Abstract:
An electrical connector is provided including first and second housings having rear ends configured to receive first and second sets of electrical contacts. The first and second housings have front ends that are matable with one another to join corresponding contacts from the first and second sets. The first and second housings are movable between initial and final positions. The electrical connector includes a lever member engaging the first and second housings and moving the first and second housings between the initial and final positions as the lever member is rotated through a range of motion. The lever member includes a cam arm having a first retention element and a second retention element. The electrical connector includes a lever retention block within an interior region of the first housing that has a pivot chamber that retains, and permits the rotation of, the first retention element within the pivot chamber.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    Certain embodiments of the present invention generally relate to a lever-based connection assembly for engaging resisting components. More particularly, certain embodiments of the present invention relate to a mate assist assembly for connecting electrical contacts contained in separate housings.  
           [0002]    In certain applications, electronic components require the mating of several electrical contacts, such as in automotive electrical components. The electronic component includes a connector housing that holds several electrical contacts, while a mating connector housing holds an equal number of electrical contacts. One connector housing includes male electrical contacts, while the other connector housing includes female electrical contacts. As the number of electrical contacts to be mated increases, it becomes difficult to fully join the mating connector housings because of friction between the mating electrical contacts. The connector housings are formed with a mate assist assembly that includes a lever-and-gear system to pull together the connector housings in order to overcome the frictional resistance created by the mating electrical contacts.  
           [0003]    A mate assist assembly is described in U.S. Pat. No. 6,099,330 issued to Gundermann that includes a lever, and first and second connector housings. Each connector housing includes electrical contacts, and the first connector housing is configured to be positioned inside the second connector housing. The lever has a handle and two arms. The arms extend from, and may be rotated alongside, end walls of the second connector housing. The arms include lever surfaces that are positioned on the end walls. The second connector housing, with the handle positioned proximate a top end, may be slid over the first connector housing to a point where the electrical contacts resist further insertion. The lever then is rotated downward along a back wall of the second connector housing which causes the lever surfaces to engage cam surfaces located on end walls of the first connector housing. As the lever surfaces engage, and are resisted by, the cam surfaces, the second connector housing is pulled further downward over the first connector housing until the electrical contacts are fully mated.  
           [0004]    Another mate assist assembly is described in U.S. Pat. No. 5,833,484 issued to Post that is similar to the &#39;330 patent, except that the second connector housing and arms of the lever are positioned on the first connector housing. Each arm includes a pinion with gears. The first connector housing includes racks situated on the first connector housing with each rack corresponding to the gear teeth of one of the pinions. As the handle is rotated upward, the racks and pinions engage and pull the second connector housing downward into the first connector housing.  
           [0005]    However, conventional mate assist assemblies suffer from a number of drawbacks. First, the arms of the lever extend out from the end walls of the connector housings and the handle extends across the top of the connector housings to the arms. The levers are therefore wide and bulky and may be difficult to rotate. Also, the levers interfere with electrical wire extending from the connector housings, and may prevent the mate assist assemblies from being used with certain space-confined electronic components. Secondly, the mate assist assemblies are time-consuming to assemble and install. The arms are pulled apart and slid along the end walls of the second connector housing. Then each arm is individually positioned into a retention cavity or aperture.  
           [0006]    Thus a need remains for a mate assist assembly that overcomes the above mated problems and addresses other concerns experienced in the prior art.  
         BRIEF SUMMARY OF THE INVENTION  
         [0007]    Certain embodiments provide an electrical connector that includes a first housing and a second housing having rear ends configured to receive first and second sets of electrical contacts. The first and second housings also include front ends that are matable with one another to join corresponding contacts from the first and second sets of electrical contacts. The first and second housings are movable between initial and final positions, at which the first and second sets of contacts partially and fully mate, respectively. The electrical connector includes a lever member that engages the first and second housings and moves the first and second housings between the initial and final positions as the lever member is rotated through a range of motion. The lever member includes a cam arm that has a first retention element provided on at least one side of the cam arm to engage the first housing and a second retention element provided on a peripheral surface of the cam arm to engage the second housing. The electrical connector includes a lever retention block provided within an interior region of the first housing. The lever retention block has a pivot chamber that retains the first retention element while permitting rotation of the first retention element within the pivot chamber as the lever member rotates through the range of motion. 
       
    
    
     BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS  
       [0008]    [0008]FIG. 1 illustrates an isometric view of a mating assist assembly according to an embodiment of the present invention.  
         [0009]    [0009]FIG. 2 illustrates an exploded isometric view of the mating assist assembly of FIG. 1.  
         [0010]    [0010]FIG. 3 illustrates an isometric view of the harness connector of FIG. 1.  
         [0011]    [0011]FIG. 4 illustrates an isometric view of a lever member for the mating assist assembly according to an embodiment of the present invention.  
         [0012]    [0012]FIG. 5 illustrates an exploded isometric view of the lever member and the harness connector of FIG. 1.  
         [0013]    [0013]FIG. 6 illustrates a cutaway side view of the lever member of FIG. 1 positioned within the harness connector of FIG. 1.  
         [0014]    [0014]FIG. 7 illustrates an isometric view of the module connector of FIG. 1.  
         [0015]    [0015]FIG. 8 illustrates a cutaway side view of the mating assist assembly of FIG. 1 in the initial staging position.  
         [0016]    [0016]FIG. 9 illustrates a side cutaway view of the mating assist assembly of FIG. 1 in the final mated position. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0017]    [0017]FIG. 1 illustrates an isometric view of a mating assist assembly  10  according to an embodiment of the present invention. The mating assist assembly  10  includes a lever member  15 , a harness connector  20 , and a module connector  25  aligned along a vertical axis  26 . The harness connector  20  contains contact pockets  110  configured to receive packets that hold groups of electrical contacts. The module connector  25  holds electrical contacts configured to mate with electrical contacts in the harness connector  20 . FIG. 1 illustrates the harness connector  20  partially inserted within the module connector  25  to an initial staging position. The lever member  15  is held within, and engages, the harness connector  20  and the module connector  25 . The lever member  15  is rotatable in the direction of arrow A from the initial staging position to a final mating position (FIG. 9). As the level member  15  is rotated, it presses the harness connector  20  downward into the module connector  25  and fully mates the electrical contacts of the harness connector  20  and the module connector  25  with each other.  
         [0018]    [0018]FIG. 2 illustrates an exploded isometric view of the mating assist assembly  10  of FIG. 1. The lever member  15  includes a cam arm  185  and pivot posts  190  on opposite sides of the cam arm  185 . The harness connector  20  includes a lever retention block  82  formed in the center thereof. The module connector  25  includes a mating post  267  formed in the center thereof. The mating post  267  includes catch notches  325 . The lever member  15  is removably inserted downward in the direction of arrow I into the harness connector  20  with the cam arm  185  and the pivot posts  190  positioned within the lever retention block  82 . The lever member  15  is then rotated in the direction of arrow P about a rotational axis  27  to a top surface  50 . The harness connector  20  is then removably inserted in the direction of arrow I into the module connector  25  to the initial staging position shown in FIG. 1, at which the mating post  267  projects up into the lever retention block  82  and the cam arm  185  situated within the catch notches  325 .  
         [0019]    [0019]FIG. 3 illustrates an isometric view of the harness connector  20  of FIG. 1. The harness connector  20  is box shaped and includes opposing side walls  30  and opposing end walls  35 . By way of example only, the side walls  30  are formed integral with, and are perpendicular to, the end walls  35 . A perimeter around the exterior of the harness connector  20  is smaller than an interior perimeter of the module connector  25  of FIG. 1, in order that the harness connector  20  may be positioned within the module connector  25 . The harness connector  20  is symmetrical, so that the harness connector  20  may be positioned inside the module connector  25  of FIG. 1 in one of two different alignments turned 180 degrees.  
         [0020]    The side and end walls  30  and  35  each include a rectangular recessed portion  60  that is centered in the corresponding side and end walls  30  and  35 , and that extends from a bottom surface  55  to the top surface  50 . The recessed portions  60  of the side walls  30  each include two square shaped retention protrusions  65  that extend outward. The recessed portions  60  of the end walls  35  each include a rectangular shaped retention protrusion  70  that extends outward. The retention protrusions  65  and  70  engage interior surfaces  275  (FIG. 7) of the module connector  25  as the harness connector  20  is slidably inserted into the module connector  25  and retain the harness connector  20  in the initial staging position within the module connector  25  (as explained below in more detail in connection with FIG. 7).  
         [0021]    The side and end walls  30  and  35  are formed integral with thin rectangular support walls  74  and  75 , respectively, that are centered along interior surfaces of the side walls  30  and  35 . The support walls  74  and  75  extend perpendicularly inward from the side and end walls  30  and  35 , respectively. The support walls  74  and  75  are formed integral with the lever retention block  82  to hold the lever retention block  82  in a desired position. The lever retention block  82  is formed with interior side walls  80  and interior end walls  85  that define and enclose a rectangular cavity  90 . The interior side and end walls  80  and  85  include top surfaces  105 . The lever retention block  82  receives, within the cavity  90 , the mating post  267  on the module connector  25  of FIG. 2. The side and end walls  30  and  35 , the support walls  75 , and the interior side and end walls  80  and  85  form the contact pockets  110  that extend through the harness connector  20  between the top and bottom surfaces  50  and  55 . By way of example, only the contact pockets  110  are L-shaped. The contact pockets  110  are configured to receive one or more contacts that mate with corresponding contacts in the module connector  25 . Electrical contacts (not shown) are loaded through each of the four contact pockets  110  from one end of the harness connector  20  toward a second end of the harness connector  20 . When the bottom surface  55  of the harness connector  20  is slidably inserted into the module connector  25 , the electrical contacts engage electrical contacts (not shown) situated in the module connector  25 .  
         [0022]    The interior side walls  80  include J-shaped ribs  120  and gearing ribs  125  formed thereon. The J-shaped ribs  120  extend inward from the interior side walls  80  and are aligned opposite each other across the cavity  90 . Likewise, the gearing ribs  125  extend inward from the interior side walls  80  and are aligned opposite each other across the cavity  90 . The J-shaped ribs  120  and gearing ribs  125  that are provided on the same interior side wall  80  include lead ends that are separated by an insertion gap  170  and body sections that define a pivot chamber  171 .  
         [0023]    The J-shaped ribs  120  include rear and front surfaces  135  and  140  that extend downward parallel to each other from the top surface  105  and curve inward toward the gearing ribs  125  to form the J shape. Side surfaces  145  of the J-shaped ribs  120  are perpendicular to the rear and front surfaces  135  and  140  and face inward toward each other across the cavity  90 .  
         [0024]    The gearing ribs  125  include rear and front surfaces  155  and  160  that extend downward parallel to each other from the top surface  105  and curve semi-circularly and concentrically away from the front surfaces  140  of the J-shaped ribs  120 . Side surfaces  165  of the gearing ribs  125  are perpendicular to the rear and front surfaces  155  and  160  and face inward toward each other across the cavity  90 .  
         [0025]    In operation, the lever member  15  is inserted into the cavity  90  with the pivot posts  190  of the lever member  15  (FIG. 4) sliding into the insertion gaps  170  until the pivot posts  190  are positioned in the pivot chambers  171  on top of the front surfaces  140  of the J-shaped ribs  120  and underneath and behind the rear surfaces  155  of the gearing ribs  125 . The pivot posts  190  are rectangular and thus are only insertable into the insertion gaps  170  when aligned along the vertical axis  26 . The pivot posts  190  are rotatable within the pivot chambers  171 .  
         [0026]    The harness connector  20  is then slidably inserted into the module connector  25 . When the harness connector  20  is fully inserted into the module connector  25 , the mating post  267  (FIG. 2) of the module connector  25  extends upward through the cavity  90  between the J-shaped ribs  120  and the interior end walls  85  and between the gearing ribs  125  and the interior end walls  85 . The mating post  267  of the module connector  25  positioned within the cavity  90  of the lever retention block  82  catches the lever member  15  as the lever member  15  is rotated in the pivot chambers  171 , causing the harness connector  20  to be pulled into the module connector  25 .  
         [0027]    [0027]FIG. 4 illustrates an isometric view of the lever member  15  for the mating assist assembly  10  according to an embodiment of the present invention. The lever member  15  includes a cylindrical handle  175 , a rectangular shaft  180 , the elbow shaped cam arm  185 , and the two rectangular pivot posts  190 . The handle  175  is formed integral with, and extends perpendicularly from, a first end of the shaft  180  to form a T-shape. The cam arm  185  is formed integral with, and extends outward from a second end of the shaft  180 . The shaft  180  includes a back surface  200 . The shaft  180  and the cam arm  185  share exterior side surfaces  195 . The shaft  180  and the handle  175  may be used to position the lever member  15  So that the pivot posts  190  rotate within the pivot chambers  171  of FIG. 2 and cause the cam arm  185  to catch or release the module connector  25  of FIG. 1.  
         [0028]    The cam arm  185  also includes a curved first contact wall  225 , a curved second contact wall  230 , and a curved retention wall  235 . The first contact wall  225  curves out from a back surface  220  of the cam arm  185  toward the back surface  200  of the shaft  180  to join the retention wall  235 . The retention wall  235  extends upward at an acute angle to a bottom surface  222  of the cam arm  185  to join the second contact wall  230 . The second contact wall  230  curves upward and out from the retention wall  235  to a top surface  210  of the cam arm  185 . The first contact wall  225  catches the mating post  267  of FIG. 2 and pulls the harness connector  20  of FIG. 2 down into the module connector  25  of FIG. 2 when the pivot posts  190  are rotated in the direction of arrow B about the rotational axis  27  within the pivot chambers  171  shown in FIG. 3. The second contact wall  230  catches the mating post  267  and pushes the harness connector  20  up and out of the module connector  25  when the pivot posts  190  are rotated in the direction of arrow C about the rotational axis  27  within the pivot chambers  171 . The retention wall  235  holds and retains a front portion  380  (FIG. 7) of the mating post  267  that the first and second contact walls  225  and  230  catch.  
         [0029]    The pivot posts  190  are aligned with each other on the opposite side surfaces  195  of the cam arm  185  and extend outward and perpendicularly away from the side surfaces  195 . The pivot posts  190  include flat side walls  240 , rounded top walls  245 , rounded bottom walls  247 , and flat exterior surfaces  250 . The side walls  240  are situated at an acute angle to the bottom surface  222  of the cam arm  185 . The side walls  240 , top walls  245 , and bottom walls  247  engage the J-shaped ribs  120  and the gearing ribs  125  when the pivot posts  190  are positioned in the pivot chambers  171 .  
         [0030]    [0030]FIG. 5 illustrates an exploded isometric view of the lever member  15  and the harness connector  20  of FIG. 1. In operation, the lever member  15  is oriented so that the side walls  240  of the pivot posts  190  are parallel to the vertical axis  26 . The lever member  15  may then be inserted downward in the direction of arrow D into the cavity  90  with a front surface  215  of the cam arm  185  facing toward an inner surface  121 . The lever member  15  is fully inserted in the cavity  90  with the exterior side surfaces  195  of the cam arm  185  positioned between and contacting the side surfaces  145  and  165  of the opposite J-shaped ribs  120  and the opposite gearing ribs  125 , respectively, and with the pivot posts  190  positioned within the pivot chambers  171  and resting on the J-shaped ribs  120 . When the side walls  240  of the pivot posts  190  are parallel to the vertical axis  26 , the bottom walls  247  of the pivot posts  190  contact the front surfaces  140  of the J-shaped ribs  120  and the exterior surfaces  250  of the pivot posts  190  contact the interior side walls  80  of the harness connector  20 . The lever member  15  is then rotated in the direction of arrow E about the rotational axis  27  until the back surface  200  of the shaft  180  rests on the top surface  50  of one of the end walls  35 .  
         [0031]    [0031]FIG. 6 illustrates a cutaway side view of the lever member  15  of FIG. 1 positioned within the harness connector  20  of FIG. 1. One side wall  240  of the pivot post  190  rests upon the front surface  140  of the J-shaped rib  120  and the other side wall  240  and the top wall  245  engage the rear surface  155  of the gearing rib  125 . The first contact wall  225  thus faces one of the interior end walls  85  and the second contact wall  230  faces downward in the direction of arrow F.  
         [0032]    [0032]FIG. 7 illustrates an isometric view of the module connector  25 . Two side walls  260  are formed integral with, and are aligned perpendicular to, end walls  265 . A base  255  is formed integral with, and extends outward from, the side and end walls  260  and  265 . The base  255  is mounted to an electronic component (not shown), such as a radio, with the side and end walls  260  and  265  extending outward from the electronic component. The mating post  267  is also mounted to the electronic component and centered between the side and end walls  260  and  265 . Electrical contacts (not shown) extend from the electronic component through the module connector  25  around the mating post  267  and between the side and end walls  260  and  265 . The module connector  25  is symmetrical throughout, so the module connector  25  may be mounted on the electronic component in one of two different alignments turned 180 degrees.  
         [0033]    Each side and end wall  260  and  265  includes two upper protrusions  290  and two lower protrusions  295  that are generally centered on, and extend inward from, the interior surface  275 . The upper protrusions  290  are aligned next to each other along a top surface  280 , and the lower protrusions  295  are aligned next to each other and are below the upper protrusions  290  to form a retention gap  300  between the upper protrusions  290  and the lower protrusions  295 . The retention gap  300  is generally similar in size to the retention protrusions  65  and  70  of the harness connector  20  of FIG. 3. Therefore, when the harness connector  20  is initially positioned into the initial staging position inside the module connector  25 , the retention protrusions  65  and  70  engage and slide past the upper protrusions  290 , and are retained in the retention gap  300 . When the lever member  15  is rotated upward in the direction of arrow G (FIG. 8) about the rotational axis  27  and the harness connector  20  is pulled further downward in the direction of arrow L (FIG. 8) to connect the electrical contacts, the retention protrusions  65  and  70  of the harness connector  20  of FIG. 3 slide out of the retention gap  300  over the lower protrusions  295  to a resting position below the lower protrusions  295 . The retention, lower, and upper protrusions  65 ,  70 ,  295 , and  290  thus engage each other to retain the harness connector  20  in the staging position in the module connector  25 .  
         [0034]    The mating post  267  includes opposed parallel side walls  305 , and opposed parallel end walls  310  extending upward through an interior region of the module connector  25 . The side walls  305  include the opposed U-shaped catch notches  325 , which are defined by flat inner walls  340  and a concave bottom wall  345 . The side walls  305  may be formed integral with, and aligned perpendicular to, the end walls  310 . The side and end walls  305  and  310  engage and slide along the interior side and end walls  80  and  85 , respectively, when the harness connector  20  is inserted into the module connector  25 .  
         [0035]    The mating post  267  includes resistance portions  320  that each have three sloped walls  355  and a top surface  360 . Two of the sloped walls  355  extend upward toward each other at an obtuse angle from exterior surfaces  330  of the side walls  305 , and one of the sloped walls  355  extends upward at an obtuse angle from the exterior surface  330  of one of the end walls  310 . All three sloped walls  355  are joined to the top surface  360  above the side and end walls  305  and  310 . The shaft  180  of FIG. 4 is positioned horizontally on top of one of the top surfaces  360  perpendicular to the vertical axis  26  when the harness connector  20  is in the staging position within the module connector  25 . Each resistance portion  320  also includes a resistance wall  365  that extends vertically downward from the top surface  360  between, and perpendicular to, the side walls  305  to a camming tooth  315 . The resistance walls  365  are positioned to engage and resist the shaft  180  as the shaft  180  is moved from a horizontal position on top of one of the top surfaces  360  upward to a position at an acute angle to the vertical axis  26 .  
         [0036]    The camming teeth  315  are situated between the side walls  305  and include ridged top portions  370 , ridged bottom portions  375 , and the flat front portions  380 . Each front portion  380  is perpendicular to, and aligned on a plane with, the inner walls  340  of one of the catch notches  325 . Each top portion  370  extends upward toward one of the resistance walls  365  at an obtuse angle to the front portion  380  and each bottom portion  375  extends downward toward one of the resistance walls  365  at an obtuse angle to the front portion  380 .  
         [0037]    [0037]FIG. 8 illustrates a cutaway side view of the mating assist assembly  10  of FIG. 1 in the staging position. The upper and lower protrusions  290  and  295  of the module connector  25  engage the protrusions  65  of the harness connector  20 . The first contact wall  225  is positioned proximate the bottom portion  375  of one of the camming teeth  315 , and the second contact wall  230  is positioned above the top portion  370  of the camming tooth  315 . The handle  175  is then used to rotate the shaft  180  upward in the direction of arrow G about the rotational axis  27 . As the shaft  180  is rotated, the pivot posts  190  rotate in the direction of arrow G about the rotational axis  27  within the pivot chambers  171  causing the first contact wall  225  to move upward in the direction of arrow N and catch the bottom portion  375  of the camming tooth  315 . As the first contact wall  225  pushes against, and is resisted by, the bottom portion  375 , the pivot posts  190  are pushed downward in the direction of arrow L against the J-shaped ribs  120  and thus position the harness connector  20  further downward into the module connector  25 .  
         [0038]    [0038]FIG. 9 illustrates a side cutaway view of the mating assist assembly  10  of FIG. 1 in the final position. When the harness connector  20  has been fully inserted into the module connector  25 , the shaft  180  is positioned at an angle, generally 60 degrees, to the top surface  50 , and the top walls  245  of the pivot posts  190  engage the rear surfaces  155  of the gearing ribs  125  and the bottom walls  247  of the pivot posts  190  engage the front surfaces  140  of the J-shaped ribs  120 . The mating post  267  extends through the cavity  90  of the lever retention block  82  of FIG. 2. The J-shaped ribs  120  and gearing ribs  125  are positioned in the catch notches  325  above the bottom walls  345  and between the inner walls  340  of the mating post  267 . The harness connector  20  may be removed from the module connector  25  by rotating the lever member  15  back downward in the direction of arrow J about the rotational axis  27  until the shaft  180  is positioned on top of the top surface  50 . As the lever member  15  is rotated in the direction of arrow J about the rotational axis  27 , the second contact wall  230  engages the top portion  370  of the camming tooth  315  and pushes downward in the direction of arrow K against the top portion  370 . The rear surfaces  155  of the gearing ribs  125  push downward in the direction of arrow K against the pivot posts  190  and retain the pivot posts within the pivot chambers  171 . Therefore, as the second contact wall  230  pushes downward in the direction of arrow K against the top portion  370  of the camming tooth  315 , the pivot posts  190  are pulled upward in the direction of arrow M and likewise pull upward in the direction of arrow M the J-shaped ribs  120  and gearing ribs  125 , and thus lift the harness connector  20  partially out of the module connector  25 . The harness connector  20  may then be fully removed from the module connector  25  by hand or a tool.  
         [0039]    In an alternative embodiment, the cam arm  185 , pivot posts  190 , and mating post  267  may be oriented so that the shaft  180  of the lever member  15  may be positioned upright at a 90 degree angle to the top surfaces  50  when the harness connector  20  is fully inserted into the module conductor  25 . Similarly, the cam arm  185 , pivot posts  190 , and the mating post  267  may be oriented so that the shaft  180  of the lever member  15  is vertically upright and parallel with the vertical axis  26  when the harness connector  20  is initially inserted into the module connector  25  to the staging position. The lever member  15  may then be rotated downward in the direction of arrow J (FIG. 9) about the rotational axis  27  (FIG. 9) until the shaft  180  is horizontal and resting upon the top surface  50  of an end wall  35  to fully insert the harness connector  20  into the module connector  25 .  
         [0040]    The mating assist assembly  10  takes up less space and thus may be used with a greater variety of electronic components. Also, the mating assist assembly  10  is easily assembled by lowering the lever member  15  within the pivot chambers  171  of the harness connector  20  and then positioning the harness connector  20  within the module connector  25 . Thus, assembling and implementing the mating assist assembly  10  may require limited time and effort.  
         [0041]    While the invention has been described with reference to certain embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from its scope. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed, but that the invention will include all embodiments falling within the scope of the appended claims.