Abstract:
An electrical connector assembly is shown having a housing member with a mating assist which rotatably draws complementary connectors together. The mating assist is actuated by way of a linear actuator which rotates the mating assist member.

Description:
RELATED APPLICATION 
     This application claims priority from Provisional patent application Ser. No. 61/128,461 filed May 21, 2008. 
    
    
     FIELD OF THE INVENTION 
     The subject application relates to electrical connectors and more importantly to electrical connectors having a mating assist feature to draw complementary connectors together. 
     In certain applications, electrical connectors must be securely mated to one another to prevent disconnection of the electrical signals routed through the connector conductors. In those same applications, it is desirable that the connectors be fully mated. 
     For example, in automotive applications where electrical signals are routed to safety equipment such as air bag deployment systems or other systems relating to the operational or safety features of the vehicle, disconnection of the electrical signals as a result of accident, negligence, or operating conditions such as vibration, etc. may result in undesirable consequences. These connectors systems further require assistance in mating, as multiple pairs of contacts are being connected. Thus, the mating force can be too high for the operator or mechanic in the case of automotive applications, to accomplish by hand. Thus, a mating assist member is normally desired, if not required. 
     Some mating assist members, include a rotatable lever, where the lever has gear teeth, which mesh with complementary gear teeth on a mating connector, such that rotation of the lever, causes the gear teeth associated with the lever to draw the mating connector into electrical connection, see for example our U.S. Pat. No. 7,255,580. Other connector styles include a camming slide type arrangement, see for example our U.S. Pat. No. 6,155,850 where the slide includes camming slots which interact with a cam lug on one of the connectors, where the slide causes the camming lugs to follow the camming slots and draw the mating connector into electrical connection. 
     While these connectors have significant utility in the market place, one of their shortcomings is the need for space at least in the adjacent vicinity of the connectors, for actuation of either the lever or the slide, and the need for the space for one&#39;s hand in order to operate the connectors. 
     SUMMARY OF THE INVENTION 
     In a first embodiment, an electrical connector assembly comprises an electrical connector assembly comprising a housing having a front mating face for mating with a mating connector along a mating axis. The housing has at least one terminal receiving cavity extending therethrough, and the housing has a mating assist member operatively connected to the housing. An actuator member causes movement of the mating assist member, upon movement of the actuator member along the mating axis relative to the housing. 
     In another embodiment, an electrical connector assembly comprises a housing having a front mating face for mating with a mating connector along a mating axis, the housing having at least one terminal receiving cavity extending therethrough. The housing has a mating assist member operatively connected to the housing, where the mating assist member includes at least one gear tooth. An actuator member is movable relative to the housing along the mating axis, and is cooperable with the mating assist member, thereby moving the at least one gear tooth upon movement of the actuator member. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a front perspective view of the electrical connector assembly of the present invention; 
         FIG. 2  is a top plan view of the connector assembly of  FIG. 1 ; 
         FIG. 3  is a rear perspective view of the electrical connector assembly of  FIG. 1  from the opposite side thereof; 
         FIG. 4  is a rear plan view of the assembly of  FIG. 3 ; 
         FIG. 5  is an exploded view of the perspective view as assembled in  FIG. 1 ; 
         FIG. 6  is an exploded view of the perspective view as assembled in  FIG. 3 ; 
         FIG. 7  is a front perspective view of the connector housing; 
         FIG. 8  is a top plan view of the connector housing of  FIG. 7 ; 
         FIG. 9  is a rear perspective view of the connector housing of  FIG. 7 ; 
         FIG. 10  is a front plan view of the connector of  FIG. 9 ; 
         FIG. 11  is an inner perspective view of the rotary mating assist member; 
         FIG. 12  is an inner plan view of the rotary mating assist member of  FIG. 11 ; 
         FIG. 13  is another view of the rotary mating assist member from a different perspective; 
         FIG. 14  is outer perspective view of the rotary mating assist member; 
         FIG. 15  is a side plan view of the rotary mating assist member; 
         FIG. 16  is an outer plan view of the rotary mating assist member; 
         FIGS. 17-18  are rear perspective views of the linear actuator member; 
         FIG. 19  is a rear plan view of the linear actuator; 
         FIGS. 20 and 21  show upper and lower perspective views respectively of the outer profile of a mating connector; 
         FIG. 22  shows a side plan view of the connector assembly with the mating connector positioned within the connector assembly, prior to movement of the linear actuator member; 
         FIG. 23  is a cross-sectional view through lines  23 - 23  of  FIG. 22 ; 
         FIG. 24  is a cross-sectional view through lines  24 - 24  of  FIG. 22 ; 
         FIG. 25  is a cross-sectional view through lines  25 - 25  of  FIG. 22 ; 
         FIG. 26  is a side plan view similar to that of  FIG. 22 , showing the linear actuator moved into an intermediate position relative to the connector housing; 
         FIG. 27  is a cross-sectional view through lines  27 - 27  of  FIG. 26 ; 
         FIG. 28  is a cross-sectional view through lines  28 - 28  of  FIG. 26 ; 
         FIG. 29  is a cross-sectional view through lines  29 - 29  of  FIG. 26 ; 
         FIG. 30  is a side plan view similar to that of  FIG. 26  showing the linear actuator in the fully actuated position; 
         FIG. 31  is a cross-sectional view through lines  31 - 31  of  FIG. 30 ; 
         FIG. 32  is a cross-sectional view through lines  32 - 32  of  FIG. 30 ; and 
         FIG. 33  is a cross-sectional view through lines  33 - 33  of  FIG. 30 . 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     With reference first to  FIGS. 1-4 , a connector assembly is shown at  2  which is mateable to a mating connector  4 . Mating connector  4  could be connected to a harness of wires, or could be an electronic device, such as a control module, and therefore is shown somewhat diagrammatically and only the outer periphery (mating interface) will be described herein. Connector assembly  2  is comprised of a connector housing  6 , a rotary mating assist member  8 , and a linear actuator member  10 . As will be discussed further herein, and with reference to  FIG. 1 , it should be appreciated that linear actuator member  10  is moveable relative to connector housing  6 , along the same axis that mating connector  4  interconnects with connector assembly  2 , that is along mating axis  12 . 
     With reference now to  FIGS. 5 and 6 , the connector assembly  2  and the mating connector  4  are shown in an exploded manner where the connector assembly  2  further comprises a terminal position assurance member (TPA)  20 , a seal  22 , and a rear plate  24 . With reference now to  FIGS. 7-10 , connector housing  6  will be described in greater detail. 
     As shown, connector housing  6  includes side walls  30  having locking lugs  32  and guiding projections  34  positioned thereon. Each of the upper and lower end walls  40  is comprised of wall portion  42  and raised wall portion  44 . Raised wall portion is connected at one side to side wall  30  and at the opposite side to wall portion  42  by way of edge wall  50  and edge front  52  ( FIG. 9 ). Side walls  30 , top wall portions  42  and raised wall portions  44  define an external shroud about an inner wall  54  ( FIG. 10 ) in which are provided a plurality of terminal receiving cavities  56  for receiving contacts or terminals of the electrical connector. Wall portion  42  is discontinuous in that it does not extend entirely between both side walls  30 . The difference in height between the wall portions  42  and  44  on both the upper and lower end walls  40  of housing  6  (together with the discontinuity) defines an internal opening at  58  ( FIGS. 8 and 10 ) as described further herein. 
     With reference now to  FIGS. 7-9 , wall portion  42  includes a mounting shaft  60  integrally molded therewith, a latching aperture  62  having a beveled edge  63  ( FIG. 8 ), and a front edge at  64  ( FIG. 8 ). Raised wall portion  44  includes a circular-shaped opening at  70  which as shown in  FIG. 8  accesses wall portion  42 , as well as opening  58  from above. Finally with respect to  FIG. 9 , housing  6  includes latches  80  for latching with rear plate  24  ( FIG. 5 ), and as shown in  FIG. 7 , housing  6  has latching arms  84  for retaining TPA  20  ( FIG. 5 ). 
     With respect now to  FIGS. 11-16 , rotary mating assist member  8  will be described in greater detail. As shown in the figures, rotary mating assist member  8  includes a central hub portion  90  having a lever crank at  92  and a contact member in the form of a contact bar  94  integrally attached thereto. The central hub portion  90  includes an outer diameter portion at  96 , a bearing surface  98  with an aperture  100  therethrough. Central hub portion  90  also includes a latch at  102  ( FIGS. 11 and 12 ) having a foot portion  104 , and as best shown in  FIG. 15 , a forwardly angled stop surface  106  and a ramped surface  108 . Latch  102  is resiliently mounted to the central hub portion  90  by way of an opening  110  ( FIG. 12 ) surrounding latch  102 . As shown in  FIGS. 11 and 12 , central hub portion  90  further includes a gear member  120  having gear surfaces  122  and  124  as described in further detail. As shown best in  FIG. 15 , contact bar  94  includes contact members  130  and  132 . Contact bar  94  further includes a bearing surface  134  which is coplanar with bearing surface  98  of central hub portion  90 . 
     With reference now to  FIGS. 17-19 , linear actuator member  10  will be described in greater detail. Linear actuator member  10  is comprised of side walls  150 , end walls  152 , and a partial back wall at  156 . Side walls  150  include slots  160  which extend entirely therethrough, and into the interior of the linear actuator member  10 , as best shown in  FIGS. 17 and 18 . Side walls  150  also include latch members  162  which extend from a front edge  164 . End walls  152  define a front edge  170  having a slot  172  therethrough. Slot  172  defines a linear channel portion  174  and a lateral channel portion at  176 , within end walls  152 . As shown best in  FIGS. 17 and 18 , lateral channel portion  176  defines an inner edge or contact surface at  178  behind front edge  170 . Finally, as shown best in  FIGS. 17-19 , a contact member camming wall  190  extends from back wall  156  and includes a front contact surface  192  which includes a radiused surface at  194 . 
     With reference now to  FIGS. 20 and 21 , the profile of mating connector  4  will be described in greater detail. Mating connector has side walls  200  and end walls  202 . A gearing mechanism  206  is positioned on diametrically opposite corners and includes a gear tooth  208  having teeth surfaces  210  and  212  as described herein. With the components as described above, the assembly and operation of the connector assembly  2  will now be described. 
     Electrical connector  2  is assembled into the configuration shown in  FIG. 22  by positioning seal  22  ( FIGS. 5 and 6 ) within connector housing  6  and by latching TPA  20  and rear plate  24  to connector housing  6 . The rotary mating assist members  8  may now be positioned to fit within the corresponding openings  70  ( FIG. 8 ) and with aperture  100  ( FIG. 16 ) positioned over mounting shaft  60  ( FIGS. 7-8 ). The rotary mating assist member  8  is positioned such that bearing surface  98  ( FIG. 12 ) sits flush against wall portion  42 . Contact bar  94  is also positioned such that surface bearing  134  is positioned against the outer surface of wall portion  42  ( FIG. 8 ) and with gear member  120  positioned within internal opening  58  ( FIG. 10 ). It should be appreciated from the above description that there are two rotary mating assist members  8 , positioned in diametrically opposite positions of connector housing  6 . During the description of the operation, only one such rotary mating assist member  8  will be described, although it should be understood that the rotary mating assist members  8  operate in a mirror image fashion. 
     Linear actuator member  10  may now be assembled to housing  6  by positioning guiding projections  34  within slots  160  and by positioning contact bar  94  through slot  172 , through linear channel portion  174  and into lateral channel portion  176 . This will position first contact surface  130  of contact bar  94  within lateral channel portion  176  and adjacent to rear edge  178  ( FIG. 18 ); and position second contact surface  132  adjacent to contact surface  192  and radiused contact surface  194 , which is best shown in  FIG. 23 . Contact bar  94  will translate within lateral channel portion  176  between rear edge  178  and contact surface  192 , depending upon whether the linear actuator member  10  is being pushed or pulled. It should also be noted at this point that the latch  102  of the rotary mating assist member  8  is positioned within its corresponding latching aperture  62  with foot portion  104  overlapping beveled edge  63  which retains the rotary mating assist member  8  in a fixed position, as best shown in  FIG. 23 . In this fixed position, the connector assembly  2  is profiled to receive the mating connector  4  as described herein. 
     With reference now to  FIGS. 24 and 25 , rotary mating assist member  8  is shown in a pre-latched position such that mating connector  4  may be received into the connector assembly  2 . Rotary mating assist member is shown latched in  FIGS. 23 and 24 , with latch  102  positioned in latching aperture  62 , and with foot portion  104  overlying beveled edge  63 . In this position, gear tooth  208  may be received between the gear surfaces  122  and  124 , as best shown in  FIG. 25 . 
     Once mating connector  4  is positioned as shown in  FIG. 25 , a force F as shown in  FIGS. 27-29  may be applied to linear actuator member  10  causing mating connector  4  to be drawn into connector housing  6  by a distance D 1 . As shown in  FIGS. 27 and 28 , linear actuator member  10  is moved inwardly and rotary mating assist member  8  is shown rotated with surface  132  of contact bar  94  sliding along contact surface  192 . As also shown in  FIGS. 27-29 , latch member  102  has now moved out of its corresponding latching aperture  62 , under the influence of the torque on rotary mating assist member  8  and the angled stop surface  106  ( FIG. 15 ) applied against beveled edge  63 , and thereafter progresses towards front edge  64  ( FIG. 29 ). At this point, gear teeth surfaces  122  and  210  are in meshing engagement ( FIG. 29 ) which causes mating connector  4  to be drawn or pulled into connector housing  6 . 
     Finally with respect to  FIGS. 30-33 , linear actuator member  10  is shown in the fully locked position with latch members  162  in latch engagement with locking lugs  32 . With respect to  FIGS. 31-33 , the rotary mating assist member  8  is now rotated to its full clockwise position, with mating connector  4  drawn into connector housing  6  by a distance D 2 . 
     It should also be understood that disconnection of the connector assembly  2  from the corresponding mating connector  4  would be a reverse process from that described above. For example, a pulling force on linear actuator member  10  from the position of  FIG. 33  causes inner edge  178  ( FIGS. 17 and 18 ) to pull contact bar  94  in the opposite direction until such time as surfaces  124  and  212  engage ( FIG. 33 ). Continued rearward movement of linear actuator member  10  causes a counter rotation of rotary assist member  8  which in turn retracts mating connector  4  back to the position shown in  FIG. 25 . Latch  102  also snaps back into its locked position in aperture  62 , after ramped surface  108  ( FIG. 15 ) assists latch over edge  64 .