Patent Publication Number: US-7914318-B2

Title: Electrical connector

Description:
TECHNICAL FIELD 
     This invention relates to electrical connectors having self-alignment features. 
     BACKGROUND OF THE INVENTION 
     Automotive vehicles typically include several electronic devices that must receive electrical energy to operate, and that sometimes must send and receive electrical signals to other electronic devices. Wiring harnesses are typically used to provide conductive pathways through the vehicle for transmission of electrical power and signals among electronic devices and power sources such as batteries. Wiring harnesses typically include a plurality of electrical connectors that are engaged with corresponding connectors on the electronic devices during automotive assembly. 
     One type of electrical connector includes conductive elements, e.g. pins, that are engageable with sockets on a corresponding type of electrical connector to establish electrical communication between an electronic device and the wiring harness. Maximizing the density of the conductive elements minimizes the size of the electrical connector and thus improves packaging efficiency. However, maximizing the density of the conductive elements, by minimizing their size, reduces their mechanical strength and thus the ability of the conductive elements to sustain nonaxial loads due to misalignment of the two connectors during insertion of the conductive elements into the corresponding sockets. 
     A shroud typically surrounds the pins to protect them from nonaxial loads, and is often used to align the sockets with the pins during the mating of the two electrical connectors. 
     SUMMARY OF THE INVENTION 
     An electrical connection system includes a first electrical connector having a first plurality of electrically conductive elements. A second electrical connector has a second plurality of electrically conductive elements and is matable with the first electrical connector such that the first plurality of electrically conductive elements are in contact with the second plurality of electrically conductive elements. 
     A probe is mounted with respect to the first electrical connector, and a receptacle is mounted with respect to the second electrical connector. The probe has a tip, an untapered section, and a tapered section between the tip and the untapered section. At least part of the probe has a cross-sectional shape that has no more than one plane of mirror symmetry. The receptacle defines a cavity having substantially the same cross-sectional shape as the probe. 
     The above features and advantages and other features and advantages of the present invention are readily apparent from the following detailed description of the best modes for carrying out the invention when taken in connection with the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic, side view of a male electrical connector having a receptacle; 
         FIG. 2  is a schematic, side view of a female electrical connector that is engageable with the mail electrical connector of  FIG. 1  and that has a probe that is insertable into the receptacle for guiding and aligning the female electrical connector; 
         FIG. 3  is a schematic, perspective view of the probe and the receptacle; 
         FIG. 4  is a schematic, side view of the probe; 
         FIG. 5  is a schematic, top view of the probe; 
         FIG. 6  is a schematic, side view of the male electrical connector of  FIG. 1  engaged with the female electrical connector of  FIG. 2 ; and 
         FIG. 7  is a schematic, side view of an alternative probe and receptacle in accordance with the claimed invention. 
     
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring to  FIG. 1 , an electrical connector  10  includes a housing  14 . The electrical connector  10  also includes a shroud  18  that protects a first plurality of conductive elements, which are pins  20  in the embodiment depicted, that protrude from the housing  14 . Each of the pins  20  is electrically conductive, and is in electrical communication with a respective wire  21 . As understood by those skilled in the art, each pin is operatively connected to its respective wire inside the housing  14 . The wires  21  extend outside of the housing  14 ; the wires  21  may be bundled together outside of the housing  14  to form a cable, as understood by those skilled in the art. The shroud  18  is characterized by an opening  22  at its forward end to provide access to the pins  20 . The electrical connector  10  also includes a receptacle  26  for aligning and guiding a corresponding electrical connector (shown at  28  in  FIG. 2 ). 
     Referring to  FIG. 2 , electrical connector  28  includes a housing  30  having a member  32  protruding therefrom. Member  32  defines a plurality of sockets  34 . Each of the sockets  34  has a respective opening  35  so that the sockets  34  are forwardly open to receive the pins (shown at  20  in  FIG. 1 ). The sockets  34  are sufficiently spaced and oriented so that, when the electrical connector  28  is sufficiently aligned with the electrical connector shown at  10  in  FIG. 1 , each of the pins  20  of connector  10  is insertable within a respective one of the sockets  34 . 
     The electrical connector  28  includes a second plurality of electrically conductive elements, which, in the embodiment depicted, are electrical contacts  36 . Each of the contacts  36  is in electrical communication with a respective wire  37  inside the housing  30 . The wires  37  extend outside of the housing  30 . Each contact  36  is exposed to a respective one of the sockets  34  such that, when the pins  20  are within the sockets  34 , each pin  20  is in contact with a respective one of the contacts  36 , and, therefore, each of wires  21  is in electrical communication with a respective one of wires  37 . Electrical connector  28  also includes a probe  42  mounted to the housing  30 . 
     Referring to  FIGS. 3-5 , wherein like reference numbers refer to like components from  FIGS. 1 and 2 , the probe  42  is characterized by an untapered section  46  having a constant cross-sectional shape  50  and constant dimensions along its length. As used herein, a cross-sectional shape refers to the shape of the probe as seen in cross-section taken about a plane that is perpendicular to the length of the probe, i.e., its greatest dimension. The probe  42  is characterized by a T-shaped cross section (shown as an inverted “T” in  FIG. 3 ). The shape  50  is characterized by only a single plane P of mirror symmetry, i.e., the shape is symmetrical (mirror) about only one plane P. 
     The probe  42  is also characterized by a tapered section  58 , which extends from a boundary  60  with the untapered section  46  to the forward tip  62  of the probe  42 . The tapered section  58  is characterized by the same cross-sectional shape as the untapered section  46 . However, although the cross-sectional shape of the tapered section  58  does not change between the boundary  60  and the tip  62 , the cross-sectional dimensions and area of the tapered section  58  get progressively smaller between the boundary  60  and the tip  62 . Thus, cross-sectional area at the forward tip  62  is smaller than at the untapered section  46 . 
     Referring specifically to  FIG. 3 , receptacle  26  defines a cavity  66  that is characterized by the same cross-sectional shape as the probe  42 . The cavity  66  is characterized by an opening  70  at its forward end for receiving the probe  42 . The cross-sectional size of the cavity  66  is slightly larger than the cross-sectional size of the untapered section  46  of the probe  42  so that the probe  42  is insertable into the cavity  66  through the opening  70 . 
     The opening  70  is characterized by the same cross-sectional shape as the probe  42 . The opening  70  is tapered such that the forwardmost end of the opening  70  is larger than the rearward end of the opening  70  and the cavity  70 . Referring again to  FIG. 2 , the probe  42  extends significantly forward of the housing  30 , the member  32 , and the contacts  36  so that the probe  42  is the most forwardly extending portion of the electrical connector  28 . The length of the probe  42  enables the tapered section (shown at  58  in  FIGS. 3-5 ) to be aggressively tapered to facilitate insertion of the probe  42  into the receptacle  26 , even if there is significant linear or angular misalignment between the probe  42  and the opening  70  and cavity  66 . The cross-sectional shape of the probe  42  prevents rotational misalignment and enables the use of only a single probe  42  and a single receptacle  26 . 
     The receptacle  26  guides the electrical connector  28 , via probe  42 , into engagement with electrical connector  10 , as shown in  FIG. 6 . More specifically, and with reference to  FIGS. 1-3  and  6 , the cavity  66  is sufficiently positioned and shaped such that, as the probe  42  is further inserted into the cavity  66  through opening  70 , the interaction between the walls of the cavity  66  and the probe  42  limits movement of the electrical connector  28  such that the member  32  enters the opening  22  of shroud  18 , and each of the pins  20  enters a respective one of the sockets  34  via one of the opening  35 . Each pin  20  contacts a respective contact  36 , thereby establishing electrical communication between wires  21  and wires  37 . 
     Referring to  FIG. 7 , wherein like reference numbers refer to like components from  FIGS. 1-6 , an alternative probe  42 A and receptacle  26 A configuration is schematically depicted. The probe  42 A includes a flexible arm  100  extending above a cavity  104 . A projection  108  extends from one end of the arm  100  and is positioned to contact the receptacle  26 A at the opening  70 . As the probe  42 A is inserted into the opening, the receptacle  26 A acts on the projection  108 , urging the projection  108  and the arm  100  into the cavity  104 , as shown at  100 A,  108 A. A notch  112  is formed in the upper surface of cavity  66 . The upper surface of cavity  66  maintains the projection in the position shown at  108 A until the projection is aligned with the notch  112 . Once the projection  108  is aligned with the notch  112 , the elastic property of the arm  100  urges the projection into the notch  112 , thereby locking the probe  42 A with respect to the receptacle  26 A. 
     It should be noted that, although various members of the electrical connectors (shown at  10  and  28  in  FIGS. 1 and 2 ) are shown as separate pieces mounted with respect to each other, the members may be formed from a single piece of material within the scope of the claimed invention. For example, the receptacle  26  may be integrally formed with the housing  14 , and the probe  42  may be integrally formed with the housing  30  and/or member  32  within the scope of the claimed invention. 
     The electrically conductive elements are shown in the embodiment depicted as pins  20  and contacts  36 . Those skilled in the art will recognize a variety of electrically conductive element configurations that may be employed within the scope of the claimed invention. For example, electrically conductive elements may include flat plates, cylindrical members, etc., within the scope of the claimed invention. Furthermore, and within the scope of the claimed invention, electrically conductive elements may define the sockets of the female electrical connector. 
     While the best modes for carrying out the invention have been described in detail, those familiar with the art to which this invention relates will recognize various alternative designs and embodiments for practicing the invention within the scope of the appended claims.