Electrical connector with seal protection

An electrical connector includes first and second housing portions that are secured to one another and respectively provide an aperture and a hole. The aperture is configured to receive a terminal of a wire. The hole is configured to receive the wire. The first housing portion includes a face that is configured to mate with another connector that carries another terminal that is engageable with the terminal. A seal is captured between the first and second housing portions and is configured to engage the other connector.

FIELD OF INVENTION

This disclosure relates to an electrical connector and seal.

BACKGROUND

Sealed connector assemblies are widely used in the automotive industry to protect the electrical wire terminals from dust, humidity, and water ingress. Typically a seal is arranged between male and female plastic connectors, which each carry the wire terminals. Due to the interference fit between the connectors, the seal may roll over during insertion or removal of the male connector relative to the female connector.

Terminal position assurance features are commonly used for automotive electrical connectors to provide additional locking for the terminals. One common secondary lock used to provide terminal position assurance is generally inserted from the outside of one of the connectors which has a large aperture to accommodate the secondary lock. Some types of secondary locks also may be configured to prevent the seal from rolling over.

SUMMARY

In one exemplary embodiment, an electrical connector includes first and second housing portions that are secured to one another and respectively provide an aperture and a hole. The aperture is configured to receive a terminal of a wire. The hole is configured to receive the wire. The first housing portion includes a face that is configured to mate with another connector that carries another terminal that is engageable with the terminal. A seal is captured between the first and second housing portions and is configured to engage the other connector.

In a further embodiment of the above, the first housing portion includes a guide wall that forms a pocket that receives the second housing portion. The guide wall circumscribes at least a portion of the second housing portion.

In a further embodiment of any of the above, the first and second housing portion includes complementary housing locking elements that secure the first and second housing portions to one another in a snap-fit relationship.

In a further embodiment of any of the above, the housing locking elements are provided by a clip with a window on one of the first and second housing portions. A tab on the other of the first and second housing portions is received in the window.

In a further embodiment of any of the above, the guide wall includes a gap that is configured to receive the clip. The tab is provided on the first housing portion. The guide wall abuts at least 50% of the seal.

In a further embodiment of any of the above, the connector includes a secondary lock that is carried by the first housing portion. The secondary lock is slideable between unlocked and locked positions. The secondary lock is configured to abut the terminal in the locked position and configured to permit insertion of the terminal into the aperture in the unlocked position.

In a further embodiment of any of the above, the secondary lock retains elements that secure the secondary lock to the first housing portion to provide a subassembly.

In a further embodiment of any of the above, the first housing portion includes a guide wall that forms a pocket that receives the second housing portion. The guide wall circumscribes at least a portion of the second housing portion. The secondary lock retains elements that are provided by a clip on the guide wall and a tab on a perimeter of the secondary lock. The tab is slideable relative to the clip between the locked and unlocked positions.

In a further embodiment of any of the above, the first housing and the secondary lock respectively include first and second protrusions. The second protrusion is arranged on one side of the first protrusion in the unlocked position. The second protrusion is arranged on an opposing side of the one side in the locked position.

In a further embodiment of any of the above, the connector includes the terminal that is arranged in the aperture. The aperture corresponds to a first aperture. The secondary lock includes an opening and includes a second aperture that provides a lip. The opening is configured to receive a tool that moves the secondary lock from the unlocked position to the locked position. The lip blocks the terminal in the locked position.

In another exemplary embodiment, a method of assembling an electrical connector includes inserting a secondary lock into a first housing portion to provide a subassembly. The method also includes arranging a seal on a second housing portion. The method further includes securing the first and second housing portions to one another and about the secondary lock. The method further includes capturing the seal between the first and second housing portions in response to the securing step.

In a further embodiment of any of the above, the first housing portion and the secondary lock respectively include first and second apertures aligned with one another. The method includes a terminal that is arranged in the first aperture. The method further includes a step of sliding the secondary lock from an unlocked position to a locked position to block the terminal from pulling past the second aperture with the secondary lock.

In a further embodiment of any of the above, the sliding step includes sliding a second protrusion past a first protrusion to the locked position.

In a further embodiment of any of the above, the inserting step includes snapping secondary lock retaining elements to one another.

In a further embodiment of any of the above, the securing step includes receiving the second housing portion in a pocket provided by a guide wall of the first housing portion. The guide wall provides a first shoulder and the second housing portion provides a second shoulder. The capturing step includes abutting the seal with the first and second shoulders.

In a further embodiment of any of the above, the securing step includes snapping housing locking elements to one another.

In a further embodiment of any of the above, the method includes a step of installing a second connector with a second terminal into the connector. The installing step includes electrically coupling the second terminal to the terminal and engaging the second connector with the seal.

In a further embodiment of any of the above, the method includes a step of rotating a lever to lock the connector and the second connector to one another.

In another exemplary embodiment, an electrical connector includes first and second housing portions that are secured to one another and respectively provide an aperture and a hole. The aperture is configured to receive a terminal of a wire. The hole is configured to receive the wire. The first housing portion includes a face that is configured to mate with another connector that carries another terminal that is engageable with the terminal. A secondary lock is carried by the first housing portion. The secondary lock is slideable between unlocked and locked positions. The secondary lock is configured to abut the terminal in the locked position and configured to permit insertion of the terminal into the aperture in the unlocked position.

In a further embodiment of any of the above, secondary lock retaining elements secure the secondary lock to the first housing portion to provide a subassembly. The first housing portion includes a guide wall that forms a pocket that receives the second housing portion. The guide wall circumscribes at least a portion of the second housing portion. The secondary lock retaining elements are provided by a clip on the guide wall and a tab on a perimeter of the secondary lock. The tab is slideable relative to the clip between the locked and unlocked positions. The first housing and the secondary lock respectively include first and second protrusions. The second protrusion is arranged on one side of the first protrusion in the unlocked position. The second protrusion is arranged on an opposing side of the one side in the locked position.

The embodiments, examples and alternatives of the preceding paragraphs, the claims, or the following description and drawings, including any of their various aspects or respective individual features, may be taken independently or in any combination. Features described in connection with one embodiment are applicable to all embodiments, unless such features are incompatible. Like reference numbers and designations in the various drawings indicate like elements.

DETAILED DESCRIPTION

A connector assembly10is illustrated inFIGS. 1A and 1Bhaving first and second connectors12,14that create a secure electrical connection between multiple wires. In the example, the first connector12includes a lever16that has an arcuate slot20receiving a pin18provided on the second connector. When the first and second connectors12,14are fully seated, the lever16may be rotated capturing the pin18within the slot20.

Referring toFIGS. 2 and 3, the first connector12includes first and second housing portions22,24. The first housing portion22includes a face23having multiple first apertures30within which wire terminals (68inFIG. 12) are disposed. A secondary lock28is carried by the first housing portion22and is captured between the first and second housing portions22,24when assembled. A seal26is also captured between the first and second housing portions22,24and engages the second connector14when assembled to the first connector12.

The first housing portion22includes a guide wall37forming a pocket36that receives the second housing portion24. The guide wall37circumscribes at least a portion of the second housing portion24when assembled (best shown inFIG. 6), for example, at least 50%, and in another example, at least 70%, such that the guide wall37engages a corresponding amount of the seal26(FIG. 10).

Referring toFIGS. 3-5B, the secondary lock28includes second apertures32that are aligned with the first apertures30. Secondary lock retaining elements42secure the secondary lock28to the first housing portion22to provide a subassembly. In the example, the secondary lock retaining elements42are provided by hooks44provided on the guide wall37. A perimeter40of the secondary lock28includes tabs46that cooperate with the hooks44. The tabs46are slidable relative to the hooks44between unlocked (FIG. 4) and locked (FIG. 11) positions. In the example embodiment, four sets of hooks44and tabs46are provided.

Referring toFIGS. 6 and 7, housing locking elements47secure the first and second housing portions22,24to one another in a snap fit relationship. The housing locking elements47are provided by a clip48on the second housing portion24that extend through gaps49in the guide wall37(FIGS. 2, 4, 7). The clip48includes a window50receiving a tab52in the first housing portion22. Ribs38extending inwardly from the guide wall37, as shown inFIG. 4, help guide the second housing portion24into the pocket36. In the example embodiment, four sets of clips48and tabs52are provided. The ribs38on the guide wall37creates a tight fit with the second housing portion24, preventing floating of the first housing portion22.

Referring toFIGS. 8-11, the first housing portion22includes an opening60that provides access to an arm61extending from the secondary lock28. A tool62, as shown inFIG. 9, can be inserted into the opening60to cooperate with the arm61. By pushing the arm61leftward as shown in the figures, the secondary lock28may be moved from the unlocked position (FIG. 8) to the locked position (FIG. 10). Secondary lock locking elements54are provided by first and second protrusions56,58that cooperate with one another. In the locked position, a first set of protrusions56on the secondary lock28move from one side of second protrusions58, as illustrated inFIG. 4, to the other side of the second protrusions58, as illustrated inFIG. 11. In the locked position, lips64associated with each aperture30of the secondary lock28, abut and block an endwall66of a terminal68to provide terminal position assurance, as illustrated inFIG. 12.

Referring toFIGS. 14, 15A, and 15B, the first and second housing portions22,24respectively provide first and second shoulders70,72, which abut the seal26. Positive contact with the first and second shoulders70,72prevents rollover of the seal26.

In operation, the electrical connector10is assembled by inserting the secondary lock28into the first housing portion22to provide a subassembly. The secondary lock retaining elements42are snapped to one another, and the secondary lock28is left in the unlocked position. The seal26is arranged on a second housing portion24.

The first and second housing portions22,24are secured to one another and about the secondary lock28, capturing the secondary lock28. During this step, the second housing portion24is received in the pocket36provided by the guide wall37. The housing locking elements47are snapped together, which captures the seal26between the first and second housing portions22,24.

A terminal68is inserted through each of the first and second apertures30,32and the holes34such that the terminals68are fully seated in their respective first aperture30. Insulated wiring extends from the holes34at a backside25of the second housing portion24(FIG. 3). At this point, the tool62can be inserted into the opening60to force the arm61to one side, sliding the secondary lock28from the unlocked position to the locked position to block the terminals68from pulling past the second aperture32with the lips64of the secondary lock28. The second protrusions58slide past the first protrusions56when moving to the locked position.

The second connector14is installed onto the first connector12, which electrically couples second terminals74to the terminals68and engages the second connector14with the seal26. The first shoulder70and the second shoulder72abut and capture the seal26, preventing seal rollover. The lever16is rotated to lock the first and second connectors12,14to one another.