Abstract:
A device has both a debris deflector and a built in CPA assist. The debris deflector is a (sufficiently) large shield that covers the CPA slot and the CPA in the pre-staged arrangement. The device further includes a CPA assist that is configured to engage the pre-staged CPA (now covered by the debris deflector) so that it can allow the manufacturer to engage the now protected CPA when desired.

Description:
RELATED APPLICATION 
       [0001]    This application is a continuation-in-part of U.S. patent application Ser. No. 14/460,506, filed on Aug. 15, 2014, the entirety of which is incorporated by reference. 
     
    
     BACKGROUND 
       [0002]    Field of the Invention 
         [0003]    This patent application relates to a device for protecting a connector lock and CPA (Connector Position Assurance device) from debris while providing CPA engagement and improving assembly ergonomics. More particularly, this application relates to a device for protecting the electrical connector lock area and CPA from debris and ensuring CPA engagement and serviceability (examples of debris including, but not limited to, paint, dirt, dust, stone, sand, and spray). 
         [0004]    Description of Related Art 
         [0005]    Existing electrical connectors located in a vehicle engine compartment can include inline wire harness to wire harness connections (Female to Male interface) as well as device specific connections (e.g. EGR (Exhaust Gas Recirculation), TPS (Throttle Position Sensor), Coolant Temp, Intake Temp, and Oil Temp). Inside passenger compartment electrical connectors can include inline wire harness to wire harness connections (Female to Male interface) and device specific connections (e.g. Power Seat, Power Window, Power Lock, and Auxiliary Power). 
         [0006]    As part of the design of these connectors, male and female, the connectors are arranged to either be manually or automatically mated to one another at some point of assembly. After the connectors are mated and locked together, a Connector Position Assurance device is additionally used to ensure the connectors are properly mated together. 
         [0007]    The CPA is used in end products allowing for increased production rates and greater quality control by more readily permitting visual inspection of the electrical connectors for proper connection. Typically, the CPA is inserted in a pre-staged position into an integrated CPA slot, e.g. positioned on the top of the female connector, prior to the connectors being assembled together as shown in more detail below. The term “pre-staged” simply means that the CPA is not fully inserted in the CPA slot on the connector. 
         [0008]    Once the connectors are assembled together and locked using the connector locks, their proper engagement can be verified by the CPA device. Thus, the electrical connectors have been properly engaged if the CPA can be inserted into active position within the CPA slot on the top of the female connector. If the CPA lock cannot be inserted/activated into the assembled electrical connectors, it is an indication that the electrical connectors are not properly engaged. See for example U.S. Pat. No. 5,236,373. 
         [0009]    For example in the manufacturing of commercial, automotive, and agricultural engines utilizing an EGR system, most engines utilize an EGR Delta Pressure device typically using a Framatome Apex 2.8 Female 3 cavity connector (model #54200309) with integrated CPA slot mating to the device. An example of this connector is shown in  FIG. 1 . The 54200309 connector has 3 cavities available to accept 3 wires with female terminals applied.  FIG. 2  shows this same Apex 2.8 connector with a CPA in the CPA slot in the pre-staged position. Upon mating the female connector (54200309) with the pre-staged CPA to the corresponding male connector, the CPA is then engaged/activated by sliding (pushing) the CPA into its locked position.  FIG. 3  shows the female connector mated to a male connector with the CPA engaged into the CPA slot. While this CPA is in place, the connectors cannot be separated and the connector lock cannot be fully disengaged. 
         [0010]    However, during its intended use in an automobile or other manufacturing item the illustrated connected connectors ( FIG. 3 ) are typically subjected to many other processes during assembly. For example, painting or coating processes may result in paint/debris coating the connectors effectively sealing the connector in the locked position by paint/gluing the CPA in place. As a result if there is a desire to disconnect the connectors for maintenance, because the CPA is essentially glued into the connector/CPA slot, the maintenance personal may have to cut the wires to disconnect the part. 
         [0011]    In the prior art, to protect the CPA and CPA slot from the painting process some manufactures use rubber boots (high cost) or masking tape (labor intensive). This lessens the risk of rendering the CPA from becoming permanently locked/inoperable. However, these methods are costly and, depending on the application, could inadvertently be removed during other assembly processes. 
       OBJECTS AND SUMMARY 
       [0012]    One embodiment of the present arrangement overcomes the drawbacks of the prior art by providing a deflector protection device that couples with a connector to cover the CPA and CPA slot, so that during other assembly processes such as painting, clear coating or undercoating, the CPA and CPA slot are shielded from debris/paint/spray. 
         [0013]    To this end, a device is provided that has both a debris deflector and a built in CPA assist. In one embodiment, the debris deflector is a (sufficiently) large shield that covers the CPA slot and the CPA in the pre-staged arrangement. The device further includes a CPA assist that is configured to engage the pre-staged CPA (now covered by the debris deflector) so that it can allow the manufacturer to engage the now protected CPA when desired. 
         [0014]    When first applied to the connector, the deflector has the CPA assist held in a pre-staged position, matching the pre-stage CPA under the deflector. After attachment with the opposing connector the CPA assist is engaged by the manufacturer, causing a corresponding engagement of the CPA. While the manufacturing item continues to be assembled, the manufacturing item (e.g. automotive engine) can be subject to other assembly processes with the debris deflector protecting the CPA and CPA slot. Therefore, once other assembly processes are completed (such as painting, undercoating, etc.), the mated connection system and CPA remains serviceable/dis-connectable while simultaneously increasing the effectiveness and speed of assembly over prior art designs. 
         [0015]    In the present arrangement, the invention is described as relating to electrical connectors used in an engine assembly setting however the features of the invention may be used in a similar fashion on any connectors in any related situations where a manufacturing process subjects a mated connection to some form of debris emitting processes, such as painting or coating. 
         [0016]    To this end, the present arrangement provides for a protection device having a deflector element with a receiving slot on its underside and a CPA assist coupled to the deflector element. The CPA assist is configured to be moved from the first pre-staged position to the second active position by pressing the CPA assist to engage a CPA positioned within the CPA slot. The protection device is configured to be placed onto a connector with the receiving slot configured to be placed over a CPA slot on the connector. 
         [0017]    In another embodiment, the present arrangement provides for a protection device for attaching to a connector body with a connector position assurance lock. The protection device has a deflector element configured to attach to the connector body and a bow strap lock. The deflector element has at least one opening configured to allow one end of the CPA lock to be exposed. The bow strap lock is configured to deformably lock against a mating component near the CPA lock so to hold the protection device on the connector body. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0018]    The present invention can be best understood through the following description and accompanying drawings, wherein: 
           [0019]      FIG. 1  shows a prior art arrangement of a connector with an integrated CPA slot; 
           [0020]      FIG. 2  shows a prior art arrangement of a connector with a pre-staged CPA in the integrated CPA slot; 
           [0021]      FIG. 3  shows a prior art arrangement of two mated connectors with an engaged CPA in the integrated CPA slot; 
           [0022]      FIG. 4  shows a top perspective view of a protection element in accordance with one embodiment; 
           [0023]      FIG. 5  shows a bottom view of the protection element in accordance with one embodiment; 
           [0024]      FIGS. 6 and 7  show a connector with the protection element with the CPA assist in a pre-staged and final engaged position, respectively in accordance with one embodiment; 
           [0025]      FIG. 8  shows a top perspective view of a protection element in accordance with one embodiment; and 
           [0026]      FIG. 9  shows a connector with the protection element of  FIG. 8  with the CPA lock in an exposed pre-staged position. 
       
    
    
     DETAILED DESCRIPTION 
       [0027]    In one embodiment of the present invention as shown in  FIG. 4 , a protection device  10  includes two components, a deflector element  12  and a CPA assist  14 . In one preferred embodiment, device  10  is constructed from Nylon™, however protection device  10  can be constructed of other materials as desired depending on the cost and protection requirements. 
         [0028]    In the embodiment shown in  FIG. 4 , deflector element  12  of protection device  10  is constructed to match a particular connector, such as for example the above described Apex 2.8 connector shown in  FIGS. 1-3 . However, it is understood that the present protection device can be re-dimensioned to fit any number of sized and shaped connectors that utilize CPA systems. In this presently described arrangement, deflector  12 , and CPA assist  14  form a Nylon™ shield approximately 28 mm×28 mm and about 8 mm in thickness/height. 
         [0029]    As shown in  FIG. 5 , the underside of device  10  shows that deflector element  12  has a receiving slot  20  for correctly fitting over the projection/CPA slot at the top of the female connector (e.g. as shown in  FIGS. 1-2 ) as well as for allowing the CPA assist element  14  to move therein, so that it allows CPA assist element  14  to be held in a first pre-staged position and then slid into a second active position to contact/activate the pre-staged CPA in the slot, as described in more detail below. CPA assist  14  is dimensioned such that it slides within receiving slot  20  from the pre-staged to the engaged position through deflection of the inner portion of the assist until it is pressed all the way in or engaged. While sliding within slot  20 , the larger thumb push portion which abuts the CPA also moves inwards pressing the CPA into the CPA slot engaging the CPA. 
         [0030]    It is noted that the underside of deflector  12  as shown in  FIG. 5  has various snap clips  24  that correspond to various ridges or physical features of the top of the connector for proper mating of device  10  to connector. 
         [0031]    As shown in  FIGS. 6 and 7 , device  10  is attached to the top of the connector (e.g. Apex 2.8 connector of  FIGS. 1-3 ). To ensure proper seating, protection device  10  audibly locks/snaps into position on the connector with clear visual confirmation. Once in place, on a connector with a CPA in the pre-staged arrangement (e.g.  FIG. 2 ) an opposing connector (connection system) is mated and locked using the connection lock on the female connector. Thereafter, CPA assist  14  is engaged which in turn abuts the CPA and engages into the CPA slot both confirming the connection and locking the connectors together.  FIG. 6  shows the female connector with CPA assist  14  of protection device  10  in the pre-staged position and  FIG. 7  shows CPA assist  14  in the engaged position. 
         [0032]    Applicants note that such an arrangement for device  10  with deflector  12  and CPA assist  14  is constructed to fit onto a connector prior to mating with a second connector and thus is arranged with assist  14  to press the CPA into the CPA slot at a later time after connector mating. However, if desired the present device  10  could be clipped onto a CPA and connector arrangement after mating, but prior to further processing such as painting. In this case the CPA could already be engaged and the CPA assist  14  could be disabled, removed or otherwise not used, as CPA engagement would be completed before device  10 /deflector  12  is snapped onto the connectors. 
         [0033]    In this arrangement, device  10  not only protects CPA and CPA clot area, but also at least part of the connector lock area as well during any additional manufacturing processes that may occur to the item to which the connector is attached, such as painting, coatings etc . . . Application of the protection device  10  with debris deflector  12  and CPA assist  14  ensures the proper function of the CPA as well as leaving the connection serviceable in the future. 
         [0034]    In another embodiment  FIG. 8  shows protection device  100  that has two features, a deflector element  102  and bow lock  104 . Device  100  essentially works the same as device  10  described above, namely it is attached to a connector near the CPA slot to protect the area during normal assembly plant environmental issues that could prevent the CPA from being fully functional at a later time. However, unlike device  10 , device  100  has no CPA assist  14 . Rather with device  100  there is just an opening so that one end of the CPA lock is simply exposed so the operator may depress the CPA lock when needed. 
         [0035]    Also, device  100  has a bow strap lock element  104  that is used to retain element  102  to the connector body as shown in  FIG. 9 . Bow strap lock  104  deflects during installation and snaps under a mating parts such as the lock/CPA protective shroud. Bow strap lock  104  is a compact lock that accommodates a large tolerance range of mating components in the variously designed connector bodies. This is achieved because the entire length of bow strap lock  104  can be utilized as a locking surface. Depending upon the size of the mating part on the connector body, the middle area of bow strap lock  104  and/or its two ends can all equally interface with the mating part. 
         [0036]    While only certain features of the invention have been illustrated and described herein, many modifications, substitutions, changes or equivalents will now occur to those skilled in the art. It is therefore, to be understood that this application is intended to cover all such modifications and changes that fall within the true spirit of the invention.