Abstract:
A connection system is shown where a lever-assist member may be added to assist in the mating between two connector housings as is needed depending upon a number of connector terminals loaded and the mating force between them. The lever-assist member is also locked in place by the interaction of the pivot-assist member and the corresponding latching structure of the connectors. The lever-assist member, when moved into the disconnection condition, has a projection which holds the cantilever beam arm of the latch in a position allowing the two connectors to be disconnected, which does not require the user to continue depressing the latch at the same time as rotating the pivot-assist member.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     The subject invention relates to a connector design having a mating assist member to assist in the mating and unmating of two hand mate capable electrical connector halves.  
         [0002]     In several different applications or industries, particularly in the automotive industry, electrical connector designs are standardized on various different harnesses or on various different discrete ends of a particular harness.  
         [0003]     Just by way of example, it is common to provide as part of a wiring harness, wiring which extends into the automobile body, for example, and be connected to a mating connector at or under the driver&#39;s seat. Such connections can be used for the power seat having multiple ways of adjustment including up, back, tilt, and lumbar, as well as providing the opportunity for multiple variances of seat heating. In such an example, it would be common to provide multiple sizes of terminals depending on the power or amperage that needs to run through the cable, and thus the connectors need to accommodate multiple sizes of terminals as well.  
         [0004]     It is also common in the industry to have standardized maximum mating forces which are allowable for the assembly line in automobile plants. One such standard, known as USCAR, has designated 75 Newtons as a maximum mating force. USCAR is an umbrella organization made up of automotive manufacturers for joint research. This is the maximum force that can be designed into a connector assembly, where the two connectors are mated into a latched condition by hand including no assistance in the connection. Above the 75-Newton requirement, some type of mating assistance between the two connectors is required.  
         [0005]     It is well known in the industry to provide for a mating assist member, sometimes in the form of a pivotal lever, for example, as shown in U.S. Pat. No. 5,833,484 incorporated herein by reference. The lever can rotate to cause cooperable teeth on the mating housings to engage and bring the housings together. It is also a requirement to have a latching structure which can retain the two housings together. This can cause difficulties where a latch must be disengaged while at the same time, a lever needs to be rotated, as two hands are normally required, and the two functions may conflict with each other ergonomically.  
         [0006]     The object then of the present invention is to provide a connector design which can accommodate all of the above-mentioned requirements.  
       SUMMARY OF THE INVENTION  
       [0007]     The objects were accomplished by providing an electrical connector, for interconnection to a mate able connector, where the mate able connector has a latch, to latch the electrical connector and the mate able connector together. The electrical connector comprises a connector housing having a mating assist member for assisting in the drawing together of the connector housing and the mate able connector, the mating assist member having a contoured surface to cooperate with, and hold down the latch, during the counter rotation of the mating assist member.  
         [0008]     The mating assist member may be comprised of a lever, which may also be profiled as a pinion gear with gear teeth which mesh with teeth on the mate able connector.  
         [0009]     The mating assist member may also be locked to the latch, when in the fully latched position. The mating assist member may be comprised of a lever member which rotates into a snap locked position with the latch, when in a fully latched position. The lever member may be comprised of an upper lever arm and two side arms, which pivot relative to the housing. The electrical connector may have a trailing edge of the upper lever arm profiled to snap lock beneath the latch of the mate able electrical connector.  
         [0010]     The electrical connector may have the contoured surface comprised as a projection, profiled to engage the latch upon movement of the mating assist member. The latch may be profiled as a cantilevered beam extending rearwardly of the housing. The extreme end of the cantilevered beam may be a contact surface. The mating assist member may be comprised of a lever which rotates into a snapped lock position with the contact surface, when in the fully latched position.  
         [0011]     In another version of the invention, an electrical connector assembly comprises a first connector housing for interconnection to a mate able second connector housing, where one of the connector housings has a latch, to latch the first connector housing and the mate able second connector together, and the other of the connector housings has a mating assist member for assisting in the drawing together of the connector housings. The mating assist member has a contoured surface to cooperate with, and hold down the latch, during the counter rotation of the mating assist member.  
         [0012]     The mating assist member may be comprised of a lever and the lever may be profiled as a pinion gear with gear teeth which mesh with teeth on the mate able connector. The mating assist member may be locked to the latch, when in a fully latched position. The mating assist member may be comprised of a lever which rotates into a snapped lock position with the latch, when in the fully latched position. The lever may be comprised of an upper lever arm and two side arms, which pivot relative to the housing. The trailing edge of the upper lever arm may be profiled to snap lock beneath the latch of the mate able electrical connector.  
         [0013]     The contoured surface may be comprised of a projection, profiled to engage the latch upon movement of the mating assist member. The latch may be profiled as a cantilevered beam extending rearwardly of the housing. The extreme end of the cantilevered beam is a contact surface. The mating assist member is comprised of a lever which rotates into a snap locked position with the contact surface, when in the fully latched position  
         [0014]     In yet another aspect of the invention, an electrical connector assembly comprises a first connector housing for interconnection to a mate able second connector housing. One of the connector housings has a latch to latch the first connector housing and the mate able second connector together. The other of the connector housings has a mating assist member for assisting in the drawing together of the connector housings, the mating assist being locked to the latch, when in a fully latched position.  
         [0015]     The latch may be profiled as a cantilevered beam extending rearwardly of the housing. The extreme end of the cantilevered beam may be a contact surface. The mating assist member may be comprised of a lever which rotates into a snapped lock position with the contact surface, when in the fully latched position. The lever may be comprised of an upper lever arm and two side arms, which pivot relative to the housing. The trailing edge of the upper lever arm may be profiled to snap lock beneath the latch of the mate able electrical connector.  
         [0016]     The mating assist member may also have a contoured surface to cooperate with, and hold down the latch, during the counter rotation of the mating assist member. The contoured surface may be comprised of a projection, profiled to engage the latch upon movement of the mating assist member. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0017]      FIG. 1  is a perspective view showing the connector assembly in a mated condition;  
         [0018]      FIG. 2  is an underside perspective view of  FIG. 1 ;  
         [0019]      FIG. 3  shows an exploded view of the entire plug assembly of the embodiment of  FIG. 1 ;  
         [0020]      FIG. 4  shows an exploded view of the lever-assist plug housing in greater detail;  
         [0021]      FIGS. 5 and 6  show alternative perspective views of the mating assist lever shown in  FIG. 4 ;  
         [0022]      FIG. 7  shows a cross-sectional view through  FIGS. 7-7  of  FIG. 6 ;  
         [0023]      FIG. 8  shows the assembled view of the components of  FIG. 4 ;  
         [0024]      FIG. 9  shows an exploded view of the header or male connector, also shown in  FIG. 1 ;  
         [0025]      FIG. 10  shows an enlarged view of the housing portion of  FIG. 9 ;  
         [0026]      FIG. 11  shows the header assembly or male half of the connector from the opposite perspective as  FIG. 10  shows the housing only;  
         [0027]      FIG. 12  shows a view showing the connectors of  FIGS. 8 and 10  poised for interconnection;  
         [0028]      FIG. 13  shows a cross-sectional view through lines  13 - 13  of  FIG. 1 ;  
         [0029]      FIG. 14  shows the connectors of  FIG. 13  in the initial disconnection state;  
         [0030]      FIG. 15  is an enlarged view of the encircled portion on  FIG. 14 ;  
         [0031]      FIG. 16  is a cross-sectional view similar to that of  FIG. 14  showing the connectors in a further disconnection state; and  
         [0032]      FIG. 17  shows an enlarged view of the encircled portion on  FIG. 16 . 
     
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0033]     With respect first to  FIGS. 1 and 2 , an electrical connector assembly is shown as  2 , which comprises a plug connector assembly  4  with a mating assist member  6 , shown here as a lever or lever arm, interconnected to a header connector assembly shown at  8 . The two connector assemblies  4 ,  8  are held together by a latch assembly shown generally at  10  and which will be described in greater detail herein.  
         [0034]     With respect now to  FIG. 3 , the plug or female connector assembly  4  is shown in an exploded manner, where mating assist member  6  is exploded away from its associated connector housing  20 , and where a rear wire seal  22  and rear cover  24  are also shown together with contacts or terminals  26  and  28 . On the front side of the connector housing  20 , a front seal  30  and a terminal position assurance member  32  are shown exploded from the front side of connector housing  20 .  
         [0035]     With reference now to  FIG. 4 , connector housing  20  and mating assist member  6  are shown exploded from each other, and connector housing  20  is shown in greater detail. Housing  20  generally includes an exterior profile defined by an outer shroud  34 , which includes alignment channels  36 , and further includes a central raised wall at  38 . This central raised wall  38  includes a central notch at  40 , with a latching mechanism in the form of locking projections  42  (only one of which can be viewed in  FIG. 4 ) extending downwardly from the central raised wall  38  along the perimeter of notch  40 , as will be further described herein. Raised wall  38  is spaced above an inner wall  46 , and defines an opening therebetween for receipt of a mating latch as will also be described in greater detail herein.  
         [0036]     With respect still to  FIG. 4 , connector housing  20  further includes a pair of mounting walls  50  connected to the connector housing  20  by side walls  52 , separating mounting walls  50  from an inner portion of housing  20  and defining channels  54  therein. Mounting walls  50  further include mounting slots shown generally at  56 , each including a narrowed passageway  58  opening into an enlarged circular bearing  60 .  
         [0037]     The connector housing  20  also includes a conventional internal housing portion at  64  having a plurality of terminal cavities, such as  66 , for smaller electrical terminals and enlarged cavities at  68 , for larger current carrying capacity electrical terminals.  
         [0038]     With respect now to  FIGS. 5 through 7 , mating assist member  6  is comprised of an upper arm at  70  having side arms at  72 . Upper arm  70  includes a notched portion at  74 , which includes a first latching projection at  76 , positioned at a trailing edge of the upper arm  70 . As best shown in  FIGS. 5 and 7 , mating assist member  6  further includes at least one contoured surface to assist in releasing the latch assembly  10 , shown here as two release projections  78  in  FIGS. 6 and 7 . With respect to  FIGS. 5 and 6 , mating assist member  6  further includes an axle portion at  80  including parallel and opposed flat surfaces  82 , with upper and lower circular portions at  84 .  
         [0039]     With respect now to  FIGS. 5 and 7 , the mating assist member  6  further includes a pinion portion  90  having drive teeth  92  and  94 . As shown in  FIGS. 5 through 7 , mating assist member  6  further includes an arcuate arm portion  100  connected to the side walls  72  via an arm portion  102 , as best shown in  FIG. 7 . Arcuate arm portion  100  is spaced away somewhat from side walls  72  and positioned above axle portion  80  so as to cause an entry opening at  106 , as best seen in  FIG. 5 . Arcuate arm portion  100  includes an inner contact surface at  108 , as will be described in further detail.  
         [0040]     It should be appreciated that the axle portions  80  are profiled such that the flat surfaces  82  can be positioned between the narrowed passageways  58  ( FIG. 4 ) with the circular portions  84  being rotatable within the enlarged circular bearing  60  ( FIG. 4 ). With respect now to  FIG. 8 , connector housing  20  is shown with mating assist member  6  installed and rotated to an open position, whereby pinion tooth  92  is positioned within the channel  54  in an assist position and poised for interconnection with a mating connector, as will be described in greater detail herein.  
         [0041]     With respect now to  FIG. 9 , header connector assembly  8  is shown in an exploded manner as including a housing portion  120 , a terminal position assurance member (TPA)  122 , a discrete wire seal  124 , contacts or terminals  126  and  128 , and rear cap  130 . As shown in  FIGS. 10 and 11 , housing  120  includes a front end  140 , and a rear wire-receiving end  142 . Front end  140  includes a shrouded portion at  144 , which is profiled to mate with the plug connector housing  20  with alignment ribs  146  positionable with alignment channels  36  ( FIG. 4 ).  
         [0042]     Housing  120  further includes a latch member  150 , as a component of latch assembly  10  which includes a cantilever beam portion  152  integrally connected to a top wall  154  by a web portion  156 , and extends rearwardly of the housing  120 . As shown best in  FIG. 10 , cantilever beam portion  152  includes side wall sections  160  having locking projections  162  upstanding therefrom. Two side wall sections  164  flank the cantilever beam portion  152  and include overstress members  166 . As shown in  FIG. 10 , the extreme end of cantilever beam portion  152  includes an angled edge portion  170 , which defines a contacting surface, whereas the top of the latch cantilever beam portion  152  includes two contact surfaces at  172 .  
         [0043]     Finally, as shown in either of  FIG. 10  or  11 , housing  120  includes a portion  180  which provides an engagement lug, in the form of a simulated a gear rack including a first tooth  182 , positioned on side wall  184 . Housing  120  further includes alignment bars  190  having a locking extension at  192 , again as will be described further herein.  
         [0044]     With both connector assemblies  4 ,  8  as described herein, the operation of the connector housings  20  and  120  will be described herein. As shown in  FIG. 12 , the two connector housings are mate able with the alignment ribs  146  aligning with the alignment channels  36 , which positions locking extensions  192  in position in openings  106  ( FIG. 6 ) of the mating assist member  6 , and which positions rack tooth  182  in position to be received below pinion tooth  92 . Thus, rotation of the mating assist member  6  in the counterclockwise sense (as viewed in  FIG. 12 ) causes the engagement of the rack and pinion teeth  182 ,  92  causing the connectors to move into an interconnected state. At the same time, arcuate arm portions  100  rotate to entrap extensions  192 .  
         [0045]     When the connectors are fully engaged, the connector pair is in the position of  FIG. 1 , and locking projections  162  are positioned behind locking projections  42 . This also positions angled edge surface  170  in a close proximity to corresponding latching projection  76  on pivot-assist member as shown in  FIG. 13 . These two corresponding surfaces prevent disengagement between the two, as a counter-rotation of mating assist member  6  (that is in the clockwise position as viewed in  FIG. 13 ) would cause the abutment of the latching projection  76  and edge surface  170  lifting latch member  150  into the overstress members  166  ( FIG. 10 ).  
         [0046]     At the same time, projections  78  assist in holding the latch member  150  down during the counter-rotation, allowing mating assist member  6  to be rotated without having to hold down latch member  150  by hand. With respect first to  FIGS. 14 and 15 , when the latch is initially depressed and the mating assist member  6  has begun a counter-rotation, in the counterclockwise sense as viewed in  FIGS. 14 and 15 , projections  78  have contoured surfaces which begin to ride up on surface  172 , which holds the latch in the downward position such that locking projections  42  and  162  are clear of each other, as best shown in  FIG. 15 . Continued rotation of the mating assist member  6 , to the position now shown in  FIGS. 16 and 17 , positions projection  78  further along on surface  172  and locking projection  162  has now cleared beneath locking projection  42 , preventing snagging between the two connectors.  
         [0047]     Advantageously, the mate assist member assists in the connection between the two connector assemblies  4  and  8 , and locks them into the configuration of the cross-sectional view of  FIG. 13 . Also as mentioned above, projections  78  in the corresponding contact with contact surfaces  172  allow the mate assist member  6  to rotate and simultaneously hold the latch down such that the two connector housing assemblies can be disengaged. Said differently, projections  42 ,  162  are held in a disengaged state by the projections  78  until the two projections pass each other and clear, whereupon the two housing assemblies may be disconnected from each other. This prevents the user, from having to try to depress the latch assembly  10 , while at the same time rotate the mate assist lever. Other advantages are shown in our patent application, Attorney Docket Number E-AV-00108, Ser. No. ______, concurrently filed and incorporated herein by reference.