Quick connect power connector isolating system

A connector system, keying member and method for electrically connecting a post to a connector. The system includes a terminal post, a connector and a keying member. The connector has a housing body with a post receiving passage for receiving the terminal post therein. The housing body has a keying member receiving recesses provided proximate a first end of the post receiving passage. A keying member is positioned on the terminal post and maintained thereon. The keying member is configured to be positioned in the keying member receiving recesses when the connector is properly inserted onto the terminal post. The keying member prevents the mating of an improper connector onto a respective post.

FIELD OF THE INVENTION

The present invention is directed to an electrical connector which provides a quick, simple and reliable connection to mating posts. In particular, the invention is directed to an isolation or keying member which prevents the mating of a respective electrical connector to a post having different electrical properties, e.g. polarity, amperage, voltage.

BACKGROUND OF THE INVENTION

Electrical connectors for military, aviation, vehicular and other applications which required power must be able to withstand the environmental conditions, such as high vibrations, to which such connectors are subjected. The connectors also must provide high quality electrical connection through very broad ranges of temperature variations.

In various applications, connectors and posts may be used to supply the power and/or ground connections required. These posts and connectors can be used to carry different amperage and/or different voltage, depending upon the requirements of the system. These electrical connectors may also be required to accommodate extremely high amperage.

Therefore, it is imperative that when installing the electrical connectors onto the posts, only connectors with consistent electrical properties with the mating post, e.g. polarity, amperage, voltage, be allowed to be placed in electrical engagement. Mating of a respective electrical connector with an improper post can cause a system failure and result in a hazardous, and potentially life threatening, situation.

It would, therefore, be beneficial to have isolation or keying members which facilitate a quick, simple and reliable connection of the connectors to the posts and which ensure for a safe and effective electrical connection between the connectors and the posts regardless of the environmental conditions.

SUMMARY OF THE INVENTION

In view of the above, it is an object of the subject invention to provide a connector system, method and keying member which permits a quick, simple and reliable connection between an electrical connector and a mating post only when electrical connector and the mating post have compatible electrical characteristics.

It is another object of the subject invention to provide a connector system, method and keying member which prohibits the connection between an electrical connector and a mating post when the electrical connector and the mating post do not have compatible electrical characteristics.

It is another object of the subject invention to provide a connector system, method and keying member which is effective for a high amperage electrical connector.

It is another object of the subject invention to provide a connector system, method and keying member which ensures that a properly mated connector is fully inserted onto the post, thereby ensuring that a positive electrical connection is provided and maintained.

It is another object of the subject invention to provide a connector system, method and keying member with a position assurance member to ensure that a positive electrical connection is provided and maintained.

It is another object of the subject invention to provide a connector system, method and keying member with a visual indication which provides a quick and cost effective means to confirm that the connection is secured.

It is another object of the subject invention to provide a connector system, method and keying member which does not require tooling to install.

It is another object of the subject invention to provide a connector system, method and keying member which allows the connector to be inserted onto the post from any direction, thereby allowing the connector to be terminated to the post regardless of orientation.

It is another object of the subject invention to provide a connector system, method and keying member which allows the electrical connection to remain secure regardless of vibration or other environmental conditions.

An embodiment is directed to a connector system, which includes a terminal post, a connector and a keying member. The connector has a housing body with a post receiving passage for receiving the terminal post therein. The housing body has a keying member receiving recesses provided proximate a first end of the post receiving passage. A keying member is positioned on the terminal post and maintained thereon. The keying member is configured to be positioned in the keying member receiving recesses when the connector is properly inserted onto the terminal post. The keying member prevents the mating of an improper connector onto a respective post.

An embodiment is also directed to a keying member for use on a terminal post. The keying member includes a positioning member which cooperates with a positioning shoulder of the post to properly position the keying member relative to the post. A keying projection extends from the positioning member. The keying projection cooperates with a projection receiving recess of a connector which is mated to the post, the use of the keying member ensures that only a connector with desired electrical characteristics is mated to a post with similar electrical characteristics ensuring for a proper, reliable and safe electrical connection.

An embodiment is also directed to a method of positioning a connector on a post. The method includes: inserting a keying member onto the post; retaining the keying member on the post; inserting the connector onto the post; engaging the keying member with the connector; and properly seating connector on the post if keying member properly mates with a keying receiving recess of the connector. The keying member ensures that only a connector with desired electrical characteristics is mated to a post with similar electrical characteristics ensuring that a proper, reliable and safe electrical connection is provided.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1shows a perspective view of two electrical connectors or plugs10prior to insertion on male posts or mating pins100.FIG. 2illustrates the connectors10fully mated to the posts100. The electrical connectors10and posts100are shown as illustrative representations. The particular configuration of the connectors10and posts100may vary without departing from the scope of the invention. While two connectors10are shown, any number of connectors can be used without departing from the scope of the invention. The connectors10can be used for power or ground depending upon the desired application. In addition, connectors10can be configured to be used in applications having different voltages and/or amperage requirements.

Referring toFIGS. 3 through 9, each electrical connector10has a housing body12with a post receiving passage14for receiving a respective post100therein. The electrical connector10has a first or top end16and an oppositely facing second or bottom end18which has an opening20to receive the post100therethrough. The opening20extends to the post receiving passage14. A conductor or wire receiving sidewall22extends between the first end16and the post receiving end18. A conductor or wire (not shown), is inserted into a conductive wire receiving member24which extends from the sidewall22and is terminated thereto by crimping or other known termination methods. An insulation receiving recess26extends circumferentially around the conductive wire receiving member24. The insulation receiving recess26allows an insulator, such as, but not limited to, a boot, to be installed over the conductive wire receiving member26, thereby insulating the conductive wire receiving member24from other components and the operator.

A contact28is positioned in the post receiving passage14. In the embodiment shown, the contact28is a band which extends around the circumference of the passage14. The band has resilient contact arms30which extend into the passage14(as best shown inFIG. 6). As the post100is inserted into the passage14, the contact arms30are resilient deformed and are placed in electrical contact with the post100. The contact28is positioned in the passage14such that the contact28will be placed in electrical engagement/contact with the post100regardless of the orientation of the contact28with respect to the post100. This allows the wire receiving member24to be oriented at any position about the circumference of the post100. The contact28and method of connecting the contact28to the post100are known in the industry. The conductor and wire provided in the wire receiving passage26is electrically connected to the contact28using known methods of termination. While the contact28is shown in the form of a band, other types of contacts can be used without departing from the scope of the invention.

A terminal post receiving opening32extends through the first or top end16of the body12of the connector10. The opening32is positioned in alignment with post receiving passage14. The opening32is dimensioned to receive a free or top end102of the post100therein.

Projections or tracks34(as best shown inFIG. 10) extend from the end16is a direction away from end18. The tracks34are provided on either side of opening32and, in the embodiment shown, extend essentially the entire width of the connector10. Each track34has a top surface36and an oppositely facing bottom surface38(as best shown inFIGS. 3 through 5). Each track34includes a stop surface or projection40positioned proximate a sidewall42of the connector10which is essentially opposed to the sidewall22. A slot44is provided in each track34and is spaced from the stop surface40at a position between the sidewall22and the sidewall42.

A first reference member or visual indicator46is provided on the top end16of the connector10. The first visual indicator46is provided proximate sidewall42. In the embodiment shown, the first visual indicator46is a red colored box; however other types of indicators (e.g. textured or raised areas) and other colors can used without departing from the scope of the invention. A second reference member or visual indicator48is provided on the top end16of the connector10. The second visual indicator48is provided proximate sidewall22. In the embodiment shown, the second visual indicator48is a green colored box; however other types of indicators (e.g. textured or raised areas) and other colors can used without departing from the scope of the invention.

A locking slide50is slidably mounted to the end18of connector body12. The locking slide50has an opening52which receives the top end102of the post100therein. The opening52is dimensioned to be larger than the top end102of the post100to allow the locking slide50to move relative to the top end102of the post100, as will be more fully described.

Track receiving recesses54(as best shown inFIG. 11) extend from a bottom surface56of locking slide50toward a top surface58. The track receiving recesses54are provided on either side of opening52and, in the embodiment shown, extend essentially the entire width of the locking slide50. Each track receiving recesses54has a projection60which is dimensioned to cooperate with the bottom surface38of the track34, as best shown inFIGS. 3 through 5. Each recess54include a hold projection62which extends therein. The projections62are provided in the recesses at a position between the sidewall22and the sidewall42.

A gripping surface64is provided on the top surface50. In the embodiment shown, the gripping surface64is a series of projections and recesses. However, any type of surface which facilitates and operator moving the locking slide50between an open position and a closed position can be used without departing from the scope of the invention.

A locking latch66is housed in the locking slide50. The locking slide may be overmolded over the locking latch. Alternatively, the locking latch66may be retained in the locking slide50by known securing techniques. The locking latch66is securely maintained in the locking slide50, whereby the locking latch66moves together with the locking slide50. As best shown inFIG. 12, the locking latch66has a pair of resilient latching arms68which extend from a locking section70. The locking section70has a radiused locking surface72which cooperates with the post100, as will be more fully described.

The resilient latching arms68extend from the locking section70and are mounted in the locking slide50to allow the resilient latching arms68to be resiliently deformed toward the top surface58of the locking slide50. The resilient latching arms68are spaced from each other to allow the top end102of post100to be inserted therebetween. Proximate free ends74of the resilient latching arms68are radiused sections76. The radiused sections76are configured to allow the radiused sections76to engage portions of the tracks34without damaging the tracks34. Other configurations of the radiused sections76may be used without departing from the scope of the invention.

When the electrical connector10is mated with the mating post100, the post100is received within the post receiving passage14of the electrical connector10, as best shown ifFIGS. 6 through 9.

FIG. 6shows a cross-sectional view of the electrical connector10as the electrical connector10is being mated with the post100. This view illustrates the post100positioned in the post receiving passage14prior to engaging the locking slide50. The locking slide50is shown in the open or prelocked position. In this position, the locking latch66is in a normal or undeflected position. In this position, the locking slide50is positioned proximate sidewall22. As locking slide50is positioned proximate sidewall22, the locking slide50covers second visual indicator48and exposes first visual indicator46. This provides the operator with a visual indication that the locking slide50is in the open or prelocked position. In this open or prelocked position, projections62of the track receiving recesses54are positioned in the slots44of the tracks34. The cooperation of the projections62with the slots44secures the locking slide50in the open or prelocked position, thereby preventing the locking slide50from being inadvertently moved to closed or locked position.

As insertion of the post100into the post receiving passage14continues, the top end102of post100moves through opening32and between latching arms68, as best shown inFIG. 7. As this occurs, the top surface102of the post100engages the top wall58of the locking slide50. The engagement of the top surface102with the top wall58causes the locking slide50to move away from the top end16of the body12. This movement is controlled and limited by the cooperation of the engagement of the projections60of the track receiving recesses54of the locking slide50with the bottom surfaces38of the tracks34of the body12of the connector10. This limited movement of the locking slide50relative to the tracks34allows the projections62of the recesses54to be moved from the slots44of the tracks34.

With the projections62moved from the slots44, the locking slide50can be moved from the prelocked or open position (FIGS. 3 and 7) to the transition position (FIGS. 4 and 8) and then to the closed or locked position (FIGS. 5 and 9). However, if the connector10is not properly mated with the post100, the locking slide50will not be allowed be moved to the closed or locked position, as will be described.

As the locking slide50is moved from the prelocked or open position ofFIG. 7to the transition position ofFIG. 8, the locking surface72of the locking section70of the locking latch66is moved toward the post100. As movement of the locking slide50continues, the locking surface72is positioned in a locking surface receiving recess104of post100. In the embodiment shown, the recess104extends circumferentially about the surface of the post100proximate end102. As the recess104extends about the entire circumference of the post100, the locking surface72can engage the recess104of the post100regardless of the orientation of the connector10with respect to the post100. This allows the wire receiving member24to be oriented at any position about the circumference of the post100. With the post100properly inserted into the connector10, the locking surface72is moved into the recess104which allows the locking latch66and the locking slide50to be moved to the fully locked position, as shown inFIG. 9. However, if the post100is not fully inserted, the locking surface72will not be aligned with the recess104. Additionally, the top end102of post100will not cause the resilient latching arms66to be moved toward the top surface58of the locking slide50. In this position, the free ends74of the latch arms66abut or engage stop surfaces or walls82of tracks34. Consequently, the locking slide50cannot be placed in the closed or locked position as the free ends74of the latch arms66will engage walls82to prevent the continued movement of the locking latch66and locking slide50toward the locked position. This prevents the connector10from being improperly inserted onto the post100.

With the post100properly inserted, the top end102of post100engages the resilient latching arms66. The causes the resilient latching arms66and the free ends74to be moved toward the top surface58of the locking slide50, allowing the free ends74to move above walls82. This allows the continued movement of the locking slide50toward the closed or locked position (FIG. 9) to continue, allowing the locking surface72to be moved into the recess104. As insertion continues, the resilient latching arms68are moved beyond the inclined surfaces78and into recesses80which allow the latching arms68to return toward an unstressed position. Further movement of the locking slide50toward the sidewall42is prevented, as the radiused sections76engage the stop projections40of the tracks34to prevent further unwanted movement of the locking slide50.

The positioning of the radiused sections76in the recesses80also prevents the unwanted movement of the locking slide50and locking latch66back toward the open position. Consequently, as the locking slide50and locking latch66are retained in the closed or locked position, environmental conditions, such as, but not limited to, vibration, do not result in the inadvertent or unwanted electrical disengagement of the connector10from the post100. This ensures that a positive electrical connection will be maintained.

When the locking slide50is in the open position, the locking slide50is position proximate sidewall22. In this position the second visual indicator48is covered and the first visual indicator46is exposed, providing the operator a visual indication that the locking slide50is in the open or prelocked position. When the locking slide50is in the closed or locked position, the locking slide50is position proximate sidewall42. In this position the second visual indicator48is exposed and the first visual indicator46is covered, providing the operator a visual indication that the locking slide50is in the closed or locked position. When the locking slide50is in the transition position, the locking slide50is position between sidewall42and sidewall22. In this position neither the second visual indicator48nor the first visual indicator46is fully exposed, providing the operator a visual indication that the locking slide50is not properly positioned in the closed or locked position. This allows the operator to visually determine if the connectors10are fully mated or only partially mated to the posts100.

The use of the visual indicators are easily detectable by either the human eye, a bar code type reader, a UV scanner or other device, thereby allowing for a positive indication to assure that the connector10is fully mated to mating post100. For example, if ink of a contrasting color, laser marking and/or a UV tracer are used for the visual indicators, a hand held scanner can be used to determine if the connectors10,100are fully mated even in blind mate areas.

The posts100and connectors10can be used for power or ground connections. In addition, the posts100and connectors10can be used to carry different amperage and/or different voltage. It is, therefore, essential that only connectors with similar electrical properties/characteristics be allowed to mate with respective posts. By limiting the mating capabilities between respective connectors10and posts100, a proper, optimum, reliable and safe electrical connection is ensured.

Referring toFIGS. 14 and 15, a connector system having a connector10, post100and keying member200is shown. While connector10is shown, connector10is an illustrative embodiment and the claims are not intended to be limited to the embodiment of the connector shown and described.

As best shown inFIG. 15, connector10has keying receiving relief or recess84which extends from the second or bottom end18of the body12of the connector10toward the first or top end16of the body12. In the embodiment shown, the keying receiving recess84is positioned proximate the post receiving passage14and extends about the circumference of the post receiving passage14. A projection receiving relief or recess86extends from the keying receiving recess84in a direction away from the bottom end18and toward the top end16. In the embodiment shown, the projection receiving recess86is positioned proximate the post receiving passage14and extends about the circumference of the post receiving passage14. The spacing of the projection receiving recess86from the post receiving passage14may vary, as will be further described below. Other embodiments of the keying receiving recess84and the projection receiving recess86may be used without departing from the scope of the invention.

Post100includes a bus mating end106which is positioned away from the top end102. In the embodiment shown, the bus mating end106has a circumference which is larger than the circumference of the top end102, however, other configuration can be used without departing from the scope of the invention. A positioning projection108extends about the circumference of the bus mating end106. The positioning projection108has a first surface110and an oppositely facing second surface112. The first surface cooperates with a substrate, circuit board, bus bar or other such component to properly seat the positioning projection108and the post100in position thereon. A first retaining recess114extends about the circumference of the mating end106. The first retaining recess114is spaced from the positioning projection108in a direction toward the top end102. A second locking recess116also extends about the circumference of the mating end106. The second locking recess116is positioned between the positioning projection108and the first retaining recess114. While the embodiment shown has both a first retaining recess114and a second locking recess116, other embodiments may utilize only the locking recess116.

Plastic, insulative or isolating keying members200are positioned on posts100. InFIGS. 14 and 15, different keying members200are shown. Post100has no keying member200and is consistent with the posts shown inFIGS. 1 through 13. Post100′ has a first keying member200′ and post100″ has a second keying member200″. Keying members200′ and200″, generically referred to as200, are representative embodiments of keying members200which cooperate with connectors10to ensures that only connectors with desired electrical properties/characteristics can be mated with respective posts with similar electrical properties/characteristics, as will be more fully described.

Keying members200have positioning members202which have first surfaces204and second surfaces206. The first surfaces204are dimensioned to cooperate with the second surfaces112of the positioning projections108of posts100when the keying members200are fully inserted onto posts100. Keying projections208extend from the second surfaces206of the positioning members202is a direction away from the first surfaces204. An opening210is provided in each keying member200. The openings210extend through the positioning members202and the keying projections208to allow the posts100to be inserted therethrough. The positioning members202extend about the circumference of openings210. The keying projections208also extend about, but are spaced from, the circumference of openings210at varying distances. Resilient arms212which are spaced apart by spaces214extend into the openings210to cooperate with recesses114,116of posts100, as will be more fully described.

In use, the connector system uses the keying members200to ensure that only connectors with desired electrical properties/characteristics can be mated with respective posts with similar electrical properties/characteristics, thereby ensuring that a safe and effective electrical connection between the connectors and the posts is affected.

The keying member200is inserted onto the post100prior to the electrical connector10being mated to the post. The opening210accepts the post100therein and allows the keying member200to be inserted onto the post100toward the positioning projection108of the post100. As this occurs, the resilient arms212of the keying member200are resiliently deformed. Insertion continues until the resilient arms212engage the first recess114of the post100. As this occurs, the resilient arms212move toward an unstressed position, securing the resilient arms212in the first retaining recess114and thereby securing the keying member212to the post100. In this position, the keying member200is not fully inserted onto the post100, but is retained on the post100, preventing the inadvertent removal of the keying member200from the post100.

With the keying member200maintained on the post100, the electrical connector10is inserted onto the post100. As this occurs, the post100is received in the post receiving passage14. As the connector is moved toward the positioning projection108of the post100, the keying recess84engages the keying member200. The continued insertion of the connector10forces the keying member200to be moved toward the positioning projection108, thereby causing the resilient arms212to move from the first retaining recess114to the second locking recess116. With the resilient arms116positioned in the second locking recess116, the keying member200is positioned and retained in its final mating position. It should be noted that the post100may not include a first recess114, thereby allowing the keying member200to be initially positioned in the second locking recess116prior to the insertion of the connector10onto the post100.

With the keying member200properly positioned in second recess116, the insertion of the connector10onto to the post100is continued. If the connector10has the appropriate electrical characteristics/properties, the keying projection208of the keying member200will align with the projection receiving recess86of the connector10, allowing the connector10to be fully mated with the post100. As previously described, in this fully mated position, the top end102of post100engages the resilient latching arms66. The causes the resilient latching arms66and the free ends74to be moved toward the top surface58of the locking slide50, allowing the free ends74to move above walls82. This allows the continued movement of the locking slide50toward the closed or locked position (FIG. 9) to continue, allowing the locking surface72to be moved into the recess104.

Alternatively, if the connector10does not have the appropriate electrical characteristics/properties, the keying projection208of the keying member200will not align with the projection receiving recess86of the connector10, thereby preventing the connector10from being fully mated with the post100. As previously described, in this position, the locking surface72will not be aligned with the recess104. Additionally, the top end102of post100will not cause the resilient latching arms66to be moved toward the top surface58of the locking slide50. In this position, the free ends74of the latch arms66abut or engage stop surfaces or walls82of tracks34. Consequently, the locking slide50cannot be placed in the closed or locked position as the free ends74of the latch arms66will engage walls82to prevent the continued movement of the locking latch66and locking slide50toward the locked position. This prevents the connector10from being improperly inserted onto the post100with differing electrical characteristics/properties.

Many different configurations of the projection receiving recesses86and the keying projections208can be provided to provide for many different keying combinations. In order to provide for different combination, the projection receiving recesses86and the keying projections208may have, but are not limited to, different spacing, different shapes/configurations, different colors and/or other visual indicators which allow the connector10to be mated to an appropriate post100with an matching keying member200. In addition, multiple, and/or different numbers projection receiving recesses86and keying projections208may be provided to facilitate further combinations.

The method of positioning a connector on a post, as described in the description above, includes: inserting a keying member onto the post; retaining the keying member on the post; inserting the connector onto the post; engaging the keying member with the post; and properly seating connector on the post if keying member properly mates with a keying receiving recess of the connector. The keying member ensures that only a connector with desired electrical characteristics is mated to a post with similar electrical characteristics ensuring that a proper, reliable and safe electrical connection is provided.

Prior to inserting the keying member onto the post, the colors of color coded projection receiving recesses86and color coded keying projections208may be checked to make certain that they match, thereby ensuring that only proper connectors10are inserted on proper posts100. With the colors properly matched, the respective keying projection208can be properly and fully positioned in a corresponding respective receiving recesses86, thereby ensuring that only proper respective connectors10are mated on proper respective posts100.

Additionally, the method may include: inserting a keying member onto the post in a first position; engaging the keying member with the connector; and moving the keying member from a first position to a second position.

Additionally, the method may include: engaging keying projections of the keying members with projection receiving recess provided proximate the keying receiving recess.

Additionally, the method may include: engaging a latching arm of a locking latch with the post; moving the latching arm; and moving the locking latch to a locked position.

Additionally, the method may include: resiliently deforming resilient arms of the keying member as the keying member is inserted onto the post.

Additionally, the method may include: moving the resilient arms toward an unstressed position as the resilient arms engage a recess of the post, thereby retaining the keying member on the post.

The connector10, system and method described herein provides a simple and reliable connector to mating posts and to the power bus to which the posts are connected. The connector is inserted onto the post making an electrical connection thereon. The use of the keying member ensures that only connectors with desired electrical characteristics are mated to posts with similar electrical characteristics ensuring that a proper, optimum, reliable and safe electrical connection is ensured.

The use of the keying member200prevents the full insertion of the post100into the connector10if the keying projection208and the projection receiving recess86of the connector10do not align or mate, thereby prohibiting the movement of the locking slide50to the locked position. However, if the keying projection208and the projection receiving recess86of the connector10properly align or mate and the connector10is properly inserted onto the post100, the use of the locking slide ensures that the connector is fully inserted onto the post, thereby ensuring that a positive electrical connection is provided and maintained. The visual indication provides a quick and cost effective means to confirm that the connection is secured.

The configuration of the connector10, the post100and the keying member200allow for the connector to be inserted onto the post100from any direction.

While the quick connect and disconnect connector can be used for many application with varying amperage, the configuration allows for, but is not limited to, use with high amperage electrical connections which require up to 1000 amps per contact.