Terminal Positioning Device

An electrical connector includes a terminal holder and a terminal positioning device. The terminal holder defines at least one terminal opening adapted to receive a terminal from a first side thereof in a terminal insertion direction. The terminal positioning device includes a sliding surface abutting a portion of the connector, and at least one terminal contact surface. The terminal positioning device is arranged adjacent the first side of the terminal holder. The device is movable relative to the terminal holder in an operating direction perpendicular to the insertion direction between a first position wherein the terminal positioning device does not overlap the at least one terminal opening in the insertion direction, and a second position wherein the at least one terminal contact surface overlaps the at least one terminal opening in the insertion direction.

FIELD OF THE INVENTION

The present invention relates to connectors, and more particularly, to a terminal positioning device and associated connector.

BACKGROUND

Electrical connector systems often suffer from assembly errors. These errors include, for example, the incorrect or insufficient insertion of terminals of the connector within a corresponding housing. As a result, electrical connectors often implement a terminal position assurance (TPA) device or component, which ensures that partially seated terminals are detected during assembly or mating of the connector system. In this way, an operator may identify and remedy a terminal placement issue during the connector assembly or connector mating processes, avoiding connector damage and/or a failed or unreliable connection.

Given these benefits, the demand for connectors utilizing TPA components has increased. However, their implementation is not without drawbacks. For example, existing TPA devices increase manufacturing and assembly costs, as well as overall connector complexity. Moreover, these components often take up significant space within the connector. Further still, they often do not ensure optimal terminal positioning.

Accordingly, there is a need for improved systems and methods for ensuring the proper installation of terminals in an electrical connector.

SUMMARY

In one embodiment of the present disclosure, an electrical connector includes a terminal holder and a terminal positioning device. The terminal holder defines at least one terminal opening adapted to receive a terminal from a first side thereof in a terminal insertion direction. The terminal positioning device includes a sliding surface abutting a portion of the connector, and at least one terminal contact surface. The terminal positioning device is arranged adjacent the first side of the terminal holder and is movable relative thereto in an operating direction perpendicular to the insertion direction between a first position wherein the terminal positioning device does not overlap the at least one terminal opening in the insertion direction, and a second position wherein the at least one terminal contact surface overlaps the at least one terminal opening in the insertion direction.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Embodiments of the present disclosure include a terminal positioning device adapted to position and lock terminals within electrical connectors. In one embodiment, an electrical connector is provided which includes a terminal holder defining at least one terminal opening, at least one terminal installed into the at least one of opening from a first side of the terminal holder in an insertion direction, and a terminal positioning device arranged adjacent the first side of the terminal holder. The terminal positioning device is movable relative to the terminal holder in an operational direction perpendicular to the insertion direction of the terminal. The terminal positioning device includes a body having a terminal locking protrusion extending from the body in a direction toward the terminal. The terminal locking protrusion defines an inclined section extending obliquely relative to the operational direction of the device. The device is movable between a first initial position wherein the terminal locking protrusion is offset from the terminal in the operational direction, and a second position wherein the terminal locking protrusion is at least partially aligned with the terminal in the operation direction.

Referring generally toFIGS.1-3, embodiments of the present disclosure will be described as implemented into an exemplary electrical connector10. The representative connector10includes a body12(e.g., a molded polymer body) defining a receiving cavity or opening14into which, for example, a mating connector may be inserted in a mating direction M. The body12houses one or more conductive terminals20, a terminal holder30, an optional pin protection device40, and a terminal positioning device100according to an embodiment of the present disclosure. In the exemplary connector10, the terminals20are rear-loaded, or installed into a rear of the terminal holder30in an insertion direction I.

Each terminal20includes a mating end21(e.g., a pin) and a connecting end22(e.g., a crimping section, as shown inFIGS.6and7). Each terminal20further defines a locking element or feature24. The locking element24of the exemplary terminal20extends from a top thereof, and is sized and positioned to engage with a corresponding locking feature of the connector10. More specifically, the terminal holder30is fixedly arranged within the cavity14of the connector10, and includes a plurality of openings32each sized to accommodate one of the terminals20. The terminal holder30defines primary terminal locks34, such as a cantilevered locking arms extending into each opening32. Each terminal lock34is operative to engage with the locking element24of each terminal20after the terminal has been inserted to a sufficient predetermined depth within the terminal holder30. Once engaged, the terminal lock34prevents the terminal20from being removed from the terminal opening32in a direction opposite the insertion direction I.

Referring toFIGS.1and2, the terminal20is only partially installed or inserted within the terminal holder30. Resultingly, the terminal lock34has not engaged with the locking clement24of the terminal20. In this position, the terminal20is at risk of being further displaced rearward (e.g., during mating), and possibly dislodged completely from the terminal holder30. Moreover, the partially installed terminal20shown inFIGS.1and2will not provide the same wipe or conductive contact area with a mating connector.

As shown inFIG.3, however, after the terminal20has been inserted into the opening32to a sufficient depth to pass the terminal lock34, the lock elastically biases vertically downward, and opposes the locking element24of the terminal in a direction opposite the insertion direction I. In this condition, while the terminal20is prevented from being dislodged from the terminal holder30, it is not necessarily maintained in this optimized position (i.e., at its forward-most position). Specifically, as can be seen inFIG.3, a gap33between the terminal lock34and the locking element24exists. As a result, the terminal20may be displaced rearward (e.g., during mating) until such gap is eliminated while remaining locked in the terminal holder30. The terminal positioning device100according to embodiments of the present disclosure is operative to prevent the partial terminal insertion condition shown inFIGS.1and2. position each terminal optimally within its terminal holder, and maintain such a position during use, as shown inFIG.3.

The terminal positioning device100further includes at least one terminal locking protrusion or terminal lock150. In the exemplary embodiment, the device100defines two rows of terminal locks150, with each lock spaced evenly along the row. The spacing of the terminal locks150corresponds to a spacing of each terminal20of the connector10. In the exemplary embodiment, each terminal lock150includes a tooth-like projection or protrusion152extending from a respective one of the top and bottom walls102,104, and a terminal contact surface including a ramped or inclined surface or section154and a planar bearing or locking surface or section156. See, for example,FIG.5, wherein the projections152of the terminal locks150extend vertically downward from the top wall102. From the projection152, the ramped surface or inclined section154extends in a direction away from the top wall102. Specifically, the ramped surface154extends obliquely relative to a sliding or bearing surface of the device100(e.g., a rear surface101of the device100and/or the planar surface154). The direction of inclination is opposite to a direction of operation O of the device100. The planar bearing section156of the contact surface is formed directly adjacent to the ramped section154. The planar bearing section156may be generally parallel to a front surface101′and/or the rear surface101of the device100, and/or to a rear surface36of the terminal holder30and acts as a bearing surface against the terminal holder30as the device100is moved in the operational direction O. SeeFIGS.6and7. Further, the planar surfaces or sections156act as mechanical stops in the closed position of the device100, preventing terminal motion in a direction opposite the insertion direction I. SeeFIGS.3,7and9.

Referring again toFIGS.4and5, the device100comprises a pair of detents or latching protrusions114. In the exemplary embodiment, one detent114is formed on each of the top and bottom walls102,104. Void spaces or openings118are formed directly under (or above) each detent114, creating a spring-like beam on which the detent114is formed. In this way, an elasticity of each detent114in a direction of the openings118is created when subject to, for example, compressive forces. As set forth in greater detail with respect toFIGS.8and9, the detents114are used to control the position of the device100in use. The terminal positioning device100further includes at least one, and in the illustrated embodiment two, actuator(s)120extending in a forward direction from the front surface101′ thereof. As can be seen inFIG.1, the actuator(s)120extend through the cavity14of the connector10and provide a means for a user to mechanically bias the device100in the operating direction O (or an opposite direction).

The function of the terminal positioning device100will now be described in reference to the figures.FIG.2provides an illustration of the terminal20in a partially inserted or installed position, and the device100in a locked or closed position, demonstrating the interference existing between the terminal locks150and a rear surface26of the terminal20.FIG.3illustrates the terminal20in a fully inserted position. As shown, the planar surface156of the terminal lock150is abutting the rear surface26of the terminal20. A front portion of the terminal27is abutted against an opposing end surface35of the terminal holder30. In this way, the terminal20is at its forward most or ideal position. As a result, terminal wipe is maximized, and movement (e.g., resulting from vibration, etc.) is minimized by the constant insertion force applied by the device100.

The device100is shown in a first or open position inFIG.6. In this position, the terminals20are free to be inserted or installed into the terminal holder30at least partially through gaps formed between adjacent terminal locks150during assembly of the connector10. As shown, each terminal20is only partially installed or inserted into its respective opening32. From the open position shown inFIG.6, the terminal positioning device100is slidable in the indicated operating direction O. Specifically, the device100is slidably held between a rear surface36of the terminal holder30and an opposing internal wall or surface15of the connector body12. Leading with the inclined surface154, each terminal lock150engages with the rear end surface26of each terminal20as the device100is biased in the direction O. As the device100is further biased in the direction O, the terminals20are urged in the insertion direction I via the inclined surface154.FIG.7shows a second or closed position of the device100, wherein the rear surfaces26of each terminal20have reached abutment with the planar surface156of each terminal lock150. The terminals20have reached, or nearly reached, their final fully seated position, and remain held there by the continued engagement with the device100.

FIG.8is a rear section view of the device100in the first or open position. The ends of the terminals20extend through the openings110of the device100, unobstructed by the terminal locks150which are offset from the terminals in the operating direction O (or a direction opposite thereto). The detents114of the device100are abutted against similar protruding elements18of the connector body12, thus providing a positive stop for identifying the open position to a user. This may also be considered a loading position of the device100, wherein the terminals20are free to be installed into the connector body12/terminal holder30without interference. By biasing the device100in the operating direction O, the detents114are compressed and pass each corresponding protruding element18as the device moves into the closed position shown inFIG.9. During this action, any terminal20not fully seated will be urged into, or nearer to, a fully seated position as described above. The resistance provided by the engagement of the detents114and the elements18provides a mechanical feel to a user, and more specifically an indication that the device100has been moved from the open position to the closed position, and thus that no further force applied on the device is required. Of course, additional detents or mechanical stops may also be provided to limit the travel of the device100so as to prevent a user from biasing it past the closed position. For example, as shown inFIG.9, the sidewall106of the device100is abutted against an opposing interior wall of the connector body12. The device100may be left in this second, locked or closed position, thereby ensuring the position of terminals20remains optimized, and improving connector performance, particularly in high vibration or shock applications.

While embodiments of the present disclosure have been described in the context of an exemplary electrical connector10, including a terminal holder30, embodiments may be used with connectors having other forms and/or features, including those without a separate terminal holder, without departing from the scope of the present disclosure.