Abstract:
A connection system is shown where a lever-assist member may be added to assist in the mating between two connector housings as is needed depending upon a number of connector terminals loaded and the mating force between them. The lever-assist member is also locked in place by the interaction of the pivot-assist member and the corresponding latching structure of the connectors. The lever-assist member, when moved into the disconnection condition, has a projection which holds the cantilever beam arm of the latch in a position allowing the two connectors to be disconnected, which does not require the user to continue depressing the latch at the same time as rotating the pivot-assist member.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     The subject invention relates to an electrical connector design and an electrical connector assembly providing the alternative to have or not have a mating-assist lever to assist in the mating of two joining electrical connector halves.  
         [0002]     In several different applications or industries, particularly in the automotive industry, electrical connector designs are standardized on various different harnesses or on various different discrete ends of a particular harness.  
         [0003]     Just by way of example, it is common to provide as part of a wiring harness, wiring which extends into the automobile body, for example, and be connected to a mating connector at or under the driver&#39;s seat. Such connections can be used for the power seat having multiple ways of adjustment including up, back, tilt, and lumbar, as well as providing the opportunity for multiple variances of seat heating. In such an example, it would be common to provide multiple sizes of terminals depending on the power or amperage that needs to run through the cable, and thus the connectors need to accommodate multiple sizes of terminals as well.  
         [0004]     It is also common that the connectors themselves are standardized to provide the maximum number of terminals required to accommodate all of the terminals for the maximum number of features allowable, but in the case where the seat heater or the electrical adjustment is not required, those particular terminals are not loaded. Thus, it is also common in the industry to have identical connector housings with a variety of different mating forces depending on the number of electrical terminals actually loaded in the mating connectors.  
         [0005]     It is also common in the industry to have standardized maximum mating forces which are allowable for the assembly line in automobile plants. One such standard, known as USCAR, has designated 75 Newtons as a maximum mating force. USCAR is an umbrella organization made up of automotive manufacturers for joint research. This is the maximum force that can be designed into a connector assembly, where the two connectors are mated into a latched condition by hand including no assistance in the connection. Above the 75-Newton requirement, some type of mating assistance between the two connectors is required.  
         [0006]     The object then of the present invention is to provide a connector design having a plurality of alternatives to accommodate all of the above-mentioned requirements.  
       SUMMARY OF THE INVENTION  
       [0007]     The objects have been accomplished by providing an electrical connector assembly, comprising a first connector housing, having a first exterior profile, the exterior profile having at least a pair of engageable lugs positioned adjacent to a leading edge of the first connector housing. A first latch member is positioned adjacent to the leading edge of the first connector housing. At least one first contact member is positioned within the first connector housing. A second connector housing comprises a second exterior profile, profiled for overlappingly receiving the first exterior profile. A pair of channels is included to receive the at least one pair of engageable lugs on the first connector housing. A second latch member is positioned for latching engagement with the first latch member of the first connector housing. At least one second contact member is positioned therein, for mate able connection with the first contact member. The pair of channels have any one of a plurality of configurations, wherein the plurality of configurations include: each channel including a solid exterior wall which receives one of the pair of engageable lugs therein; or each channel may include a mounting wall having a mating assist member attached thereto, where the mating assist member is functional with the pair of engageable lugs to move the first and second connector housings into mated condition.  
         [0008]     The first latch member may be profiled as a cantilever beam extending rearwardly away from the leading edge. The second latch member may be comprised of a raised wall, the cantilever beam of the first latch member being receivable into an area beneath the raised wall. The first and second latch members may also include first and second joining latch projections. The first latching projection may project upwardly from the cantilever beam, and the second latching projection may project downwardly from the raised wall. The pair of engageable lugs may be positioned on side walls of the first connector housing, and the first latch extends from a top wall.  
         [0009]     The mating assist member may be a lever arm. The lever arm may be comprised of side arms attached to the mounting wall, and an upper arm spanning across the top wall. The lever arm may snap in place behind the cantilever beam when in the fully mated position. The engageable lugs and the lever arm may be profiled as rack and pinion teeth.  
         [0010]     An inventive method of manufacturing an electrical connector assembly, comprises the steps of providing a first connector housing having a first exterior profile, where the exterior profile has at least one engageable lug positioned adjacent to a leading edge of the first connector housing. The first connector housing is provided with at least one first contact member therein. A second connector housing is provided having a second exterior profile profiled for overlappingly receiving, the first exterior profile. The second connecting housing has at least one second contact member therein, for mate able connection with the first contact member. A channel is provided on the second connector housing to receive the at least one engageable lug. A mounting wall is provided on the connector housing for an optional mating assist member. The method also includes selectively determining if a mating assist member is required on the basis of the anticipated mating force between the first and second connector housings, and if selected, mounting a mating assist member on the mounting wall in position for engagement with the at least one engageable lug.  
         [0011]     The first latch member may be profiled as a cantilever beam extending rearwardly away from the leading edge. The second latch member may be comprised of a raised wall. The cantilever beam of the first latch member is receivable into an area beneath the raised wall. The first and second latch members may include first and second cooperating latching projections. The first latching projection may project upwardly from the cantilever beam, and the second latching projection may project downwardly from the raised wall. The pair of engageable lugs may be positioned on side walls of the first connector housing, and the first latch may extend from a top wall.  
         [0012]     The mating assist member may be a lever arm, comprised of side arms attached to the mounting wall, and an upper arm spanning across the top wall. The lever arm may snap in place behind the cantilever beam when in the fully mated position. The engageable lugs and the lever arm may be profiled as rack and pinion teeth. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0013]      FIG. 1  is a perspective view showing the connector assembly in a mated condition;  
         [0014]      FIG. 2  is an underside perspective view of  FIG. 1 ;  
         [0015]      FIG. 3  shows an exploded view of the entire plug assembly of the embodiment of  FIG. 1 ;  
         [0016]      FIG. 4  shows an exploded view of the lever-assist plug housing in greater detail;  
         [0017]      FIGS. 5 and 6  show alternative perspective views of the mating assist lever shown in  FIG. 4 ;  
         [0018]      FIG. 7  shows a cross-sectional view through  FIGS. 7-7  of  FIG. 6 ;  
         [0019]      FIG. 8  shows the assembled view of the components of  FIG. 4 ;  
         [0020]      FIG. 9  shows an exploded view of the header or male connector, also shown in  FIG. 1 ;  
         [0021]      FIG. 10  shows an enlarged view of the housing portion of  FIG. 9 ;  
         [0022]      FIG. 11  shows the header assembly or male half of the connector from the opposite perspective as  FIG. 10  shows the housing only;  
         [0023]      FIG. 12  shows a view showing the connectors of  FIGS. 8 and 10  poised for interconnection;  
         [0024]      FIG. 13  shows a cross-sectional view through lines  13 - 13  of  FIG. 1 ;  
         [0025]      FIG. 14  shows the connectors of  FIG. 13  in the initial disconnection state;  
         [0026]      FIG. 15  is an enlarged view of the encircled portion on  FIG. 14 ;  
         [0027]      FIG. 16  is a cross-sectional view similar to that of  FIG. 14  showing the connectors in a further disconnection state;  
         [0028]      FIG. 17  shows an enlarged view of the encircled portion on  FIG. 16 ;  
         [0029]      FIG. 18  shows an alternative plug housing, where the mating assist lever is not required; and  
         [0030]      FIG. 19  shows an alternative plug housing having no mating assist lever required.  
     
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0031]     With respect first to  FIGS. 1 and 2 , an electrical connector assembly is shown as  2 , which comprises a plug connector assembly  4  with a mating assist member  6 , shown here as a lever or lever arm, interconnected to a header connector assembly shown at  8 . The two connector assemblies  4 ,  8  are held together by a latch assembly shown generally at  10  and which will be described in greater detail herein.  
         [0032]     With respect now to  FIG. 3 , the plug or female connector assembly  4  is shown in an exploded manner, where mating assist member  6  is exploded away from its associated connector housing  20 , and where a rear wire seal  22  and rear cover  24  are also shown together with contacts or terminals  26  and  28 . On the front side of the connector housing  20 , a front seal  30  and a terminal position assurance member  32  are shown exploded from the front side of connector housing  20 .  
         [0033]     With reference now to  FIG. 4 , connector housing  20  and mating assist member  6  are shown exploded from each other, and connector housing  20  is shown in greater detail. Housing  20  generally includes an exterior profile defined by an outer shroud  34 , which includes alignment channels  36 , and further includes a central raised wall at  38 . This central raised wall  38  includes a central notch at  40 , with a latching mechanism in the form of locking projections  42  (only one of which can be viewed in  FIG. 4 ) extending downwardly from the central raised wall  38  along the perimeter of notch  40 , as will be further described herein. Raised wall  38  is spaced above an inner wall  46 , and defines an opening therebetween for receipt of a mating latch as will also be described in greater detail herein.  
         [0034]     With respect still to  FIG. 4 , connector housing  20  further includes a pair of mounting walls  50  connected to the connector housing  20  by side walls  52 , separating mounting walls  50  from an inner portion of housing  20  and defining channels  54  therein. Mounting walls  50  further include mounting slots shown generally at  56 , each including a narrowed passageway  58  opening into an enlarged circular bearing  60 .  
         [0035]     The connector housing  20  also includes a conventional internal housing portion at  64  having a plurality of terminal cavities, such as  66 , for smaller electrical terminals and enlarged cavities at  68 , for larger current carrying capacity electrical terminals.  
         [0036]     With respect now to  FIGS. 5 through 7 , mating assist member  6  is comprised of an upper arm at  70  having side arms at  72 . Upper arm  70  includes a notched portion at  74 , which includes a first latching projection at  76 , positioned at a trailing edge of the upper arm  70 . As best shown in  FIGS. 5 and 7 , mating assist member  6  further includes at least one contoured surface to assist in releasing the latch assembly  10 , shown here as two release projections  78  in  FIGS. 6 and 7 . With respect to  FIGS. 5 and 6 , mating assist member  6  further includes an axle portion at  80  including parallel and opposed flat surfaces  82 , with upper and lower circular portions at  84 .  
         [0037]     With respect now to  FIGS. 5 and 7 , the mating assist member  6  further includes a pinion portion  90  having drive teeth  92  and  94 . As shown in  FIGS. 5 through 7 , mating assist member  6  further includes an arcuate arm portion  100  connected to the side arms  72  via an arm portion  102 , as best shown in  FIG. 7 . Arcuate arm portion  100  is spaced away somewhat from side walls  72  and positioned above axle portion  80  so as to cause an entry opening at  106 , as best seen in  FIG. 5 . Arcuate arm portion  100  includes an inner contact surface at  108 , as will be described in further detail.  
         [0038]     It should be appreciated that the axle portions  80  are profiled such that the flat surfaces  82  can be positioned between the narrowed passageways  58  ( FIG. 4 ) with the circular portions  84  being rotatable within the enlarged circular bearing  60  ( FIG. 4 ). With respect now to  FIG. 8 , connector housing  20  is shown with mating assist member  6  installed and rotated to an open position, whereby pinion tooth  92  is positioned within the channel  54  in an assist position and poised for interconnection with a mating connector, as will be described in greater detail herein.  
         [0039]     With respect now to  FIG. 9 , header connector assembly  8  is shown in an exploded manner as including a housing portion  120 , a terminal position assurance member (TPA)  122 , a discrete wire seal  124 , contacts or terminals  126  and  128 , and rear cap  130 . As shown in  FIGS. 10 and 11 , housing  120  includes a front end  140 , and a rear wire-receiving end  142 . Front end  140  includes a shrouded portion at  144 , which is profiled to mate with the plug connector housing  20  with alignment ribs  146  positionable with alignment channels  36  ( FIG. 4 ).  
         [0040]     Housing  120  further includes a latch member  150 , as a component of latch assembly  10 , which includes a cantilever beam portion  152  integrally connected to a top wall  154  by a web portion  156 , and extends rearwardly of the housing  120 . As shown best in  FIG. 10 , cantilever beam portion  152  includes side wall sections  160  having locking projections  162  upstanding therefrom. Two side wall sections  164  flank the cantilever beam portion  152  and include overstress members  166 . As shown in  FIG. 10 , the extreme end of cantilever beam portion  152  includes an angled edge portion  170 , which defines a contacting surface, whereas the top of the latch cantilever beam portion  152  includes two contact surfaces at  172 .  
         [0041]     Finally, as shown in either of FIGS.  10  or  11 , housing  120  includes a portion  180  which provides an engagement lug, in the form of a simulated gear rack including a first tooth  182 , positioned on side wall  184 . Housing  120  further includes alignment bars  190  having a locking extension at  192 , again as will be described further herein.  
         [0042]     With both connector assemblies  4 ,  8  as described herein, the operation of the connector housings  20  and  120  will be described herein. As shown in  FIG. 12 , the two connector housings are mate able with the alignment ribs  146  aligning with the alignment channels  36 , which positions locking extensions  192  in position in openings  106  ( FIG. 6 ) of the mating assist member  6 , and which positions rack tooth  182  in position to be received below pinion tooth  92 . Thus, rotation of the mating assist member  6  in the counterclockwise sense (as viewed in  FIG. 12 ) causes the engagement of the rack and pinion teeth  182 ,  92  causing the connectors to move into an interconnected state. At the same time, arcuate arm portions  100  rotate to entrap extensions  192 .  
         [0043]     When the connectors are fully engaged, the connector pair is in the position of  FIG. 1 , and locking projections  162  are positioned behind locking projections  42 . This also positions angled edge surface  170  in a close proximity to corresponding latching projection  76  on pivot-assist member as shown in  FIG. 13 . These two corresponding surfaces prevent disengagement between the two, as a counter-rotation of mating assist member  6  (that is in the clockwise position as viewed in  FIG. 13 ) would cause the abutment of the latching projection  76  and edge surface  170  lifting latch member  150  into the overstress members  166  ( FIG. 10 ).  
         [0044]     At the same time, projections  78  assist in holding the latch member  150  down during the counter-rotation, allowing mating assist member  6  to be rotated without having to hold down latch member  150  by hand. With respect first to  FIGS. 14 and 15 , when the latch is initially depressed and the mating assist member  6  has begun a counter-rotation, in the counterclockwise sense as viewed in  FIGS. 14 and 15 , projections  78  have contoured surfaces which begin to ride up on surface  172 , which holds the latch in the downward position such that locking projections  42  and  162  are clear of each other, as best shown in  FIG. 15 . Continued rotation of the mating assist member  6 , to the position now shown in  FIGS. 16 and 17 , positions projection  78  further along on surface  172  and locking projection  162  has now cleared beneath locking projection  42 , preventing snagging between the two connectors.  
         [0045]     As mentioned above, depending upon the mating force between the two connectors (as a result of the number of terminals loaded), it is possible to have a connection pair that does not require the mating assist member  6 , and two embodiments of the modified connection system are shown in  FIGS. 18 and 19 .  
         [0046]     With respect first to  FIG. 18 , it is possible to have a connector housing, such as  204 , which simply eliminates the mating assist member  6  leaving a mounting slot at  256  identical in nature to mounting slots  56  described above. In this configuration, the two connectors are simply connected together by hand, whereby the latch assembly  210  holds the two connectors together.  
         [0047]     As shown in  FIG. 19 , a revised housing is shown at  304  having solid outer walls at  350 , which eliminates any of the mounting slots  56  or  256 . This is accomplished by simply eliminating the mold tooling, which forms the passageways  58  and circular bearing  60  of the embodiment shown in  FIG. 4 . This housing would work in almost identical nature to that shown in  FIG. 18 , whereby the two connectors are simply brought into engagement with each other and into a latched condition, as described above.  
         [0048]     Advantageously, the connector assembly can easily accommodate multiple configurations for various numbers of terminals loaded in the connection system. As mentioned above, depending on the number of terminals loaded in the various connector assemblies, the mating forces between them may be above or below the USCAR 75 Newton threshold, which may require or not require the mating assist member  6 . Thus, the design can easily accommodate either having or not having the lever-assist member by either simply eliminating it as in the  FIG. 18  embodiment or by simply removing the side mold tooling as in the  FIG. 19  embodiment. Other advantages are shown in our patent application, Attorney Docket Number E-AV-00073, Ser. No. ______, concurrently filed and incorporated herein by reference.