Abstract:
Connector position assurance apparatus, methods and articles of manufacture are disclosed. The preferred embodiments comprise a connector position assurance mechanism mounted upon a plug assembly component. The connector position assurance mechanism provides a relatively fixed connection to a mounting latch which is used to ensure connection between the plug assembly and a header assembly.

Description:
FIELD OF THE INVENTION  
         [0001]    This invention relates to apparatus, methods and articles of manufacture for electrical connectors. More particularly, this invention relates to apparatus, methods and articles of manufacture for electrical connectors, comprised of mating housings, for vehicles and the like.  
         BACKGROUND OF THE INVENTION  
         [0002]    Electrical connectors for vehicles and the like are often comprised of separate housings that are engaged through pressure, or “snap fit,” upon installation. Snap fit connectors are desirable because of the ease of installation. However, in order to ensure proper installation various complexities must be taken into account.  
           [0003]    For example, the housings must be must be securely fastened so they do not come apart after installation. Additionally, they must properly aligned so that an electrical connection is made upon installation.  
           [0004]    In order to attempt to resolve these and other difficulties, various mechanisms have been used. One especially desirable mechanism is a connector position assurance (CPA) mechanism. CPA mechanisms, placed externally to the housings, are used to assure locking and/or positioning of connector housings.  
           [0005]    Use of a CPA may lead to further difficulties when designing a connector. An external CPA may increase the space required for the connector, so a CPA may be unavailable for a connector to be mounted in a tight space. Accordingly, it would be beneficial to have a small, effectively integrated CPA mechanism for use in electrical connectors.  
           [0006]    Therefore, it is an object of the present invention to provide an electrical connector with integrated CPA.  
           [0007]    It is a further object of the present invention to provide an electrical connector with integrated CPA that minimally increases the size of the connector.  
           [0008]    It is yet a further object of the present invention to provide a small, lightweight electrical connector with integrated CPA.  
         SUMMARY OF THE INVENTION  
         [0009]    The present invention comprises connector position assurance apparatus, methods and articles of manufacture. The preferred embodiments are used with connectors that have a rear housing and front housing wherein the two are assembled together to form an mechanical and electrical connection. The connector position assurance mechanism of the preferred embodiments is mounted at least partially upon the rear housing and slides to a predetermined locking position so as to lock a mating latch used to connect the rear housing to a front housing. Audible and tactile feedback assure the connector position assurance mechanism has reached its predetermined locking position. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0010]    [0010]FIG. 1 shows a plan view of a preferred embodiment.  
         [0011]    [0011]FIG. 2 shows a plan view of a preferred embodiment.  
         [0012]    [0012]FIG. 3 shows a plan view of a preferred embodiment.  
         [0013]    [0013]FIG. 4 shows a plan view of a preferred embodiment.  
         [0014]    [0014]FIG. 5 shows a plan view of a preferred embodiment.  
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0015]    [0015]FIG. 1 shows a preferred embodiment of the present invention as it might be mounted upon support surface a. Header assembly  40  is mounted upon support surface a through a mounting base on the inside of the support surface (not shown) through screws or other mounting means as known in the art. Present within header assembly  40  are a plurality of male contacts (not shown) that engage with respective female contacts (not shown) when plug assembly  10  is installed, as will be further described. Mating latch engagement means  41 , comprised of mating latch engagement lugs  41   a,    41   b,    41   c  and  41   d,  are provided on header assembly  40 . These engagement means will provide positive engagement with mating latch  25  when plug assembly  10  is installed, as will be further described below.  
         [0016]    It should be noted that header assembly and plug assembly are used herein to denote a first and second connector housing respectively. The first and second housings are to be understood as connector components so that, when properly connected, a desired mechanical and electrical contact is made between the housings.  
         [0017]    Returning now to FIG. 1, plug assembly  10  is provided with mating latch  25 , which provides an engagement between the assemblies. The plug assembly described herein also comprises a wire seal cover  11 , which provides insulation for any wires (or other electrical conduit as known in the art) provided. Other embodiments may be used on plug assemblies, also known herein as second connector housings, that do not use a wire seal cover, or use other wire protection and/or insulation mechanisms as are known in the art. The various components of the embodiments are made from materials as known in the art, such as for example, 15% Glass PBT for the CPA tab, and possibly, the housings.  
         [0018]    The electrical conduit shown here is also provided with wire dress cover  26 . Also shown is recess  28 , and lugs  20   a,    20   b,    21   a  and  21   b,  which have mounted therein connector position assurance (CPA) tab  30  and CPA base  35 , as will be further described below. CPA tab  30  is, in this Figure, in mated position, thus providing position assurance support to mating latch  25  and so locking the assemblies. However, in installed position, and as will be further described below, under normal use the CPA tab  30  will remain in unmated position until header assembly  40  and plug assembly  10  are connected. Of course, in other embodiments, the CPA might be placed in mating position before housing connection.  
         [0019]    Turning to FIG. 2, a view of the plug assembly  10  and wire seal cover  11 , without a wire dress cover, is seen. Face plate  22  comprises openings for female contacts on a wire harness to engage male contacts on a header assembly, as had been described above. Of course, in other embodiments other contacts as known in the art may be used, such as, for example, providing female contacts on a header assembly with corresponding male contacts on a plug assembly; interlocking contacts on corresponding housings; etc.  
         [0020]    Extending upwardly from wire seal cover  11  are lugs  20   a  and  20   b  and extending upwardly from plug assembly  10  are lugs  21   a  and  21   b.  Connector position assurance (CPA) tab  30  is slideably mounted within lugs  20   a,    20   b,    21   a  and  21   b,  and upon CPA base  35 , as will be further described below.  
         [0021]    [0021]FIG. 3 shows a view of the embodiment of FIGS. 1 and 2 with the CPA tab removed. In ordinary use, the tab remains installed on the plug assembly and wire seal cover in this embodiment, but is removed here. Lug  36  comprises a stop, preventing backward movement of the CPA tab when installed. The direction of movement of the CPA tab is shown by arrow b, along CPA base  36  as retained by lugs  20   a,    20   b,    21   a  and  21   b,  as will be further described below. To assist in assuring movement of the CPA tab only when desired, lug  22   d  of the CPA tab (shown in FIG. 4) rests in recess  39  when the CPA tab is unmated. A corresponding recess not shown here, will engage lug  22   c  (also shown in FIG. 4.) When desired, CPA tab is moved into mating position, and lug  22   d  will be moved out of recess  39  and into recess  38 . A similar lug—recess engagement will occur with regard to lug  22   c  and a recess not shown here. The engagement of lug  22   c  and  22   d  in their respective recesses, and concomitant CPA tab mating will be confirmed by an auditory and tactile click feedback in this embodiments. Other embodiments may use other feedback, or none at all, to confirm CPA tab mating. It should be noted that the preferred embodiments use a relatively fixed connection between the connector position assurance and mounting latch means.  
         [0022]    The CPA tab of the embodiment of FIG. 3 is shown in FIGS. 4 and 5. Legs  22   a  and  22   b  engage lugs  20   a,    20   b,    21   a  and  21   b  as the tab is being slid along base  35  (shown in FIG. 3) for connector positioning. As had been described above, when the connector is properly positioned, lugs  22   c  and  22   d  are mated with corresponding recesses.  
         [0023]    [0023]FIG. 5 shows recess  37 , which engages lug  36  shown in FIG. 3 to prevent reverse movement (or disengagement from the plug assembly and wire seal cover) of the CPA tab.  
         [0024]    Returning now to FIG. 2, CPA tab  30  is shown in an unmated position, that is, disengaged from mating latch  25 .  
         [0025]    [0025]FIG. 6 shows the embodiment of FIG. 1 in connected position, with header assembly  40  connected to plug assembly  25 . Mating latch  25  has been slid over lugs  41   a - 41   c.  CPA tab  30  has been slid to a mated position. Thus, CPA surface  23  (shown in FIG. 4) engages with mating latch surface  24  (shown in FIG. 3) and lugs  22   c  and  22   d  (not shown here—see FIGS. 4 and 5) have engaged with corresponding recesses as had been described above. This mating of CPA tab prevents matching latch  25  from moving off latch engagement lugs  41   a,    41   b,    41   c  and so provides locking for the header and plug assemblies.  
         [0026]    It should be noted that, in this embodiment, the mating of CPA tab  30  will usually occur in a two step process. First, the plug assembly is connected to the header assembly and the mating latch  25  engages latch engagement lugs  41   a,    41   b  and  41   c.  Then, CPA tab  30  is slid forward to contact with mating latch  25  as described above, and provides audible and tactile feedback to ensure proper positioning. Thus the CPA serves to lock the plug assembly to the header assembly.  
         [0027]    The above description and the views and material depicted by the figures are for purposes of illustration only and are not intended to be, and should not be construed as, limitations on the invention.  
         [0028]    Moreover, certain modifications or alternatives may suggest themselves to those skilled in the art upon reading of this specification, all of which are intended to be within the spirit and scope of the present invention as defined in the attached claims.