Abstract:
An electrical connector system having a male and female connector. The male connector includes a U-shaped shroud axially surrounding a male terminal having an opening generally perpendicular to the male terminal&#39;s longitudinal axis. The female connector includes a female terminal having two openings, one generally parallel with the female terminal&#39;s longitudinal axis and another generally perpendicular to that axis. The male and female terminals mate in a parallel configuration having the male terminal axis generally parallel to the female terminal axis or in a perpendicular configuration having the male terminal axis generally perpendicular to the female terminal axis. A connector body holds the female terminal. The connector body defines a locking means that releasably secures the connector body to the shroud in both the parallel and perpendicular mating configurations. The locking means may include a triangular shaped lock tab that engages a similarly shaped lock aperture.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims the benefit under 35 U.S.C. §119(e) of U.S. Provisional Patent Application No. 61/809,976 that was filed Apr. 9, 2013, the entire disclosure of which is hereby incorporated herein by reference. 
     
    
     TECHNICAL FIELD OF THE INVENTION 
       [0002]    The invention generally relates to electrical connectors, and more particularly relates to a connector system that may be connected in either a straight or right angle configuration. 
       BACKGROUND OF THE INVENTION 
       [0003]    Electrical connection systems may have a wide variety of applications. Some applications may require a straight connection wherein the major axes of the connectors are generally parallel to one another while other applications require a ninety-degree connection wherein the major axes of the connectors are generally perpendicular to one another. Typically these different connector alignments require two different sets of connectors, one set configured for straight connections and a second set configured for ninety-degree connections. Requiring two different sets of connectors may increase manufacturing cost by necessitating two different sets of manufacturing tooling for each set of connectors. 
         [0004]    The subject matter discussed in the background section should not be assumed to be prior art merely as a result of its mention in the background section. Similarly, a problem mentioned in the background section or associated with the subject matter of the background section should not be assumed to have been previously recognized in the prior art. The subject matter in the background section merely represents different approaches, which in and of themselves may also be inventions. 
       BRIEF SUMMARY OF THE INVENTION 
       [0005]    In accordance with one embodiment of this invention, an electrical connector system is provided. The electrical connector system comprises a male connector and a female connector. The male connector includes a male terminal and a U-shaped shroud axially surrounding the male terminal, wherein the shroud defines an opening generally perpendicular to a male terminal longitudinal axis. The female connector includes a female terminal defining a first terminal opening generally parallel with a female terminal longitudinal axis and a second terminal opening generally perpendicular to the female terminal longitudinal axis. The female terminal is configured to mate with the male terminal in a parallel mating configuration having the male terminal longitudinal axis generally parallel to the female terminal longitudinal axis. The female terminal is also configured to mate with the male terminal in a perpendicular mating configuration having the male terminal longitudinal axis generally perpendicular to the female terminal longitudinal axis. The female connector further includes a connector body that holds the female terminal. The connector body defines a locking means configured to releasably secure the connector body to the shroud in both the parallel mating configuration and the perpendicular mating configuration. 
         [0006]    According to other embodiments of the invention a male connector and a female connector are provided. 
         [0007]    The shroud may defines a lock aperture and the locking means may include a resilient lock tab configured to engage the lock aperture, thereby securing the connector body to the shroud in the parallel mating configuration and in the perpendicular mating configuration. The lock tab defines a shape having 90 degrees of rotational symmetry. The lock tab and the lock aperture may be characterized as having a generally isosceles right triangle shape. The connector body may include a resilient cantilever beam defining the lock tab. The lock tab is proximate a free end of the cantilever beam. The connector body may further comprises a connector position assurance device including an arm configured to slide behind the cantilever beam, thereby inhibiting inward flexing of said cantilever beam. 
         [0008]    Further features and advantages of the invention will appear more clearly on a reading of the following detailed description of the preferred embodiment of the invention, which is given by way of non-limiting example only and with reference to the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING 
         [0009]    The present invention will now be described, by way of example with reference to the accompanying drawings, in which: 
           [0010]      FIG. 1  is a perspective view of an electrical connector system in a straight connection configuration in accordance with a first embodiment; 
           [0011]      FIG. 2  is a perspective view of the electrical connector system of  FIG. 1  in a ninety-degree connection configuration in accordance with the first embodiment; 
           [0012]      FIG. 3  is an exploded view of a male connector of the electrical connector system of  FIG. 1  in accordance with the first embodiment; 
           [0013]      FIG. 4  is an perspective view of the male connector of the electrical connector system of  FIG. 1  in accordance with the first embodiment; 
           [0014]      FIG. 5  is an exploded view of a female connector of the electrical connector system of  FIG. 1  in accordance with the first embodiment; 
           [0015]      FIG. 6  is a perspective side view of the female connector of the electrical connector system of  FIG. 1  in accordance with the first embodiment; 
           [0016]      FIG. 7  is a perspective side view of the electrical connector system of  FIG. 1  in a straight connection configuration in accordance with the first embodiment; 
           [0017]      FIG. 8  is a cut-away top view of the electrical connector system of  FIG. 1  in a straight connection configuration in accordance with the first embodiment; 
           [0018]      FIG. 9  is a perspective side view of the electrical connector system of  FIG. 1  in a ninety-degree connection configuration in accordance with the first embodiment; 
           [0019]      FIG. 10  is a perspective view of an electrical connector system in a straight connection configuration in accordance with a second embodiment; 
           [0020]      FIG. 11  is a perspective view of the electrical connector system of  FIG. 10  in a ninety-degree connection configuration in accordance with the second embodiment; 
           [0021]      FIG. 12  is an exploded view of a male connector of the electrical connector system of  FIG. 10  in accordance with the second embodiment; 
           [0022]      FIG. 13  is an perspective view of the male connector of the electrical connector system of  FIG. 10  in accordance with the second embodiment; 
           [0023]      FIG. 14  is an exploded view of a female connector of the electrical connector system of  FIG. 10  in accordance with the second embodiment; 
           [0024]      FIG. 15  is a perspective side view of the female connector of the electrical connector system of  FIG. 10  in accordance with the second embodiment; 
           [0025]      FIG. 16  is a cut-away top view of the electrical connector system of  FIG. 10  in a straight connection configuration in accordance with the second embodiment; 
       
    
    
       [0026]    Similar components in the various embodiments are identified in the Figures by reference numbers having the same last two digits. 
       DETAILED DESCRIPTION OF THE INVENTION 
       [0027]    An electrical connector system is presented herein that allows a male connector and a female connector to be connected in either a straight or ninety-degree connection configuration. This electrical connector system allows a wider application the connector system than connector systems requiring separate connectors for straight connections and ninety-degree connections. The connector system presented herein also provides the benefits of reduced manufacturing tooling cost, since only one set of manufacturing tools for the male connector and one set of manufacturing tools for the female connector are needed. 
         [0028]      FIGS. 1 and 2  illustrate a non-limiting example of an electrical connector system  100  that includes a male connector  102  and a female connector  104 . The electrical connector system  100  is configured so that the same male connector  102  and female connector  104  may be connected in a straight connection as shown in  FIG. 1  or connected in a ninety-degree connection as shown in  FIG. 2 . As used herein, a straight connection is one in which a male terminal axis A is generally parallel to a female terminal axis B as illustrated in  FIG. 1  and a ninety-degree connection is one in which the male terminal axis A is generally perpendicular, or at a ninety-degree angle, from the female terminal axis B. As used herein, generally perpendicular means equal to or less than 30 degrees within absolutely perpendicular and generally parallel means equal to or less 30 degrees within absolutely parallel. 
         [0029]      FIGS. 3 and 4  illustrate a non-limiting example of the male connector  102 . As shown in this exploded view, the male connector  102  includes a male blade terminal  106  that is preferably formed of a conductive material having high conductivity, such as a copper alloy. 
         [0030]    The male connector also includes an insulative shroud  108  that is configured to hold the male terminal  106 . The shroud  108  is formed of a dielectric material such as glass-filled polybutylene terephthalate (PBT). The shroud  108  partially surrounds the male terminal  106 . The shroud  108  generally forms a U-shape having an open side  110  so that the shroud  108  will not interfere with the female connector  104  when the female connector  104  and male connector  102  form a ninety-degree connection. The male terminal  106  may be interference press fit or insert molded into the shroud  108 . The male terminal  106  may further include inserts  112  for threaded fasteners  114  may be interference press fit or insert molded to secure the male connector  102  to a panel or bulkhead (not shown). 
         [0031]      FIGS. 5 and 6  illustrate a non-limiting example of the female connector  104 . As shown in this exploded view of  FIG. 5 , the female connector  104  includes a female terminal  116  that is preferably formed of an electrically conductive material having high conductivity, such as a copper alloy. The female terminal  116  has a mating portion  118  that is configured to mate, i.e. form a mechanical and electrical connection, with the male terminal  106 . The mating portion  118  is generally U-shaped having a first opening  120  that is generally parallel to the female terminal axis B and a second opening  122  that is generally perpendicular to the female terminal axis B. The first opening  120  allows the female terminal  116  to mate with the male terminal  106  in a straight connection and the second opening  122  allows the female terminal  116  to mate with the male connector  102  in a ninety-degree connection. 
         [0032]    The female terminal  116  also has a cable connection portion  124  that is configured to electrically and mechanically connect the female terminal  116  to a wire cable  126 . As shown in the example in  FIG. 5 , the cable connection portion  124  is configured to be sonically welded to the wire cable  126 . Sonically welding the cable to the female terminal  116  provides the benefit of a lower interface resistance between the wire cable  126  and the female terminal  116  and provides the benefit of a shorter terminal length compared to a terminal configured for a crimp connection to the wire cable  126 . Alternative embodiments of the female terminal configured for crimp connection to a wire cable may be envisioned since a connector with a crimp connection terminal may provide cost savings in applications that allow a larger terminal and/or higher interface resistance. 
         [0033]    The female terminal  116  may also include a terminal insert  128  that is disposed within the U-shaped portion of the female terminal  116 . The terminal insert  128  is also generally U-shaped having a first opening that is generally parallel to the female terminal axis B and a second opening that is generally perpendicular to the female terminal axis B. The terminal insert  128  is preferably formed of an electrically conductive material having high conductivity, such as a copper alloy. The terminal insert  128  defines a plurality of fins (not shown) that provide a more forceful interference fit between the female terminal  116  and the male terminal  106 . 
         [0034]    The female connector  104  also includes an insulative connector body  130  that surrounds and houses the female terminal  116 . The connector body  130  is formed of a dielectric material, such as glass-filled PBT. As illustrated in  FIG. 6 , the connector body  130  has two terminal openings or slots. The first terminal slot  132  shown in  FIG. 6  is generally aligned with the first opening  120  of the female terminal  116 , allowing the male terminal  106  to mate with the female terminal  116  when connectors form a straight connection. The second terminal slot  134  shown in  FIG. 7  is generally aligned with the second opening  122  of the female terminal  116 , allowing the male terminal  106  to mate with the female terminal  116  when connectors form a ninety-degree connection. 
         [0035]    As illustrated in  FIGS. 5-9 , the male connector and female connectors  102 ,  104  also include a connector position assurance (CPA) device to assure that the male terminal  106  and the female terminal  116  are fully mated when the male and female connectors  102 ,  104  are connected and to assure that the connectors do not become inadvertently disconnected. The CPA device comprises a pair of lock apertures  136  in the side walls  140  of the shroud  108  and a pair of lock tabs  142  on the side walls  144  of the connector body  130 . The lock apertures  136  and lock tabs  142  are configured so that they are not fully engaged until the male and female terminals  106 ,  116  are fully mated. Once the male and female terminals  106 ,  116  are fully mated, the outer edges of the lock tabs  142  will engage the inner edges of the lock apertures  136 , inhibiting relative motion between the male and female connectors  102 ,  104 . As best shown in  FIG. 6 , the CPA device also includes a cantilever beam  146  that is defined in both side walls  144  of the connector body  130 . One of the pair of lock tabs  142  is located on each cantilever beam  146  near the free end  148  of the cantilever beam  146 . A raised or “button” portion  150  is located on the cantilever beam  146  near the fixed end  152  of the cantilever beam  146 . When the female connector  104  is mated with the male connector  102 , an operator may grasp the female connector  104  by the button portion  150 , thereby flexing the cantilever beam  146  inward so that the lock tabs  142  clear the interior of the side walls  140  of the shroud  108  as the female connector  104  is inserted into the male connector  102 . After the lock tabs  142  are inserted into the shroud  108 , the operator may release the button portion  150 . As the female connector  104  is further inserted into the male connector  102 , the trailing edge of the lock tab  142  will clear the edges of the opening at which point the cantilever beam  146  will snap the lock tab  142  into place within the opening. This may produce an audible and/or tactile “click” that may provide feedback to the operator that the male and female connectors  102 ,  104  are fully engaged. 
         [0036]    As shown in  FIG. 5 , the CPA also includes a lock tab  154  that is configured to inhibit inward movement of the cantilever beam  146 . The lock tab  154  includes a pair of arms  156  that are disposed between the inner walls of the connector body  130  and the female terminal  116 . The arms  156  are connected to a thumb tab  158  that allows the arms  156  to be moved within the connector body  130 . Before the female connector  104  is inserted into the shroud  108  of the male connector  102 , the arms  156  are moved by the thumb tab  158  to a position wherein the arms  156  are not between cantilever beam  146  and the female terminal  116 , allowing the cantilever beam  146  to flex inward when an operator presses on the button portion  150 . After the connectors are mated, the arms  156  are moved by the thumb tab  158  to a position wherein the arms  156  are between the cantilever beam  146  and the female terminal  116 , preferably near the free end  148  of the cantilever beam  146 , thereby inhibiting the cantilever beam  146  from flexing inward and securing the lock tabs  142  within the lock apertures  136 . 
         [0037]    The lock tabs  142  and the lock apertures  136  have a shape that has 90 degrees of rotational symmetry, such as a square, rhombus, circle, octagon, isosceles right triangle, X, or cross, so that the lock tabs  142  may engage with the lock apertures  136  in the shroud  108  in either a straight connection or a ninety-degree connection. 
         [0038]    The female connector  104  may also include a terminal position assurance (TPA) device  160  that is configured to assure that the female terminal  116  is fully seated within the connector body  130  when the female terminal  116  is inserted into the connector body  130 . 
         [0039]    While the embodiments of this invention shown in the Figures illustrate a male connector  102  configured for panel mounting and a female connector  104  configured to be attached to a cable end, alternate embodiments of this invention may be envisioned in which the male connected is cable mounted or the female connector is panel mounted. 
         [0040]    Further, the embodiments shown in the Figures illustrate an electrical connector system having a single set of male and female terminals. Other embodiments of this invention may be envisioned having multiple sets of male and female terminals. Still other embodiments of the invention may be envisioned to connect fiber optic cables, pneumatic hoses, or fluid carrying hoses. 
         [0041]      FIGS. 10-16  illustrate another embodiment of an electrical connector system  200  that may be used in applications requiring a lower current carrying capability than the electrical connector system  100 . Elements of the electrical connector system  200  that are similar to the elements of electrical connector system  100  share the last two digits of the reference number. 
         [0042]    While this invention has been described in terms of the preferred embodiments thereof, it is not intended to be so limited, but rather only to the extent set forth in the claims that follow. Moreover, the use of the terms first, second, etc. does not denote any order of importance, but rather the terms first, second, etc. are used to distinguish one element from another. Furthermore, the use of the terms a, an, etc. do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items.