Electrical connector

An electrical connection system includes a first electrical connector having a first plurality of electrically conductive elements. A second electrical connector has a second plurality of electrically conductive elements and is matable with the first electrical connector such that the first plurality of electrically conductive elements are in contact with the second plurality of electrically conductive elements. A probe is mounted with respect to the first electrical connector, and a receptacle is mounted with respect to the second electrical connector. The probe has a tip, an untapered section, a tapered section between the tip and the untapered section, and a cross-sectional shape that has no more than one plane of mirror symmetry. The receptacle defines a cavity having substantially the same cross-sectional shape as the probe.

TECHNICAL FIELD

This invention relates to electrical connectors having self-alignment features.

BACKGROUND OF THE INVENTION

Automotive vehicles typically include several electronic devices that must receive electrical energy to operate, and that sometimes must send and receive electrical signals to other electronic devices. Wiring harnesses are typically used to provide conductive pathways through the vehicle for transmission of electrical power and signals among electronic devices and power sources such as batteries. Wiring harnesses typically include a plurality of electrical connectors that are engaged with corresponding connectors on the electronic devices during automotive assembly.

One type of electrical connector includes conductive elements, e.g. pins, that are engageable with sockets on a corresponding type of electrical connector to establish electrical communication between an electronic device and the wiring harness. Maximizing the density of the conductive elements minimizes the size of the electrical connector and thus improves packaging efficiency. However, maximizing the density of the conductive elements, by minimizing their size, reduces their mechanical strength and thus the ability of the conductive elements to sustain nonaxial loads due to misalignment of the two connectors during insertion of the conductive elements into the corresponding sockets.

A shroud typically surrounds the pins to protect them from nonaxial loads, and is often used to align the sockets with the pins during the mating of the two electrical connectors.

SUMMARY OF THE INVENTION

An electrical connection system includes a first electrical connector having a first plurality of electrically conductive elements. A second electrical connector has a second plurality of electrically conductive elements and is matable with the first electrical connector such that the first plurality of electrically conductive elements are in contact with the second plurality of electrically conductive elements.

A probe is mounted with respect to the first electrical connector, and a receptacle is mounted with respect to the second electrical connector. The probe has a tip, an untapered section, and a tapered section between the tip and the untapered section. At least part of the probe has a cross-sectional shape that has no more than one plane of mirror symmetry. The receptacle defines a cavity having substantially the same cross-sectional shape as the probe.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring toFIG. 1, an electrical connector10includes a housing14. The electrical connector10also includes a shroud18that protects a first plurality of conductive elements, which are pins20in the embodiment depicted, that protrude from the housing14. Each of the pins20is electrically conductive, and is in electrical communication with a respective wire21. As understood by those skilled in the art, each pin is operatively connected to its respective wire inside the housing14. The wires21extend outside of the housing14; the wires21may be bundled together outside of the housing14to form a cable, as understood by those skilled in the art. The shroud18is characterized by an opening22at its forward end to provide access to the pins20. The electrical connector10also includes a receptacle26for aligning and guiding a corresponding electrical connector (shown at28inFIG. 2).

Referring toFIG. 2, electrical connector28includes a housing30having a member32protruding therefrom. Member32defines a plurality of sockets34. Each of the sockets34has a respective opening35so that the sockets34are forwardly open to receive the pins (shown at20inFIG. 1). The sockets34are sufficiently spaced and oriented so that, when the electrical connector28is sufficiently aligned with the electrical connector shown at10inFIG. 1, each of the pins20of connector10is insertable within a respective one of the sockets34.

The electrical connector28includes a second plurality of electrically conductive elements, which, in the embodiment depicted, are electrical contacts36. Each of the contacts36is in electrical communication with a respective wire37inside the housing30. The wires37extend outside of the housing30. Each contact36is exposed to a respective one of the sockets34such that, when the pins20are within the sockets34, each pin20is in contact with a respective one of the contacts36, and, therefore, each of wires21is in electrical communication with a respective one of wires37. Electrical connector28also includes a probe42mounted to the housing30.

Referring toFIGS. 3-5, wherein like reference numbers refer to like components fromFIGS. 1 and 2, the probe42is characterized by an untapered section46having a constant cross-sectional shape50and constant dimensions along its length. As used herein, a cross-sectional shape refers to the shape of the probe as seen in cross-section taken about a plane that is perpendicular to the length of the probe, i.e., its greatest dimension. The probe42is characterized by a T-shaped cross section (shown as an inverted “T” inFIG. 3). The shape50is characterized by only a single plane P of mirror symmetry, i.e., the shape is symmetrical (mirror) about only one plane P.

The probe42is also characterized by a tapered section58, which extends from a boundary60with the untapered section46to the forward tip62of the probe42. The tapered section58is characterized by the same cross-sectional shape as the untapered section46. However, although the cross-sectional shape of the tapered section58does not change between the boundary60and the tip62, the cross-sectional dimensions and area of the tapered section58get progressively smaller between the boundary60and the tip62. Thus, cross-sectional area at the forward tip62is smaller than at the untapered section46.

Referring specifically toFIG. 3, receptacle26defines a cavity66that is characterized by the same cross-sectional shape as the probe42. The cavity66is characterized by an opening70at its forward end for receiving the probe42. The cross-sectional size of the cavity66is slightly larger than the cross-sectional size of the untapered section46of the probe42so that the probe42is insertable into the cavity66through the opening70.

The opening70is characterized by the same cross-sectional shape as the probe42. The opening70is tapered such that the forwardmost end of the opening70is larger than the rearward end of the opening70and the cavity70. Referring again toFIG. 2, the probe42extends significantly forward of the housing30, the member32, and the contacts36so that the probe42is the most forwardly extending portion of the electrical connector28. The length of the probe42enables the tapered section (shown at58inFIGS. 3-5) to be aggressively tapered to facilitate insertion of the probe42into the receptacle26, even if there is significant linear or angular misalignment between the probe42and the opening70and cavity66. The cross-sectional shape of the probe42prevents rotational misalignment and enables the use of only a single probe42and a single receptacle26.

The receptacle26guides the electrical connector28, via probe42, into engagement with electrical connector10, as shown inFIG. 6. More specifically, and with reference toFIGS. 1-3and6, the cavity66is sufficiently positioned and shaped such that, as the probe42is further inserted into the cavity66through opening70, the interaction between the walls of the cavity66and the probe42limits movement of the electrical connector28such that the member32enters the opening22of shroud18, and each of the pins20enters a respective one of the sockets34via one of the opening35. Each pin20contacts a respective contact36, thereby establishing electrical communication between wires21and wires37.

Referring toFIG. 7, wherein like reference numbers refer to like components fromFIGS. 1-6, an alternative probe42A and receptacle26A configuration is schematically depicted. The probe42A includes a flexible arm100extending above a cavity104. A projection108extends from one end of the arm100and is positioned to contact the receptacle26A at the opening70. As the probe42A is inserted into the opening, the receptacle26A acts on the projection108, urging the projection108and the arm100into the cavity104, as shown at100A,108A. A notch112is formed in the upper surface of cavity66. The upper surface of cavity66maintains the projection in the position shown at108A until the projection is aligned with the notch112. Once the projection108is aligned with the notch112, the elastic property of the arm100urges the projection into the notch112, thereby locking the probe42A with respect to the receptacle26A.

It should be noted that, although various members of the electrical connectors (shown at10and28inFIGS. 1 and 2) are shown as separate pieces mounted with respect to each other, the members may be formed from a single piece of material within the scope of the claimed invention. For example, the receptacle26may be integrally formed with the housing14, and the probe42may be integrally formed with the housing30and/or member32within the scope of the claimed invention.

The electrically conductive elements are shown in the embodiment depicted as pins20and contacts36. Those skilled in the art will recognize a variety of electrically conductive element configurations that may be employed within the scope of the claimed invention. For example, electrically conductive elements may include flat plates, cylindrical members, etc., within the scope of the claimed invention. Furthermore, and within the scope of the claimed invention, electrically conductive elements may define the sockets of the female electrical connector.