130  that are slidably received by the CPA  22 . The beams  130  only extend approximately half-way inward from the rear edge  120  of the cover  16  to the center of the end wall  112 . The beams  130  retain the CPA  22  while in its initial pre-staged position. The end wall  112  includes a notch  132  centered therein and extending rearward from the front edge  116 . The notch  132  receives the projections  72  on the header  12  which disengages the CPA  22  and allows it to move from the preset to the final position to lock the slide  20  closed thus keeping the connections mated. Ribs  134  are formed along either side of the notch  132  and aligned to extend in the same direction as notch  132 . The ribs  134  are connected by a cross bar  135  and include projections  136  on the outer surface thereof and located near the rear ends of the ribs  134 . The projections  136  engage a CPA  22  to prevent disengagement of the CPA  22  from the cover  16 . An additional projection  138  is formed on the end wall  112  immediately adjacent the notch  132 . The projection  138  is located forward of the projections  136  at an intermediate point along the end wall  112 . The projection  138  engages the CPA  22  when the CPA  22  is moved to its final engaged position (at which the header  12  and plug housing  24  are fully engaged with one another). Once the CPA  22  is moved to the forward location, the projection  138  retains the CPA  22  in a fully engaged position. The projection  138  also engages a surface  171  on the CPA  22  (FIG. 3) to hold the CPA  22  in the preset position. The latching projection  172  is deflected by the projection  72  on the header  12 , thereby moving the surface  171  above the projection  138  and allowing the CPA  22  to be moved to the final position that locks the sliding latch  20  closed. 
     As shown in FIG. 3, the CPA  22  includes a base  150  with front and rear ends  152  and  154 , and sides  156 . The CPA  22  includes L-shaped channels  158  formed along both sides  156  and extending between the front and rear ends  152  and  154 . The channels  158  define key ways  160  that slidably receive the beams  130  formed on brackets  126 . The channels  158  include pins  162  located near the front ends  152 . The pins  162  engage the sliding latch  20  when in the fully locked position. The pins  162  prevent the CPA  22  from being disengaged from the cover  16 , thereby functioning in a manner similar to projections  136 , except in the opposite direction. The front ends  152  of the base  150  and channels  158  include beveled surfaces  164  to facilitate alignment to beams  221  (FIG. 4) on the sliding latch  20 , as the CPA  22  is pushed from preset to a final position to lock the sliding latch  20  in place. When the guideway  160  straddle beams  130  and  221 , the CPA is in the final position and the slide is locked closed. The CPA  22  further includes projections 166  formed proximate, and extending along, the rear end  154  that work with projections  136 . A CPA latch arm  168  includes one end that is formed on the cross beam  166  and is deflectable toward and to away from the base  150 . An opposite end of the latch arm  168  includes a lateral ridge  170  and a latching projection  172  formed thereon. The latching projection  172  includes a ramp surface  174 . 
     The latching arm  168  cooperates with the projection  72  on the header  12  to ensure that the header  12  and plug housing  24  are fully engaged with one another before the CPA  22  may be moved to a final locking position. More specifically, the ramp surface  174  engages the ramp rear surface  76  on the projection  72  to bias the latching arm  168  toward the base  150  as the connectors are mated, allowing the CPA  22  to be moved to its final engaged position. Once the projection  172  rides over the projection  72 , a latching surface  176  on the projection  170  engages a latching surface  138   b  (FIG. 2) located on the front surface of the projection  138 . 
     As shown in FIGS. 1 and 4, the sliding latch  20  includes upper and lower beams  200  and  202  that are interconnected through a cross member  204 . A handle  206  is formed with the cross member  204 . The upper and lower beams  200  and  202  include cutouts  210  extending along a length of the front and rear edges thereof. The cutouts  210  are received within the channels formed by flanges  118  proximate the front edges  116  of the cover  16 . The slots  114  operate such that if the sliding latch  20  is flipped over, it is prevented from being installed into the cover  16 . The cutouts  210  are only received in the front channels  118 . The upper and lower beams  200  and  202  include an inner surface  212  having a notch  214  therein that is aligned to extend from a front edge  216  of the lower beam  202  at an acute angle across the width of the lower beam  202 . The notch  214  includes a front end forming a mouth  218  opening to and facing the front edge  216 . The notch  214  extends through the lower beam  202  along the main body of the notch  214 , but not at the mouth  218  to prevent degradation of the structural integrity. The mouth  218  receives a corresponding boss  80  during connection and guides the boss  80  along the main body of the notch  214 . The boss  80 , when moved from the mouth  218  into the main body of the notch  214 , extends outward into the notch  214 . Optionally, the upper and/or lower beam  200  and  202  may include a second notch  220  having one end forming a mouth  222 . 
     FIGS. 4-6 illustrate the sliding latch  20  in more detail. Rear edges  224  of the upper and lower beams  200  and  202  do not include cutouts, such as cutouts  210  along the front edges  216 . Outer ends  226  of the upper and lower beams  200  and  202  include cantilevered latches  228 . Optionally only one latch  228  need be used. 
     As shown in FIG. 5, the cantilevered latch  228  includes an action beam  230  formed with a latch beam  232 . The cantilevered latches  228  are formed integrally with a pivot post  235  on the outer ends  226  of the upper and lower beams  200  and  202 . The upper end of the latch beam  232  includes a latching projection  234  with a ramp forward surface  236  and a catch surface  238 . The lower end of the action beam  230  includes a beveled surface  237  that engages a boss  80  when the header  12  is initially engaged with the connector assembly  10 . 
     As shown in FIG. 5, the cover  16  includes a latching member  240  mounted on rear wall  120  and aligned to engage the latch beam  232 . When the boss  80  is moved  5  from a first engagement position (as denoted by the boss  80  shown in a dashed line in FIG. 6) to a premated position (as denoted by the boss  80  shown in a solid line in FIG.  6 ), the boss  80  biases of the action beam  230  outward in a direction denoted by arrow A. As the action beam  230  is driven outward, the latch beam  232  is cantilevered downward in the direction of arrow B until the latching projection  234  clears the latching member  240 . The latching projection  234  and latching member  240  cooperate such that the sliding latch  20  is not permitted to be completely engaged until the header  12  and plug assembly  10  are joined in a premated position. 
     The cover  16  further includes an embossment  242  aligned with the front or rear edge of one of the upper and lower beams  200  and  202 . At least one edge of the upper or the lower beam  200  and  202  includes a projection  241  formed thereon and aligned with embossment  242 . The embossment  242  and projection  241  engage one another. Optionally, projection  244  may be included, but is not necessary if catch surface  238  is used. Once the projection  241  is moved forward past the embossment  242 , they cooperate to prevent the sliding latch  20  from being entirely removed from the cover  16 . Projection  245  engages embossment  242  to assist in holding latching slide  20  in the fully closed position. 
     When the header  12  is moved into the premated position with the plug housing  24 , the bosses  80  are aligned to enter the mouths  218  and  222  of the notches  214  and  220 , respectively. Once the bosses  80  enter the mouths  218  and  222 , the sliding latch  20  may be moved in the direction of arrow C. As the latch  20  is closed in the direction of arrow C, the bosses  80  are forced along the notches  214  and  220 . The notches  214  and  220  force the bosses  80  forward relative to the plug housing (i.e., in a direction orthogonal to the contact mating faces of the plug housing  24  and header  12 ), thereby drawing the header  12  into a fully engaged position with the plug housing  24 . 
     FIGS. 7-10 illustrate the operation of the sliding latch  20  in cooperation with the cover  16 . FIGS. 7 and 9 illustrate the sliding latch  20  while in an initial premated position, while FIGS. 8 and 10 illustrate the sliding latch  20  when in a fully engaged position. FIGS. 9 and 10 illustrate cross-sectional views taken along lines  9 — 9  in FIG.  7  and  10 — 10  in FIG.  8 . As shown in FIG. 7, the cross member  204  on the sliding latch  20  includes a pair of vertical beams  246  with vertical keys  248  formed thereon. The vertical keys  248  face one another. The beams  246  and vertical keys  248  block premature insertion of the CPA  22 . The beams  246  and vertical keys  248  extend upward from the lower beam  202  to an intermediate height along the cross member  204  (FIG.  9 ). The top edge  249  of the keys  248  are dimensioned to fit below, and align with the beams  130  formed on brackets  126 . The vertical keys  248  are aligned with guide ways  160  once the sliding latch  20  is moved in the direction of arrow C to the fully engaged position. The vertical keys  248  contact the front end  152  of the CPA  22  until the sliding latch  20  is moved to the fully engaged position, at which time the CPA  22  is movable in the direction of arrow D (FIG. 10) to the fully engaged position. As the CPA  22  is moved to the fully engaged position, the projection  172  travels over the projection  72  on the end wall  70  of the header  12 . 
     The foregoing structure operates in the opposite manner when disconnecting the header  12  and plug assembly  14 . In particular, the sliding latch  20 , when pulled outward, forces the header  12  and plug assembly  14  apart. Before the sliding latch  20  is movable, the CPA  22  must first be disengaged to allow the connector assembly to be unmated. 
     While the preferred embodiments illustrate the sliding latch  20  as being connectable to a cover  16 , the present invention is not limited to any such implementation. Optionally, the sliding latch  20  may be configured to directly engage one of the cover  12  and plug housing  24 . For example, the top and bottom surfaces of the plug housing  24  may be formed with at least one channel therein extending along the length of the rear portion  34  of the plug housing  24 , while the interior surfaces of the upper and lower beams  200  and  202  may be formed with parallel keys facing one another and extending along the beams  200  and  202 . The keys ride in the channels. 
     Alternatively, the sliding latch  20  may be slidably mounted to the header  12 , while the bosses  80  are formed on the plug housing  24 . In the alternative configuration, the sliding latch  20  is mounted in a premated position on the cover  12 , and arranged to accept bosses  80  located on the plug housing  24 . Once the bosses  80  on the plug housing  24  are received within the sliding latch  20 , the sliding latch  20  may be closed to facilitate engagement. As a further alternative, the CPA  22  may be formed on either of the cover  12  and plug housing  24 . 
     The embodiment illustrated in FIG. 1 shows the sliding latch  20  to be mounted from one side of the cover  16 . However, the present invention is not limited to any such implementation. For example, the sliding latch  20  may be mounted to the opposite side of the cover  16 , or to either side of the header  12  or plug housing  24 . As a further alternative, the sliding latch  20  may be mounted to the top or bottom of the cover  16 , plug housing  24  or header  12 . 
     The embodiment illustrated in FIG. 1, uses multiple notches  214  and  220  on the upper and lower beams  200  and  202 . However, the present invention is not limited to any such implementation. Instead, a single notch may be used on both beams or only on one beam. Alternatively, more than two notches may be used on each beam or on either beam. As a further alternative, the notches  214  and  222  may be formed on either of the header  12  and plug housing  24 , while the bosses  80  may be formed on the sliding latch  20 . Optionally, features other than notches and bosses may be used to engage the sliding latch  20  and cover  12 . 
     While particular elements, embodiments and applications of the present invention have been shown and described, it will be understood, of course, that the invention is not limited thereto since modifications may be made by those skilled in the art, particularly in light of the foregoing teachings. It is therefore contemplated by the appended claims to cover such modifications as incorporate those features which come within the spirit and scope of the invention.