Electrical Terminal Including Rocker Lock

An electrical connector assembly includes a connector body, a plurality of terminals arranged within the connector body, and a rotatable terminal lock. The plurality of terminals each include an elastic terminal latch fixing the terminal in an installed position within the connector body. The terminal lock is rotatably connected to the connector body between an unlocked position and a locked position. In the unlocked position a first portion of the terminal lock biases each of the terminal latches into a release state whereby the terminals may be removed from connector body in a removal direction. In the locked position a second portion of the terminal lock opposes each of the terminals in the removal direction.

FIELD OF THE INVENTION

The present invention relates to electrical connectors, and more particularly, to an electrical connector having a secondary lock which aids in the removal of installed terminals.

BACKGROUND

Reliable electrical connector systems must maintain the positional integrity of their conductive terminals while minimizing assembly errors. These errors include, for example, the incorrect or insufficient insertion of the terminals of the connector within a corresponding housing. As a result, in addition to primary locking or latching features of the terminals and connector, secondary terminal locking components and/or terminal position assurance (TPA) devices are often implemented. These systems not only ensure that partially seated terminals are detected during assembly of the connector system, but further reduce the risk that a terminal may be displaced from an installed position during connector use.

At the same time, it is advantageous to be able to remove the connector's terminals for replacement and/or recycling purposes. Currently, however, the terminal removal process is time consuming, often necessitating the release and removal of a single terminal at a time, and/or requiring multiple independent operations to disengage both the primary and secondary locking features of the terminal being removed.

Accordingly, there is a need for improved systems which facilitate the expedient removal of connector terminals, while maintaining their positional integrity in an assembled or operating state of the connector.

SUMMARY

In one embodiment of the present disclosure, an electrical connector assembly includes a connector body, a plurality of terminals arranged within the connector body, and a rotatable terminal lock. The plurality of terminals each include an elastic terminal latch fixing the terminal in an installed position within the connector body. The terminal lock is rotatably connected to the connector body between an unlocked position and a locked position. In the unlocked position a first portion of the terminal lock biases each of the terminal latches into a release state whereby the terminals may be removed from connector body in a removal direction. In the locked position a second portion of the terminal lock opposes each of the terminals in the removal direction.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Embodiments of the present disclosure include a connector assembly having a connector body or housing defining a plurality of terminal openings for receiving a corresponding plurality of conductive terminals in an insertion direction. A rotatable terminal lock or secondary terminal locking device, also referred to herein as a locking arm, is rotatable connected to the housing, and is movable between an unlocked position and a locked position. Like prior art secondary locking devices, in the locked position the terminal lock opposes motion of inserted terminals in a removal direction. The terminal lock may also function as a type of terminal position assurance (TPA) device, wherein it cannot be placed into the locked position without the terminals being in a fully seated or installed position within the connector housing.

According to embodiments, as the terminal lock is moved from the locked position to the unlocked position it engages with the primary locking devices (e.g., elastic latches) of the terminals, biasing them from an engaged or locked state to a released or unlocked state. In this way, with a single movement of the terminal lock according to embodiments of the present disclosure, both primary and secondary terminal locking features of the terminal and/or connector are released, and the terminals are free to be removed from the connector housing (e.g., for replacement or for recycling purposes). This is an improvement over the prior art which, after release of a secondary terminal lock, each terminal must still have its primary lock or latch released by a separate operation in order to free each terminal for removal. Accordingly, embodiments of the present disclosure significantly improve the case and speed with which terminals may be released and removed from a connector assembly, without affecting the connector's ability to secure the terminals reliably and accurately in an installed state.

Referring generally toFIGS.1-3, an exemplary connector or connector assembly100according to embodiments of the present disclosure is shown in each of three different operating positions. The assembly100generally includes a connector body or housing101(e.g., a molded polymer body) which may be formed monolithically, or from a plurality of discrete, assembled components. A plurality of terminal openings102are defined by and formed into the body101. Each opening102is adapted to receive a corresponding conductive terminal in an insertion direction I. The body101further defines a mating end103adapted to engage with a mating connector in a mating direction M.

The assembly100further includes a rocking or rotating terminal lock or terminal locking device120.FIG.1illustrates the terminal lock120in an open position O, whileFIGS.2and3illustrate the terminal lock in an intermediate or neutral position N (FIG.2) and a closed or locked position L (FIG.3). In the locked position L, the terminal lock120is selectively received into a corresponding terminal lock opening or recess110formed into the body101. As shown inFIG.1, the recess110is in communication with each of the terminal openings102.

The terminal lock120is rotatable between the open, neutral and locked positions about an axis of rotation A. Specifically, an axle-like portion121of the terminal lock120is rotatably supported via a bearing support or trunnion portion104defined by the housing101. In embodiments, the axle-like portion121may be formed in segments, such that the terminal lock120may be snap-fit into place. In other embodiments, the housing101may be formed from multiple components, wherein the terminal lock120may be installed before final assembly and capture thereof. In other embodiments, additive manufacturing methods may be used to form the terminal lock120as one piece with a remainder of the housing101.

The terminal lock120defines a lead-in surface or chamfer123and a latching surface122. As shown inFIG.2, the lead-in surface123aids the terminal lock120in being seated within the recess110as it is moved into the locked position L ofFIG.3. As shown inFIG.3, in the locked position L, the latching surface122of the terminal lock120is held or opposed by a corresponding protruding latch or lip112defined by the housing101along an edge of the recess110. In this way, once placed in the locked position shown inFIG.3, the terminal lock120will remain locked until a sufficient amount of force is placed thereon to disengage the corresponding latching or locking features112,122.

FIG.4is a partial cross-sectional view of the connector assembly100further illustrating an insertion operation of a conductive terminal200. The exemplary terminal200includes a contact or front end202, a rear or crimping end204(seeFIG.5A), and a primary latch or latch arm206(e.g., an elastic latch or arm). As shown, the latch206is cantilevered, having a free end extending opposite the insertion direction I. The terminal200further includes additional radially protruding features208which may function as locking surfaces for opposing the terminal lock120for performing its secondary locking function, as will be set forth in detail herein. With the terminal lock120in the neutral position N shown inFIG.4(or the open position O), the terminal200is free to be inserted into the terminal opening102in the insertion direction I. As the front end202of the terminal200is inserted, it passes a latch guide106arranged within the terminal opening102, which will in-turn depress the latch206as it passes thereunder.

Still referring toFIG.4, the terminal lock120may be described as including a locking block or body126connected to the axle-like portions121via a plurality of connecting arms130. The locking block126may include a plurality of spaced vertical guides125corresponding to a plurality of slots113formed in the latch or lip112of the body101. These features aid in maintaining the terminal lock120in proper alignment with the terminal openings102of the housing101in a lateral direction (i.e., along the axial direction of the rotational axis A). Further, the axle-like portion(s)121of the terminal lock120and/or the connecting arms130define latch release arms or cams132arranged on a side of the rotational axis A opposite the locking block126. The latch release arms132may define a projection134extending in a direction generally away from the locking block126. A recess or notch136may also be formed into the latch release arm132, and is sized to receive a free end of the terminal latch206. It should be understood that the profile of the illustrated and described latch release arm132may be continuous over the length of the terminal lock120, or may only be present in areas corresponding to each of the plurality of terminals200to be held by the housing101.

With reference now toFIGS.5A and5B, the terminal200is shown in a fully inserted position, wherein the front end202thereof is in abutting contact with a front of the terminal opening102. The primary elastic latch206of the terminal200has passed under the latch guide106, and has resiliently returned to a latching or locking position. In the exemplary embodiment, the free end of the latch206has returned into the notch136formed in the latch release arm132. In this fully inserted position, each of the potential terminal secondary locking features208of the terminal200has passed the recess110. In this way, from the neutral position N of the terminal lock120shown inFIGS.5A and5B, the terminal lock120is free to be rotated into the locked position L within the recess110, as shown inFIGS.6A and6B. It should be understood, however, that if the terminal200were not fully inserted into the terminal opening102, the locking projections208of the terminal would prevent the terminal lock120from being placed into the locked position. In this way, a TPA function is also achieved by the terminal lock120.

Referring now toFIGS.6A and6B, the terminal lock120is shown rotated into the locked position L, and held therein via the corresponding latching features112,122. Despite its further rotation, the notch136of the latch release arm132still retains the free end of the primary terminal latch206therein. Specifically, a rear wall defining the notch206opposes the free end of the terminal latch206in a terminal removal direction (i.e., a direction opposite the insertion direction I). In this way, the terminal200is held in place via the engagement of its primary latching mechanism (i.e., latch206) with a first portion of the terminal lock120(e.g., the latch release arm132). Likewise, the locking block126of the terminal lock120is held securely behind the locking feature(s)208of the terminal200, opposing it in the removal direction of the terminal. In this way, in the locked position of the terminal lock120, the secondary terminal lock function is also realized.

According to the prior art, removing the terminal200from the position shown inFIGS.6A and6Bmay include, for example, releasing the terminal lock from the locked position, and manually depressing the primary terminal latch to release it (e.g., through an access window in the connector housing101). Moreover, a user may be required to hold the primary terminal latch in a released position as it is being drawn out of the housing in the removal direction. This process is time consuming, and generally requires that each of the terminals be released on an individual basis. Embodiments of the present disclosure significantly improve one's ability to quickly and efficiently remove one or more of the terminals.

Specifically, referring now toFIG.7, an operator may rotate the terminal lock120counter clockwise about its rotational axis through the neutral position N and into the open position O. As shown, moving the terminal lock120into the open position O is met with elastic resistance as each of the terminal latches206is biased in the downward direction shown by the protruding end134of latch release arm132. Continued rotation of the terminal lock120will bias the latch206into a released position or state, wherein it has been deflected sufficiently enough to clear the latch guide106in the removal direction. In this way, not only has the secondary terminal lock been released by the rotation of the locking block126out of the recess110, but the terminal latch206has also been disengaged. In the illustrated released position, the terminal200may be moved freely in the removal direction (e.g., via a tension force placed on the terminal200by a user). As shown inFIG.8, with the terminal200partially removed, the primary latch206may at least partially resiliently return to a locked or latched position. However, an opposing top wall of the terminal opening102defines a tapered surface109that will act to deflect the latch206downward, permitting the continued removal of the terminal200.

It should be understood that while only a single terminal is shown, the above-described operations would be the same or similar for each terminal installed within the connector housing101. Likewise, it should be understood that embodiments of the present disclosure may operate as described above on each of the terminals simultaneously, eliminating the often one-by-one nature of terminal removal/replacement operations of prior art arrangements.