Patent Publication Number: US-11387604-B2

Title: Wave connector position assurance lock with dual overlap connector lock

Description:
FIELD OF INVENTION 
     This disclosure relates to an electrical connector for use in a wiring harness, for example. 
     BACKGROUND 
     Due to the increased demand of data connections in safety systems on vehicles, a robust connector position assurance (CPA) system is necessary to guarantee proper mating and positioning of the connection system and avoid unintentional connector unlocking of first and second connectors. Current connector lock robustness and performance is limited due to package size constraints. 
     One CPA system disclosed in U.S. Pat. No. 6,261,116 to Ceru uses a CPA lock 12 to lock first and second connectors together when properly mated. The CPA lock 12 is movable with respect to a center lock arm 84 between a unlocked position (FIG. 6) and a fully locked position (FIG. 7). Even with such a CPA system, it is still possible to cause the center lock arm to buckle during an unintentional CPA mate such that proper connector mating is not guaranteed. 
     SUMMARY 
     In one exemplary embodiment, an electrical connector assembly includes, among other things, a connector that includes a connector lock arm that is cantilevered from one side of the connector to a free end. The connector lock arm has first and second apertures that are separated by a block. The assembly further includes a connector position assurance lock that has a base that supports a wave-shaped center lock arm that is received in the connector lock arm. The center lock arm extends to a nose that has a shoulder. The connector position assurance lock is slidable between unlocked and fully locked positions that respectively correspond to the shoulder arranged in the first and second apertures. The center lock arm has a bend joined to the nose by a portion that is parallel to the connector lock arm in the unlocked and fully locked positions. The center lock arm is configured to be deflected to an improper mating position with the portion arranged non-parallel to the connector lock arm. 
     In a further embodiment of any of the above, the connector has spaced apart rails that each provide a channel. The base has spaced apart slides that are each received in a respective channel. Each slide includes a clip and a stop. Each rail includes a recess that receives the clip. The stops are spaced from the rails with the connector position assurance lock in the unlocked position. The stops abut the rails with the connector position assurance lock in a fully locked position. 
     In a further embodiment of any of the above, the base includes a leg that is arranged between the center lock arm and each of the slides. The legs and the center lock arm extend in a same direction from the base. 
     In a further embodiment of any of the above, the center lock arm includes first and second bends and first and second portions. The bend is a second bend, and the portion is a second portion. The first bend is arranged at the base. The first portion extends from the first bend to the second bend. The first and second bends and the first and second portions provide the wave-shaped center lock arm. 
     In a further embodiment of any of the above, the nose includes a notch that defines the shoulder. The block is seated in the notch in the unlocked position. 
     In a further embodiment of any of the above, the connector includes spaced apart lock tabs that partially overlap the free end. The free end includes spaced apart arms that extend laterally from a central portion. Each arm is arranged beneath a respective lock tab. The arms abut the lock tabs in the improper mating position. 
     In a further embodiment of any of the above, an opening is defined between the lock tabs. The central portion extends through the opening and between terminal ends of the lock tabs in the improper mating position. 
     In a further embodiment of any of the above, the connector is a first connector and includes a second connector that has a wall that provides a space. The wall includes a slot that receives the block in a fully seated position. The shoulder is disposed in the slot in a fully locked position. 
     In a further embodiment of any of the above, the central portion abuts the wall in the fully seated position. 
     In a further embodiment of any of the above, the wall engages the shoulder in a transition position to deflect the nose inward away from the block. 
     In another exemplary embodiment, an electrical connector assembly includes a first connector that includes a connector lock arm that is cantilevered from one side of the first connector to a free end. The connector lock arm has first and second apertures that are separated by a block. Spaced apart lock tabs partially overlap the free end. The free end includes spaced apart arms that extend laterally from a central portion. Each arm is arranged beneath a respective lock tab. The arms abut the lock tabs in an improper mating position. The assembly also includes a second connector that has a wall that provides a space. The wall includes a slot that receives the block in a fully seated position. The assembly further includes a connector position assurance lock that has a base that supports a center lock arm that is received in the connector lock arm. The center lock arm extends to a nose that has a shoulder. The connector position assurance lock is slidable between unlocked and fully locked positions that respectively correspond to the shoulder being arranged in the first and second apertures. The shoulder is disposed in the slot in the fully locked position. The center lock arm has a bend that is joined to the nose by a portion that is parallel to the connector lock arm in the unlocked and fully locked positions. The center lock arm is configured to be deflected to the improper mating position with the portion arranged non-parallel to the connector lock arm. 
     In a further embodiment of any of the above, the center lock arm is wave-shaped. The nose includes a notch that defines the shoulder. The block is seated in the notch in the unlocked position. The wall engages the shoulder in a transition position to deflect the nose inward away from the block. 
     In a further embodiment of any of the above, an opening is defined between the lock tabs. The central portion extends through the opening and between terminal ends of the lock tabs in the improper mating position. 
     In a further embodiment of any of the above, the central portion abuts the wall in the fully seated position. 
     In a further embodiment of any of the above, the connector has spaced apart rails that each provide a channel. The base has spaced apart slides that are each received in a respective channel. Each slide includes a clip and a stop. Each rail includes a recess that receives the clip. The stops are spaced from the rails with the connector position assurance lock in the unlocked position. The stops abut the rails with the connector position assurance lock in the fully locked position. The base includes a leg that is arranged between the center lock arm and each of the slides. The legs and the center lock arm extend in a same direction from the base. The bend is a second bend. The portion is a second portion. A first bend is arranged at the base. A first portion extends from the first bend to the second bend. The first and second bends and the first and second portions provide the center lock arm. 
     In another exemplary embodiment, a method of assembling an electrical connector includes the steps of pushing first and second connectors together, sliding a connector position assurance lock from an unlocked position, catching a connector lock arm on the first connector with a shoulder of the connector position assurance lock, deflecting the connector lock arm upward along with a wave-shaped center lock arm of the connector position assurance lock, and preventing the connector position assurance lock from moving to a locked position. 
     In a further embodiment of any of the above, the method includes the steps of fully seating first and second connectors with one another to electrically connected mating terminals by seating a block in a slot in the second connector. The method also includes, again, sliding the connector position assurance lock from an unlocked position. The method further includes, again, deflecting the wave-shaped center lock arm of the connector position assurance lock inward. The method further includes inserting a nose of the wave-shaped center lock arm into the slot in the second connector with the connector position assurance lock in the locked position. 
     In a further embodiment of any of the above, spaced apart lock tabs partially overlap a free end of the connector lock arm. The free end includes spaced apart arms that extend laterally from a central portion. Each of the spaced apart arms are arranged beneath a respective lock tab. The deflecting step includes abutting the lock tabs with the spaced apart arms in an improper mating position. 
     In a further embodiment of any of the above, the central portion abuts a wall in a fully seated position. 
     In a further embodiment of any of the above, an opening is defined between the lock tabs. The central portion extends through the opening and between terminal ends of the lock tabs in the improper mating position. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The disclosure can be further understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein: 
         FIG. 1A  is perspective view of a first connector with a connector position assurance (CPA) lock in a unlocked position. 
         FIG. 1B  is an elevational view of the first connector as shown in  FIG. 1A . 
         FIG. 1C  is a cross-sectional view of the first connector taken along line  1 C- 1 C in  FIG. 1B . 
         FIG. 2A  is a cross-sectional view of the first connector and a second connector of an electrical connector in a fully seated position relative to one another and with the CPA lock in a unlocked position similar to  FIG. 1C . 
         FIG. 2B  is a partial cross-sectional view of the electrical connector with the CPA lock between the unlocked position and a fully locked position. 
         FIG. 2C  is a cross-sectional view of the electrical connector shown in  FIG. 2A , but with the CPA lock in the fully locked position. 
         FIG. 3  is an elevation view of the first connector similar to that of  FIG. 1B , but with the CPA lock in a fully locked position. 
         FIG. 4A  is a perspective view of the CPA lock. 
         FIG. 4B  is a side view of the CPA lock. 
         FIG. 5  is an end view of the assembled connector shown in  FIG. 1B . 
         FIG. 6  is an enlarged, partial cross-sectional view illustrating the CPA lock in an improper mating position. 
         FIG. 7  is another cross-sectional view depicting the CPA lock in the improper mating position. 
         FIG. 8  is a cross-sectional view depicting a deformed lock tab with the CPA lock in the improper mating position. 
     
    
    
     DETAILED DESCRIPTION 
     A plastic electrical connector assembly  10  ( FIGS. 2A-2C and 5 ) includes a first connector  12  ( FIGS. 1A-3 and 6-8 ) and a second connector  14  ( FIGS. 2A-2C and 5 ) that mate with one another to electrically connect complementary wire terminals in a wiring harness. Typically, one of the connectors carries male terminals, and the other connector carries female terminals. In order to ensure that the terminals have a good electrical connection, full engagement is needed between the first and second connectors  12 ,  14 . A connector position assurance (CPA) lock  16  ( FIGS. 1A-7 ) is used to lock the first and second connectors  12 ,  14  together—only when fully seated with one another—to ensure electrical continuity between the mating terminals is not compromised during use. The CPA lock  16  should not move to a locked position if the first and second connectors  12 ,  14  are not fully seated. In this manner, the unlocked CPA lock  16  acts a visual indicator to the assembler that a proper connection has not yet been achieved. 
     Referring to  FIGS. 1A-1C , the first connector  12  includes a flexible connector lock arm  18  cantilevered from one side of the connector  12  to a free end  61 . The connector lock arm  18 , which deflects during connector assembly, has first and second apertures  26   a ,  26   b  separated by a block  24 . 
     The CPA lock  16  ( FIGS. 4A-4B ) has a base  29  supporting a wave-shaped center lock arm  20  received in the connector lock arm  18 . The CPA lock  16  is retained with respect to the first connector  12 , but is slidable relative thereto between unlocked and locked positions. 
     The first connector  12  has spaced apart rails  40  that each provide a channel  44 , as shown in  FIG. 1A . The CPA lock  16  is shown in detail in  FIGS. 4A-4B  and is arranged in a space  42  between the rails  40 . The base  29  has spaced apart slides  30  each received in a respective channel  44 . Each slide  30  includes a clip  32  and a stop  34 . Each rail  40  includes a recess  43  ( FIG. 1C ) receiving its clip  32 . The stops  34  are spaced from the rails  40  with the CPA lock  16  in the unlocked position. The stops  34  abut the backside of the rails  40  with the CPA lock  16  in the fully locked position. The base  29  includes a leg  36  arranged between the center lock arm  20  and each of the slides  30 . The legs  36  and the center lock arm  20  extend in a same direction from the base  29  and operate to stabilize the CPA lock  16  during sliding movement. 
     The center lock arm  20  has a first bend  50  arranged at the base  29 . A first portion  46  extends from the first bend  50  to a second bend  52 . Each of the first and second bends  50 ,  52  are arcuate in shape. The second bend  52  is joined to the nose  22  by a second portion  48  that is parallel to the connector lock arm  18  in the unlocked position ( FIGS. 1A-1C and 2A ) and fully locked positions ( FIGS. 2C and 3 ). The center lock arm  20  is configured to be deflected to an improper mating position ( FIGS. 6-8 ) with the second portion  48  arranged non-parallel to the connector lock arm  18 . The first and second bends  50 ,  52  and the first and second portions  46 ,  48  provide the wave-shaped, or S-shaped center beam geometry for the connector lock arm  18 . 
     Referring to  FIGS. 1A and 1C , the center lock arm  20  extends to a nose  22  that has a notch defining a shoulder  23 . The CPA lock  16  is slidable between the unlocked position ( FIGS. 1A-1C and 2A ) and a fully locked position ( FIGS. 2C and 3 ) respectively corresponding to the shoulder  23  being arranged in the first and second apertures  26   a ,  26   b . The block  24  is seated in the notch in a unlocked position, best shown in  FIG. 1C . 
     Referring to  FIGS. 2A-2C , the second connector  14  has a wall  58  providing a space  56 . During connector assembly, the first connector  12  is inserted into the space  56  of the second connector  14 . The first and second connectors  12 ,  14  are pushed together, and the connector lock arm  18  is deflected inward as the end  64  of the wall  58  slides along a ramped surface  62  ( FIGS. 1A, 1C and 2A ) until the central portion of the free end  61  abuts and end  64  the wall  58 . In this fully seated position, a slot  60  in the wall  58  receives the block  24 , and the connector lock arm  18  returns to a relaxed position, as shown in a  FIG. 2A . 
     To further maintain the first and second connectors  12 ,  14  in engagement with one another, the CPA lock  16  is slid from the unlocked position ( FIG. 2A ) to the locked position  FIG. 2C ). As shown in  FIG. 2B , the tapered surface of the nose  22  begins to force the nose  22  inward and below the wall  58  until the shoulder  23  drops below the wall  58 , deflecting the nose  22  inward away from the block  24 . The inward deflection of the center lock arm  20  is facilitated by its wave shape. The wall  58  reinforces the connector lock arm  18  and prevents the connector lock arm  18  from being deflected outward, enabling the shoulder  23  to be slid into the slot  60  in the fully locked position shown in  FIG. 2C . 
     Referring to  FIG. 5 , the first connector  12  includes spaced apart lock tabs  28  partially overlapping the free end  61  of the center lock arm  20 . In the example configuration, an opening  63  is defined between the lock tabs  28 . The free end  61  includes spaced apart arms  66  extending laterally from a central portion of the free end  61 . Each arm  66  is arranged beneath a respective lock tab  28 . 
     If the first and second connectors  12 ,  14  are not fully seated with one another, the CPA lock  16  will not be able to move to the locked position. The block  24  will not be fully received in the slot  60  when the first and second connectors  12 ,  14  are not fully seated, i.e. an improper mating position. Moreover, the end  64  of the wall will not be flush with the block  24 . As a result, in an attempt to slide the CPA lock  16  from the unlocked position to the locked position, the connector lock arm  18  will be deflected upward as the shoulder  23  catches the block  24 , as shown in  FIGS. 6 and 7 . The base  29  may lift off of the first connector  12 , creating a gap  68 , as shown in  FIG. 7 . At the same time, the arms  66  will abut the lock tabs  28  in the improper mating position, as shown in  FIG. 8 . In this improper mating position, the central portion of the free end  61  extends through the opening  63  and between terminal ends of the lock tabs  28 . 
     Due to package size constraints, the connector lock arm  18  does not have sufficient column strength to prevent unintentional seating of the CPA in a purely linear direction. To this end, the disclosed features of the CPA lock  16  work integrally with the connector lock arm  18  to increase blocking force and prevent unintentional seating by combining an upward and linear deflection. The CPA nose design provides upward force against connector lock arm  18 , via the block  24 . The design of the nose  22  provides linear force against connector lock arm block  24 . Overlapping connector side arms interact with connector lock tabs, providing additional downward force to prevent connector lock arm from buckling during an unintentional CPA mate. 
     During proper CPA mating, i.e., the locked position, the wave-shaped center beam geometry provides reduced engagement and adequate deflection with minimal strains while the CPA lock transitions from the unlocked position to the fully seated position. 
     It should also be understood that although a particular component arrangement is disclosed in the illustrated embodiment, other arrangements will benefit herefrom. Although particular step sequences are shown, described, and claimed, it should be understood that steps may be performed in any order, separated or combined unless otherwise indicated and will still benefit from the present invention. 
     Although the different examples have specific components shown in the illustrations, embodiments of this invention are not limited to those particular combinations. It is possible to use some of the components or features from one of the examples in combination with features or components from another one of the examples. 
     Although an example embodiment has been disclosed, a worker of ordinary skill in this art would recognize that certain modifications would come within the scope of the claims. For that reason, the following claims should be studied to determine their true scope and content.