Connector assembly with integrated lever locking system

An electrical connector assembly comprising a connector housing; and a mate assist mechanism comprising a lever pivotably arranged on the connector housing. The lever is movable from a preliminary mating position to a fully mated position, and is configured to be releasably held in the preliminary mating position by a holding means. The holding means comprises a locking protrusion and a corresponding locking reception receiving said locking protrusion when the lever is in the preliminary mating position.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a national stage application under 35 U.S.C. §371 of PCT Application Number PCT/EP2014/072264 having an international filing date of Oct. 16, 2014, which designated the United States, said PCT application claiming the benefit of priority under Article 8 of the Patent Cooperation Treaty to European Patent Application No. 13188960.2, having a filing date of Oct. 16, 2013, the entire disclosure of each of which are hereby incorporated herein by reference.

TECHNICAL FIELD OF THE INVENTION

The present invention relates to an electrical connector assembly comprising a mate assist lever, which can be locked in a preliminary mating position.

BACKGROUND OF THE INVENTION

In many fields of applications, in particular in the case of mass production assembly processes, it is important that electrical connectors can be connected easily and fast. In cases where connectors have a plurality of electrical contact terminals to be mated, as it is often the case in the field of automotive applications, it is common that the connectors are provided with mate assist mechanisms in the form of mate assist levers or sliders to facilitate mating of connector and counter connector (mating connector).

Such mate assist mechanisms usually are provided linearly movable or pivotably movable on a connector housing. Upon mating of the connector with a corresponding mating connector, the mate assist mechanisms are moved from a first, preliminary mating position, to a second, fully mated position, thereby facilitating the mating process.

A typical example of a lever mated connector assembly is for example described in WO 2007/098253. In this document, an electrical connector assembly comprising a mate assist lever, which serves to facilitate the mating of the connector assembly, is described. The mate assist lever is pivotably mounted to a first connector and can be moved from a preliminary mating position to a fully mated position. During this movement, a cam element provided on the pivotable lever engages a corresponding cam mechanism of the counter connector, whereby the two connectors are pulled towards each other upon movement of the lever. When moved into the final mated position, a portion of the lever snaps behind a latch member on the connector housing to lock the mate assist lever in the position, thereby also locking the mating of the two connectors.

A typical example of a connector assembly with a mate assist lever is further described in US 2006/0089031 A1. Similarly as in the case of the prior document discussed above, the mate assist lever disclosed in this document is provided pivotably on a connector housing and has generally a U-shaped form with two lever arms connected by common web. Each lever arm has a pivot axis that passes through the lever arm. The lever arms are provided such that, from the preliminary mating position, they can only be rotated into the fully mated position, but not in the opposite direction. However, with this prior art construction it is possible that the lever moves unintentionally or intentionally from the preliminary mating position to another position in the direction to the fully mated position, when no counter connector is present. In such a position different from the preliminary mating position, it is not possible to mate the two connectors, so that an operator has to manually displace the lever back into the preliminary mating position to start the mating process. This requires an additional working step that is undesirable.

BRIEF SUMMARY OF THE INVENTION

According to the invention, an electrical connector assembly is provided which comprises a connector housing and a mate assist mechanism comprising a lever pivotably arranged on or assigned to the connector housing. The lever is movable from a preliminary mating position to a fully mated position. In the preliminary mating position, it is possible to initiate a mating process of the connector housing with a corresponding mating connector. In the fully mated position, both connectors are fully mated with each other. As it is generally known in the art, by moving the lever from the preliminary mating position to the fully mated position, suitable cam means provided on lever, connector housing and/or mating connector interact with each other, to pull the two connector parts towards each other into a desired mating position. Furthermore, the connector assembly comprises holding means to releasably hold the lever in the preliminary mating position. In other words, the lever is held in the preliminary mating position, so that it does not unintentionally or intentionally move to a position, where it is not possible to initiate the mating process between the connector housing and a corresponding mating connector. This has the advantage, that the connector can be shipped to the customers with the lever in the preliminary mating position, so that upon assembly, in for example a vehicle, the operator does not have to align the lever into a position, which allows to initiate the mating process, but the lever is always in the correct position, i.e. the preliminary mating position. Thus, the connector housing can be inserted into a corresponding mating connector (or vice versa) and the mating process can be finished by rotating the lever into the fully mated position.

According to the present invention, the holding means comprise at least one locking protrusion and a corresponding locking reception receiving the locking protrusion when the lever is in the preliminary mating position. Furthermore, the locking protrusion may be arranged on the connector housing. To this end, the locking reception may be arranged on the lever and have first and second locking walls arranged on opposite sides of the locking protrusion, when the protrusion is received in the reception. Upon mating with a corresponding mating connector, the mating connector displaces the locking protrusion to release the lever. Thus, it is not possible to release the lever either intentionally or unintentionally when no corresponding mating connector is mated with the connector housing. In other words, the holding means allows only a release of the lever when a corresponding mating connector is mated with the connector housing. This has the further advantage that it is clear to the operator that, when he can move the lever, i.e. the lever is released, the mating parts are mated correctly.

To provide the desired holding functionality of the locking protrusion, the locking protrusion advantageously is an L-shaped hook that is configured to engage behind one of the first and second locking walls of the locking reception. Such an L-shaped hook provides a solid and firm holding of the lever when engaged behind one of the first and second locking walls of the locking reception.

A variant of an L-shaped hook is a T-shaped hook that allows engaging behind both of first and second locking walls of the locking reception, thereby providing a firm and solid holding of the lever.

The locking protrusion may comprise an inclined surface facing the mating direction, which inclined surface of the locking protrusion facilitates the displacement of the locking protrusion by the mating connector. Such an arrangement allows a very controlled and smooth displacement of the locking protrusion, thereby avoiding any restraints in the mating, displacement or advantageously the unmating process, respectively. Alternatively, the inclined surface may be arranged in addition in any other direction or a combination of directions, e.g. the locking protrusion comprises an inclined surface on all four sides.

The lever may have a U-shaped form with two lever arms connected by a common web. A U-shaped form means that the two lever arms are arranged parallel to each other and extend in the same direction when seen from the common web. Furthermore, the connector housing comprises peripheral walls and the lever arms are arranged adjacent to the inner sides of the peripheral walls. By arranging the lever arms adjacent to the inner side of the peripheral walls of the connector housing, the movement of the lever is assured, because the movement cannot be blocked by any parts outside the connector housing. In other words, the movement of the lever is protected by the peripheral walls of the connector housing from being blocked or being damaged.

The lever may be pivotable around a pivot axis perpendicular to the mating direction, when released.

The locking reception may be configured such that the contact surfaces of the first or second locking walls with the locking protrusion are oriented in a plane parallel to the mating direction and parallel to the pivot axis of the lever. The orientation of the contact surfaces provides a simple and strong means for securing a firm holding and correct holding position of the lever.

The connector housing may comprise four peripheral walls, wherein the mating connector comprises mating walls that are configured to fit between the peripheral walls. The peripheral walls respectively the mating walls may be arranged perpendicular to at least another peripheral wall respectively mating wall and are therefore arranged such that a simple and strong means for securing the correct orientation and fitting of the mating parts is achieved.

The connector housing may comprise a mating face and at least two guiding grooves that are formed on the mating face and that are arranged to interact with corresponding guiding projections of the mating connector. The guiding grooves and projections are advantageously arranged such that they are compatible with common corresponding mating parts. Thereby, a firm mating of the corresponding parts is ensured, it is advantageously prevented to mate non-corresponding parts and the correct orientation of the mating parts to each other is ensured.

The lever may further comprise cam grooves and the mating connector may comprise cam followers that are configured to interact with the cam grooves. The provision of cam grooves and corresponding cam followers ensures a firm and correct mating of the corresponding mating parts and ensures advantageously a strong locking position when the lever is moved into the fully mated position.

The locking protrusion may be displaced by the corresponding cam follower of the mating connector, thereby releasing the lever. Thus, the lever is only released when the mating connector is in the correct (initial) mating position with the connector housing. In other words, the connector housing and the mating connector are physically interacting and can be pushed towards each other to the final mating position by means of the lever action: when the two corresponding connector parts are mated with each other, the cam followers of the mating connector displace the at least one locking protrusion of the connector housing. Thus, the lever is only released when a release is functionally necessary, and an operator wants to finalize the mating by moving the lever from the preliminary mating position to the fully mated position. Consequently, it is prevented that the lever is released intentionally or unintentionally during transport or shipment. This holding means has the further advantage that it is a compact and light construction that can be easily injection molded.

At least one, and possibly both, lever arm(s) comprise(s) the locking reception, wherein the first and second locking walls are arranged on opposite sides of the pivot axis when in the preliminary mating position as seen in mating direction.

Two locking protrusions corresponding to the two locking receptions may be arranged each on opposite peripheral walls of the connector housing. This arrangement of two protrusions on opposite peripheral walls provides a particularly advantageous arrangement that prevents an overstressing of a single locking protrusion by distributing the stress applied thereon among two locking protrusions, when the lever is not released, but moved. Furthermore, it is possible to symmetrically release the lever on opposite peripheral walls, which advantageously enables a smooth and correct mating process.

The holding means may comprise at least four locking protrusions and four corresponding locking receptions. This further improves the durability of the holding means by preventing an overstressing of a single locking protrusion or two locking protrusions by distributing the stress applied thereon among four locking protrusions due to an application of force on the unreleased lever. Furthermore, it is possible to symmetrically release the lever on opposite peripheral walls, which advantageously further improves the mating process to be smooth and correct.

The electrical connector assembly may comprise a corresponding mating connector.

DETAILED DESCRIPTION OF THE INVENTION

It is therefore an object of the present invention to provide an electrical connector assembly with a mate assist lever of robust and simple construction, whereby it is secured, that the lever stays in the preliminary mating position and thus neither unintentionally nor intentionally moves out of this preliminary mating position when no counter connector is present. It is further an object of the present invention, to achieve these advantages with an inexpensive product, which can be produced by injection molding.

FIG. 1shows a connector assembly10in a three dimensional schematic view in assembled condition. The connector assembly10comprises a lever100, a connector housing200and a wire shroud30which forms a part of connector housing200. The lever100is pivotably arranged on the connector housing200and is configured to be pivotable around a pivot axis110. The lever100has a general U-shape configuration with two parallel lever arms102,103connected by a common web105, which extends perpendicular to the arms. In the shown embodiment each lever arm102,103is symmetrical to the other and has a pivot axis110that passes through the lever arm102. The lever100serves to facilitate a mating process between the connector housing200and a corresponding mating connector300. The working principle of such mate assist mechanisms is generally well known to the skilled person, as from e.g. the prior art discussed above, so that it is refrained herein from giving a more detailed explanation thereof. The connector housing200comprises a latch wing220that comprises a locking protrusion222(seeFIG. 2). In the position shown inFIGS. 1 and 2, the lever100is in the preliminary mating position, since the entrance to cam grooves130is aligned such that a cam follower of a mating connector300can enter the grooves (seeFIG. 6).

FIG. 2shows the connector assembly10ofFIG. 1in a bottom view, i.e. as seen in mating direction. In the shown embodiment, the connector housing200comprises a mating face230that comprises pin receptions270and that is configured to interact with a corresponding mating face230of a corresponding mating connector300. The connector housing200further comprises a locking protrusion222that is arranged on the latch wing220. However, it is to be noted that the locking protrusion222can also be arranged on another part of the connector housing200. The lever100comprises a locking reception120that receives the locking protrusion222when the lever100is in the preliminary mating position. The first122and second124locking walls (see alsoFIG. 3) are arranged on opposite sides of the pivot axis110in the shown preliminary mating position as seen in mating direction. The lever100further comprises two cam grooves130that are respectively arranged in each of the lever arms102,103. As can be seen fromFIG. 2, the dashed line shows a pivot axis110, around which the lever100is pivotable.

FIG. 3shows details of the holding means118. In the embodiment shown, the locking protrusion222is arranged on the connector housing200and is received by the locking reception120that is arranged in the lever arm102,103respectively when the lever100is in the preliminary mating position. The locking reception120comprises a first locking wall122and a second locking wall124that are arranged on opposite sides of the locking protrusion222. In the embodiment shown, the locking protrusion222comprises an inclined surface228that faces the mating direction, wherein the inclined surface228of the locking protrusion222facilitates the displacement of the locking protrusion222by the corresponding mating connector300. The locking protrusions222,223extend into the respective entrances to the cam grooves130of the lever arms102,103.

FIG. 4shows further details of the holding means in a two-dimensional view of the holding means. The locking protrusion222is an L-shaped hook that is configured to engage behind the first locking wall122of the locking reception120. However, it is to be understood that the locking protrusion222can alternatively be arranged such that it engages behind the second locking wall124of the locking reception120. The person skilled in the art will understand that it is further possible that the locking protrusion222is a T-shaped hook that is configured to engage behind one of the first and the second locking walls122,124of the locking reception120. It is to be understood that the T-shaped hook is a specific embodiment of the L-shaped hook. The holding means118is configured to releasably hold the lever100in the preliminary mating position. It is to be understood that any number of locking protrusions can be arranged on the connector housing200.

FIG. 5shows a cut side view of the connector assembly10. In the embodiment shown, the lever100is in the preliminary mating position. As can also be seen fromFIGS. 1 to 4, the connector assembly10comprises symmetrically arranged identical holding means118. In the embodiment shown inFIG. 5, the arrow400referred to as “force” indicates the application of a force component in the direction of the arrow400. When released, upon the connector housing200being mated with a corresponding mating connector300, the lever100that is in the preliminary mating position is movable upon application of the force as indicated inFIG. 5, in the rotational direction115around the pivot axis110. However, due to the fact that the connector housing200is not mated with a corresponding mating connector300in the embodiment shown, as indicated by the circular arrow inFIG. 5, the lever100cannot be moved around the pivot axis110, because the holding means118, i.e. the locking protrusions222,223and the corresponding locking receptions120hold the lever100in the preliminary mating position. Thus, it is neither intentionally nor unintentionally possible to move the lever100into the fully mated position or to another position than the preliminary mating position when no corresponding mating connector300is present. Furthermore, as can be seen fromFIG. 5, the arrow450indicates a mating direction.

FIG. 6shows a cut bottom view of the connector assembly10in mating position in accordance with the invention. The mating connector300comprises a mating connector housing310and two cam followers in form of cam bolts330,331being arranged and protruding from two opposite mating walls350,352(outer walls) of mating connector300. When mated, as shown inFIG. 6, the corresponding mating connector300, the cam bolts330,331displace the locking protrusions222,223of the connector housing200, thereby releasing the lever100. Although not clearly visible inFIG. 6, the skilled person will recognize that thereby the locking protrusions will be moved or deflected outwardly out of engagement with locking reception120. In the mating process the inclined surface228that faces the mating direction of the locking protrusion222interacts with the cam bolts330, thereby facilitating the displacement of the locking protrusion222by the corresponding mating connector300. The skilled person will recognize that the corresponding cam bolt331displaces the locking protrusion223, which can comprise an identical inclined surface228as locking protrusion222, in a similar way. Upon mating of the corresponding mating connector300with the connector housing200and the displacement of the locking protrusions222,223, the lever100is now free to be pivoted around the pivot axis110perpendicular to the mating direction. In the embodiment shown inFIG. 6, one can also see that the guiding grooves240of the connector housing200are formed on the mating face230of the connector housing200and are arranged to interact with corresponding guiding projections340of the mating connector300. The cam bolts330of the mating connector300are configured to interact with the cam grooves130of the lever100as shown inFIG. 2.

FIG. 7shows a cut front view of the connector assembly10in mating position. The mating connector300further comprises mating connector pins320that are configured to interact with corresponding pin receptions270arranged on the mating face230(see e.g.FIG. 2) for establishing an electrical connection when the connectors are in mated position. The cam bolts330of the corresponding mating connector300displace the locking protrusion222,223of the connector housing200to such an extent, that thereby the lever100is released. Furthermore, the lever arms102,103are arranged adjacent to the inner sides of the peripheral walls250,252,260,262and the mating connector300comprises mating walls350,352,360,362that are configured to fit between the corresponding peripheral walls250,252,260,262of the connector housing200, as also indicated inFIG. 6. In the position shown inFIG. 7, it is now possible to move the lever100from the preliminary mating position to the fully mated position. As the skilled person recognizes, upon turning the lever100clockwise (as seen inFIG. 1) from the preliminary mating position to the fully mated position, the cam means130,330provided on the lever100and the mating connector300interact so that the connector housing200and the mating connector300are pulled towards each other to achieve a full mating of the connectors.

By the concept of displacing the locking protrusion222by the cam bolts330of the mating connector300it is assured that the lever100can only be released, when the connector housing200is in the correct initial mating position with the corresponding mating connector300; in other words when the cam followers are arranged in the entrances of the cam grooves130. Thus, the rotation or movement of the lever100is only allowed, when the rotation or movement of the lever100is necessary, i.e. in the mating process. Moreover, an improved displacement of the locking protrusion222,223can be achieved by the advantageous form of the locking protrusion222,223, e.g. by the inclined surface228of the locking protrusion222,223facing the mating direction. It is advantageously prevented that, e.g. during transport or shipment of the connector assembly10, the lever100is displaced unintentionally or intentionally when no corresponding mating connector300is present and it is prevented that an additional working step has to be provided to bring the lever100back into the preliminary mating position as it is necessary with the prior art connector assemblies.

The skilled person will recognize that the connector assembly10can be used and is used in practice in any spatial orientation, so that the expressions clockwise, up, down, left or right as used herein are only used to facilitate the description of the different elements of the connector assembly10shown in the figures.

LIST OF REFERENCE NUMERALS