Patent Publication Number: US-7223131-B2

Title: Three position electrical connector assembly

Description:
BACKGROUND AND SUMMARY OF THE INVENTION 
   The present invention relates generally to electrical connectors and, more particularly, to a three position coaxial cable connector assembly. 
   Radio frequency (RF) coaxial cable connector assemblies have been used for numerous automotive applications, such as global positioning systems (GPS), car radios, mobile phones, air bag systems, and multimedia devices. Coaxial cables typically consist of an outer conductor, an inner conductor, a dielectric, and a jacket. The outer conductor and the inner conductor of the cable often electrically interface with a mating coaxial cable through jack and plug connectors. Such conventional coaxial cable connectors are known in the art, for example, in U.S. Pat. Nos. 6,676,445 and 6,824,403, which are assigned to the assignee of the present invention and are expressly incorporated by reference herein. 
   Certain automotive applications may require that multiple coaxial cables be coupled through a single connector assembly. For example, three position connector assemblies are often used to electrically couple three coaxial jack connectors with three coaxial plug connectors. 
   Typically, electrical connector assemblies have retention means in a housing in order to secure the electrical connectors therein. One such retainer is a plastic movable member which is configured to move in place over the connector to lock the connector in place. Some of such movable members are moved transversely to the axial direction, while others are designed as hinged flaps which are rotated into place. 
   In order to standardize various types of connectors and thereby avoid confusion, certain industry standards have been established. One of these standards is referred to as FAKRA. FAKRA is the Automotive Standards Committee in the German Institute for Standardisation, representing international standardization interests in the automotive field. The FAKRA standard provides a system, based on keying and color coding, for proper connector attachment. Like jack keys can only be connected to like plug keyways in FAKRA connectors. Secure positioning and locking of connector housings is facilitated by way of a FAKRA defined catch on the jack housing and a cooperating latch on the plug housing. 
   According to an illustrative embodiment of the current disclosure, a connector position assurance device for use in an electrical connector assembly is provided. The connector position assurance device includes a first leg, a second leg, and a bridge member connecting the first leg and the second leg. A first engagement surface is supported by the first leg and is configured to engage a shoulder of a first electrical connector to restrict axial movement thereof. A second engagement surface is supported by the second leg and is configured to engage a shoulder of a second electrical connector to restrict axial movement thereof. A third engagement surface is supported by the bridge member and is configured to engage a shoulder of a third electrical connector to restrict axial movement thereof. 
   According to a further illustrative embodiment of the disclosure, an electrical connector assembly includes a housing having a plurality of axial passageways, each of the axial passageways defining a longitudinal axis and including a non-cylindrical portion having at least one flat. A plurality of electrical connectors are configured to be received within the plurality of axial passageways. Each of the electrical connectors includes a shell having a shoulder configured to be received within the non-cylindrical portion of one of the axial passageways. The at least one flat of each non-cylindrical portion extends parallel to and in close proximity to one of the flats of an adjacent non-cylindrical portion, thereby facilitating close spacing of the longitudinal axes of the plurality of axial passageways. 
   According to yet another illustrative embodiment of the disclosure, an electrical connector assembly includes a housing having a plurality of axial passageways and a transverse slot. A plurality of electrical connectors are configured to be received within the plurality of axial passageways, each of the electrical connectors including a shell having an annular groove. A connector position assurance device is configured to be received within the transverse slot and includes a plurality of arcuate engagement surfaces. Each of the engagement surfaces is configured to be received within one of the annular grooves of the shells. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a top perspective view of an illustrative embodiment electrical connector assembly of the present disclosure; 
       FIG. 2  is a bottom perspective view of the electrical connector assembly of  FIG. 1 ; 
       FIG. 3  is a partially exploded perspective view of the electrical connector assembly of  FIG. 1 ; 
       FIG. 4  is a perspective view of the jack housing of the present disclosure; 
       FIG. 5  is a cross-sectional view of the jack assembly taken along line  5 — 5  of  FIG. 1 ; 
       FIG. 6  is a perspective view of a connector position assurance device of the present disclosure; 
       FIG. 7  is a front elevation view of the connector position assurance device of  FIG. 6 ; 
       FIG. 8  is a side elevation view, in partial cross-section, of a jack connector and ferrule; 
       FIG. 9  is a first end perspective view of a plug housing and plug connectors of the present disclosure; 
       FIG. 10  is a second end perspective view of a plug housing of the present disclosure; and 
       FIG. 11  is a side elevational view, in partial cross-section, of a plug connector and ferrule. 
   

   DESCRIPTION OF INVENTION 
   Referring initially to  FIGS. 1–3 , an electrical connector assembly  10  according to the present disclosure includes a jack assembly  12  which is configured to couple to a plug assembly  14 . The jack assembly  12  includes a jack housing  16  having a plurality of axial passageways  18   a ,  18   b ,  18   c  which define longitudinal axes  19   a ,  19   b ,  19   c  and are configured to receive corresponding coaxial cables  20   a ,  20   b ,  20   c . The coaxial cables  20   a ,  20   b ,  20   c  each include a conventional jack connector  22  ( FIG. 8 ), referred to in  FIGS. 1–3  as  22   a ,  22   b ,  22   c.    
   The plug assembly  14  similarly includes a plug housing  24  having a plurality of axial passageways  26   a ,  26   b ,  26   c  which define longitudinal axes  27   a ,  27   b ,  27   c  and are configured to receive coaxial cables  28   a ,  28   b ,  28   c . Each of the coaxial cables  28   a ,  28   b ,  28   c  includes a conventional plug connector  30  ( FIG. 10 ), referred to in  FIGS. 1–3  as  30   a ,  30   b ,  30   c . Each plug connector  30  is configured to receive a corresponding jack connector  22  and provide electrical communication between respective cables  20   a ,  20   b ,  20   c  and  28   a ,  28   b ,  28   c.    
   With reference to  FIGS. 1 ,  3 , and  4 , the jack housing  16  includes a front mating end  36  and a rear connector receiving end  38 . As best shown in  FIG. 4 , the passageways  18   a ,  18   b ,  18   c  each include a cylindrical portion  40  adjacent the mating end  36  and a non-cylindrical, illustratively hexagonal, portion  42  adjacent the connector receiving end  38  ( FIG. 4 ). Passageway  18   c  is positioned vertically above passageways  18   a  and  18   b  and is laterally offset therefrom. In such an arrangement, the hexagonal portions  42  facilitate efficient space utilization by placing the passageways  18   a ,  18   b ,  18   c  in close proximity to each another. More particularly, each hexagonal portion  42  includes six planar walls or flats  43 , wherein at least one of the flats  43  of each hexagonal portion  42  extends parallel to and in close proximity to one of the flats  43  of an adjacent hexagonal portion  42 . The proximity of parallel flats  43  conserves space by closely positioning the longitudinal axes  19  of the axial passageways  18 . In the illustrative embodiment, each hexagonal portion  42  shares a pair of flats  43  with the two adjacent hexagonal portions  42 . 
   In addition to axial passageways  18   a ,  18   b ,  18   c , the jack housing  16  includes a transverse slot  44  configured to slidably receive a lock or connector position assurance device (CPA)  46 . With reference to  FIGS. 5–7 , the CPA  46  includes a first leg  48 , a second leg  50 , and an arcuate bridge member  52  connecting the first leg  48  and the second leg  50 . A first arcuate engagement surface  54  is supported by the first leg  48  and is configured to engage a shoulder  56   a  ( FIG. 5 ) of the first jack connector  22   a  to restrict axial movement thereof. Similarly, a second arcuate engagement surface  58  is supported by the second leg  50  and is configured to engage a shoulder  56   b  of the second jack connector  22   b  to restrict axial movement thereof. A third arcuate engagement surface  62  is supported by the bridge member  52  and is configured to engage shoulder  56   c  of the third electrical connector  22   c  to restrict axial movement thereof. 
   The first engagement surface  54  has a first radius of curvature, the second engagement  58  has a second radius of curvature and the third engagement surface  62  has a third radius of curvature. In one illustrative embodiment, the third radius of curvature is greater than both the first radius of curvature and the second radius of curvature to facilitate positioning of a larger jack connector  22   c  within the axial passageway  18   c.    
   First and second latches or latch arms  66  and  68  extend downwardly from the bridge member  52  intermediate the first and second legs  48  and  50 . The latches  66  and  68  each include a latch lug  70  and  72  which is configured to couple the bridge member  52  to the jack housing  16 . The first and second latch arms  66  and  68  are illustratively formed as an integral part of the CPA  46  and are resiliently biased in a direction toward each other. More particularly, the latch lugs  70  and  72  are biased inwardly to couple the CPA  46  to retaining ledges  74  and  76  defined by an internal wall  78  of the jack housing  16  ( FIG. 5 ). A pair of slots  79   a  and  79   b  are illustratively positioned at opposing ends of the bridge member  52  and are configured to receive a tool (not shown) for facilitating removal of the CPA  46  from the housing  16 . 
   Referring now to  FIGS. 1 and 8 , the jack connector  22  illustratively includes an outer shell  80  which receives traditional coaxial components including a front dielectric  82  and a rear dielectric  84 . As known, the front dielectric  82  and the rear dielectric  84  may be replaced with a single dielectric. The shell  80  includes radially outwardly extending flanges or shoulders  56  and  90  which define an annular groove  92  therebetween. A cylindrical ferrule  94  extends outwardly from the shell  80  and is configured to retain the outer conductor  96  and the jacket  95  of the coaxial cable  20 . More particularly, the outer conductor  96  of the coaxial cable  20  is received within the jacket  95  and is coupled between a cylindrical mount  97  of the shell  80  and the mating ferrule  94 . Cable dielectric  98  passes into an interior bore  100 . Inner conductor  102  of cable  20  passes through the interior bore  100  where it is crimped and/or soldered to a pin contact (not shown) of the jack connector  22  in a conventional manner. 
   The shell  80  has a cylindrical body  104  such that the groove  92  includes a cylindrical cross-section. The shoulders  56  and  90  illustratively have a hexagonal cross-section and are configured to cooperate with the hexagonal portion  42  of the axial passageways  18   a ,  18   b ,  18   c . The engagement surfaces  54 ,  58 ,  62  of the CPA  46  are configured to be received within the grooves  92  such that engagement with the shoulders  56  and  90  restricts axial movement of the shells  80 . 
   With reference to  FIGS. 2 ,  3 ,  9 , and  10 , the plug housing  24  includes a front mating end  110  and a rear connector receiving end  112 . The mating end  110  includes a receiving flange  118  configured to slidably receive the mating end  36  of the jack housing  16 . The jack housing  16  includes a plurality of alignment ribs  120  ( FIG. 4 ) which are configured to be received within alignment grooves  122  formed within the plug housing  24  ( FIG. 9 ). By ensuring such positioning, the passageways  18  of the jack housing  16  are coaxially aligned with the passageways  26  of the plug housing  24 . 
   With reference to  FIG. 10 , the passageways  26   a ,  26   b ,  26   c  each include a cylindrical portion  124  adjacent the mating end  110  and a non-cylindrical, illustratively hexagonal, portion  126  adjacent the connector receiving end  112  ( FIG. 10 ). Passageway  26   c  is positioned vertically above passageways  26   a  and  26   b  and is laterally offset therefrom. In such an arrangement, the hexagonal portions  126  facilitate efficient space utilization by placing the passageways  26   a ,  26   b ,  26   c  in close proximity to each other. More particularly, each hexagonal portion  126  includes six flats  127 , wherein at least one of the flats  127  of each hexagonal portion  126  extends parallel to and in close proximity to one of the flats  127  of an adjacent hexagonal portion  126 . The proximity of parallel flats  127  conserves space by closely positioning the longitudinal axes  27  of the axial passageways  26 . In the illustrative embodiment, each hexagonal portion  126  shares flats  127  with the two adjacent hexagonal portions  126 . In addition to the axial passageways  26 , the plug housing  24  includes a transverse slot  128  configured to slidably receive a connector position assurance device (CPA)  46 ′. The CPA  46 ′ is illustratively identical to the CPA  46  described in detail above. 
   Referring now to  FIGS. 2 and 11 , the plug connector  30  includes an outer shell  130  which receives traditional coaxial components including an outer contact  132 , a retaining ring  134 , a front dielectric  136 , and a rear dielectric  138 . As known, the front dielectric  136  and the rear dielectric  138  could be replaced with a single dielectric. The shell  130  includes radially outwardly extending flanges or shoulders  140  and  142  which define an annular groove  144  therebetween. A cylindrical ferrule  146  extends outwardly from the shell  130  and is configured to retain the coaxial cable  28 . More particularly, the outer conductor  148  of the coaxial cable  28  is received within a jacket  147  and is mounted between a cylindrical mount  149  of the shell  130  and the mating ferrule  146 . Cable dielectric  150  passes into an interior bore  152 . Inner conductor  154  of cable  28  passes through the interior bore  152  where it is crimped and/or soldered to a socket contact (not shown) of the plug connector  30  in a conventional manner. 
   The shell  130  has a cylindrical body  156  such that the groove  144  includes a cylindrical cross-section. The shoulders  140  and  142  illustratively have a hexagonal cross-section and are configured to cooperate with the hexagonal portion  126  of the axial passageways  26 . The engagement surfaces  54 ,  58 ,  62  of the CPA  46 ′ are configured to be received within the groove  144  such that engagement with the shoulders  140  and  142  restricts axial movement of the shells  130 . 
   As shown in  FIG. 2 , a conventional latch  160  may be configured to releasably couple the jack housing  16  with the plug housing  24 . More particularly, a catch  162  supported by the jack housing  16  may be positioned within an opening  164  supported by the plug housing  14  to secure together the jack assembly  12  and plug assembly  14 .