Patent Publication Number: US-9837763-B2

Title: Electrical connector

Description:
RELATED APPLICATIONS 
     This application claims priority to Japanese Application No. 2014-132722, filed Jun. 27, 2014, which is incorporated herein by reference in its entirety. 
     FIELD OF THE INVENTION 
     The present disclosure relates to a connector and, more specifically, to a locking structure incorporated on the connector. 
     DESCRIPTION OF RELATED ART 
     A typical lever-type electrical connector includes an assembly of a first connector or housing and a second connector or header. To mate the connectors together, the assembly has an actuating or assist lever mounted for pivoting on the first connector with pivoting of the lever causing the first and second connectors to shift between unmated and fully mated configurations. To this end, the actuating lever and the second connector typically have a cam groove and a cam follower arrangement for drawing the second connector into mating condition with the first connector in response to pivoting of the lever. Such connectors are commonly used in the automotive industry; however, other uses are also possible. 
     Accordingly, there is a need for a lever actuator for an electrical connector assembly that generates a more efficient mechanical advantage, particularly with large electrical connectors that require the lever actuator to be able to generate large output forces without requiring large input actuator forces on the lever. In addition, a lever actuator that is not deformed as it is pivoted would be desired. 
     SUMMARY OF THE INVENTION 
     In a connector of the prior art, the interlocking member, the lever, and the housing are arranged in sequential order in a direction extending from the inside towards the outside, and the lever is accommodated inside a lever accommodating groove formed in the housing. However, in this structure, the range of movement for the lever is limited and therefore a purpose of the present disclosure to provide a connector which is able to expand the range of movement for a lever. 
     In order to solve this problem, the present disclosure is a connector comprising: a housing including an outer shell portion facing a holding portion in a second direction orthogonal to a first direction when the first direction is the direction in which the holding portion holding the terminals is inserted into an opposing housing; a slider held movably in a third direction orthogonal to the first direction and the second direction between the holding portion and the outer shell portion, the slider having an engaging portion switch between engaging and disengaging an engaging protrusion provided on the opposing housing in response to the position of the slider; and a lever able to turn around a turning shaft portion provided to the outside of the outer shell portion in the second direction, the lever having a cam shaft portion inserted through a window formed in the outer shell portion into a cam groove formed in the slider. 
     In one aspect of the present disclosure, the can shaft portion may have a hook portion hooking the edge of the window in the outer shell portion on the inside of the outer shell portion in the second direction. 
     In another aspect of the present disclosure, the hook portion may protrude towards the far side from the turning shaft portion relative to the base portion through which the window passes, and the distance from the turning shaft portion of the outer shell portion to the far side of the window may be smaller than the distance from the turning shaft portion of the lever to the far end of the hook portion but larger than the distance from the turning shaft portion of the lever to the far end of the base portion. 
     In another aspect of the present disclosure, the cam shaft portion of the lever may be inserted through the window of the outer shell portion, and the turning shaft portion of the outer shell portion may be inserted into the turning shaft hold of the lever while the lever is being elastically deformed. 
     In another aspect of the present disclosure, the distance from the turning shaft portion of the outer shell portion to the far edge of the window may be smaller than the distance from the turning shaft portion of the lever to the far end of the hook portion along the entire far edge. 
     In another aspect of the present disclosure, the edge of the window near the turning shaft portion may include a portion whose distance from the far edge is greater than the distance from the near end of the cam shaft portion including the hook portion to the far end, and a portion whose distance is smaller. 
     In another aspect of the present disclosure, the hook portion may have a shape whose width narrows as the far end is approached. 
     In another aspect of the present disclosure, the turning shaft portion may have a hook portion protruding on the opposite side from the hook portion of the cam shaft portion. 
     In the present disclosure, the lever is arranged to the outside of the outer shell portion, which expands the range of movement for the lever. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       This application is illustrated by way of example and not limited in the accompanying figures in which like reference numerals indicate similar elements and in which: 
         FIG. 1  is a perspective view of the connector in an embodiment of the present disclosure; 
         FIG. 2  is a front view of the connector; 
         FIG. 3  is a right side view of the connector; 
         FIG. 4  is a front view of the housing; 
         FIG. 5  is a right side view of the housing; 
         FIG. 6  is a front view of the slider; 
         FIG. 7  is a right side view of the slider; 
         FIG. 8  is a left side view of the slider; 
         FIG. 9  is a front view of the lever; 
         FIG. 10  is a right side view of the lever; 
         FIG. 11  is a front view used to explain how the lever is attached; 
         FIG. 12  is a right side view used to explain how the lever is attached; 
         FIG. 13A  is a cross-sectional view used to explain how the lever is attached; 
         FIG. 13B  is a cross-sectional view used to explain how the lever is attached; and 
         FIG. 13C  is a cross-sectional view used to explain how the lever is attached. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The following is an explanation of an embodiment of the present disclosure with reference to the drawings. 
       FIG. 1 ,  FIG. 2 , and  FIG. 3  are a perspective view, a front view, and a right side view, respectively, of the connector  1  in an embodiment of the present disclosure. In  FIG. 1 , depiction of the slider  3  has been omitted.  FIG. 4  and  FIG. 5  are a front view and a right side view of the housing  2 .  FIG. 4  and  FIG. 5  show the housing  2  accommodating the slider  3 .  FIG. 6 ,  FIG. 7 , and  FIG. 8  are a perspective view, a front view, and a right side view, respectively, of the slider  3 . In  FIG. 8 , engagement with the opposing housing  9  is depicted for explanatory purposes using two-dot chain lines.  FIG. 9  and  FIG. 10  are a front view and a right side view of the lever  4 . 
       FIG. 11 ,  FIG. 12  and  FIG. 13A  through  FIG. 13C  are a front view, a right side view, and cross-sectional views, respectively, used to explain how the lever  4  is attached.  FIG. 13A  is a cross-sectional view from line A-A in  FIG. 12 .  FIG. 13A  through  FIG. 13C  show how the lever  4  is attached in stages. 
     In the specification and the drawings, the first direction is the direction in which the connector  1  is inserted and removed. In the first direction, the near side relative to the opposing housing  9  (see  FIG. 8 ) is below, and the far side is above. The second direction is the direction orthogonal to the first direction, and is the normal direction of the long panel portion  23  of the housing  2 . In the second direction, the side on which the slider  3  is positioned relative to the long panel portion  23  is the inside, and the side on which the lever  4  is positioned is the outside. The third direction is the direction orthogonal to the first and second directions, and is the direction in which the slider  3  accommodated in the housing  2  moves. In the third direction shown in  FIG. 1 , the side on which the leading end of the lever  4  is positioned is the disengaged side, and the side on which the protruding portion of the housing  2  is positioned is the engaged side. 
     The arrows at both ends of the single-dot chain line in  FIG. 3  indicate the circumferential direction centered on the turning shaft portion  231 , and indicate the directions in which the lever  4  turns. Arrows F and N on both ends of the solid line indicate the far side from the turning shaft portion  231  and the near side of the turning shaft portion  231  in the radial direction centered on the turning shaft portion  231 . 
     As shown in  FIG. 1  through  FIG. 3 , the connector  1  includes a housing  2 , a slider  3  slidably accommodated in the housing  2 , and a lever  4  supported turnably by the housing  2  which moves the slider  3 . All of these components are made of a synthetic resin. 
     The housing  2  includes an outer shell portion  21  which is a case with a rectangular profile arranged so that the axial direction is in the first direction. The outer shell  21  includes a pair of long panel portions  23  facing each other in the second direction, and a pair of short panel portions  25  facing each other in the third direction. The long panel portions  23  each have a protruding portion  27  which protrudes upward. 
     A holding portion  29  for holding the terminals (see  FIG. 13A  through  FIG. 13C ) is arranged to the inside of the outer shell  21 . The holding portion  29  may be integrated with the outer shell portion  21  or may be a separate component. When the housing  2  is fitted into the opposing housing  9  (see  FIG. 8 ), the holding portion  29  is inserted into the opposing housing  9 , and the outer shell portion  21  envelops the opposing housing  9 . 
     As shown in  FIG. 4  and  FIG. 5 , a turning shaft portion  231  protruding to the outside in the second direction is provided in the central portion of the long panel portions  23  in the third direction and in the bottom portion in the first direction. The turning shaft portion  231  includes a column-shaped base portion  233  and a hook portion  235  which protrudes from the base portion  233  in the radial direction to prevent detachment. 
     Arc-shaped windows  23   a  passing through in the second direction are formed in the central portions of the long panel portions  23  in the third direction and in the central portions in the first direction. The windows  23   a  have an arc shape centered on the turning shaft portion  231 . The shape of the windows  23   a  is explained in greater detail below. 
     Insertion hole  25   a  for accommodating the slider  3  are formed in the long panel portions  23 , and openings for the insertion holes  25   a  are formed in the short panel portion  25  on the disengaged side in the third direction. Rail grooves  251 ,  252  for movably holding the slider  3  in the third direction are formed above and below the insertion holes  25   a  (see  FIG. 13A  through  FIG. 13C ). 
     As shown in  FIG. 6  through  FIG. 8 , the slider  3  is a rectangular panel. A cam groove  3   a  extending in the first direction is formed on the outer surface of the slider  3  in the second direction. When the slider  3  is accommodated in the housing  2 , a portion of the cam groove  3   a  is visible in a window  23   a  formed in the long panel portion  23  (see  FIG. 3  and  FIG. 5 ). 
     An engaging groove  3   b  is formed on the inner surface of the slider  3  in the second direction. The engaging groove  3   b  extends towards the disengaged side in the third direction and upwards in the first direction. When the housing  2  is fitted into the opposing housing  9 , the engaging protrusion  91  on the opposing housing  9  is inserted into the engagement groove  3   b  formed in the slider  3 . 
     When the slider  3  is moved towards the engaged side in the third direction by the turning lever  4 , the engaging groove  3   b  engages the engaging protrusion  91 , and the action of the cam moves the housing  2  downward in the first direction. As a result, engagement of the housing  2  and the opposing housing  9  is completed, and the housing  2  is kept from moving in the first direction. 
     As shown in  FIG. 9  and  FIG. 10 , the lever  4  includes a pair of panel-shaped arm portions  41  which face each other. A keyhole-shaped turning shaft hole  41   a  is formed at one end in the extension direction of each arm portion  41  for receiving an inserted turning shaft portion  231  on the housing  2 . A bridge portion  43  spans the other end portion in the extension direction of the arm portions  41 . 
     A cam shaft portion  411  is provided on the opposing inside surfaces of the arm portions  41  at a position on the side N nearer the turning shaft holes  41   a  than the middle point between the turning shaft holes  41   a  and the bridge portion  43 . Each cam shaft portion  411  has a column-shaped base portion  413  and a hook portion  415  protruding from the base portion  413  in the radial direction to prevent detachment. Each hook portion  415  extends towards the far side F away from the turning shaft holes  41   a.    
     A cam shaft portion  411  is passed through a window  23   a  formed in the outer shell portion  21  and is inserted into a cam groove  3   a  formed in a slider  3  (see  FIG. 3  and  FIG. 13A  through  FIG. 13C ). The attachment of the lever  4  is explained below in greater detail. 
     When the lever  4  is turned around the turning shaft portion  231 , the cam shaft portion  411  inserted into the cam groove  3   a  pushes the slider  3  primarily in the third direction, and this moves the slider  3  along the rail grooves  251 ,  252  in the third direction. The direction in which the slider  3  moves includes the third direction  3  but is not limited to the third direction alone. 
     In the embodiment explained above, the lever  4  is arranged to the outside of the housing  2 , enabling the range of movement for the lever  4  to be expanded and increasing design freedom for the connector  1 . 
     However, when the lever  4  is arranged to the outside of the housing  2 , the force required to spread apart the pair of arm portions  41  is easier to generate, and the cam shaft portions  411  are more likely to become detached from the cam grooves  3   a . This force is thought to be generated because the edges of the turning shaft hole  41   a  push the turning shaft portions  231  in the radial direction when the lever  4  is being turned, and the turning shaft portions  231  become deformed. 
     In the embodiment, as shown in  FIG. 3  and  FIG. 13C , a hook portion  415  on each cam shaft portion  411  is hooked on the edge  237  on the far side F of the window  23   a  from the turning shaft portion  231  on the inside of the long panel portion  23  in the second direction, which keeps the cam shaft portion  411  from detaching from the cam groove  3   a.    
     More specifically, as shown in  FIG. 13C , the distance Lr from the turning shaft portion  231  (or turning shaft hole  41   a ) to the edge  237  on the far side F of the window  23   a  is smaller than the distance Ln from the turning shaft hole  41   a  (or the turning shaft portion  231 ) to the end on the far side F of the hook portion  415  but greater than the distance Lb from the turning shaft hole  41   a  (or the turning shaft portion  231 ) to the end on the far side F of the base portion  413 . These distances Lr, Ln, Lb are all centered on the turning shaft portion  231  in the radial direction. 
     As shown in  FIG. 5  and  FIG. 13C , the distance Lr from the turning shaft portion  231  to the edge  237  on the far side F of the window  23   a  is smaller than the distance Ln from the turning shaft portion  231  to the end on the far side F of the hook portion  415  along the entire edge  237 . This keeps the cam shaft portion  411  from coming detached from the cam groove  3   a  no matter where the cam shaft portion  411  moved by the turning lever  4  is located in the window  23   a.    
     The edge  238  on the near side N of the window  23   a  relative to the turning shaft portion  231  includes a section  238   a  in which the interval Lwa between it and the edge  237  on the far side F is smaller than the maximum diameter Lc of the cam shaft portion  411 , and an edge  238  in which the interval Lwb between it and the edge  237  on the far side F is larger than the maximum diameter Lc of the cam shaft portion  411 . Along the edge  238  on the near side N, the section  238   b  with interval Lwb is positioned on the disengaged side in the third direction. The maximum diameter Lc of the cam shaft portion  411  is the distance from the end on the near side N of the cam shaft portion  411  including the hook portion  415  to the end on the far side F. 
     This enables the cam shaft portion  411  pass through the window  23   a  in section  238   b  of interval Lwb, and the hook portion  415  to then engage the edge  237  on the far side F, thereby preventing the cam shaft portion  411  from detaching from the window  23   a  and the cam groove  3   a . Also, when the cam shaft portion  411  is in section  238   a  with interval Lwa, interval Lwa is smaller than the maximum diameter Lc of the cam shaft portion  411  with the hook portion  415  engaging the edge  237  on the far side F, thereby preventing the cam shaft portion  411  from detaching from the cam groove  3   a.    
     In addition, as shown in  FIG. 3  and in  FIG. 10 , the hook portion  415  of the cam shaft portion  411  has a shape whose width narrows and whose end tapers from the turning shaft portion  231  as the far side F is approached. Thus, when the turning lever  4  moves the cam shaft portion  411 , the hook portion  415  is kept from coming into contact with the inner surface of the cam groove  3   a , and the base portion  413  is able to push against the inner surface of the cam groove  3   a.    
     The following is an explanation of how the lever  4  is attached. 
     First, as shown in  FIG. 11 ,  FIG. 12  and  FIG. 13A , the lever  4  is arranged so that the pair of arm portions  41  on the lever  4  sandwich the housing  2  accommodating the slider  3  in the second direction. 
     More specifically, the lever  4  is arranged so that the cam shaft portions  411  of the lever  4  are fitted into the disengaged side of the window  23   a  in the third direction. Because, as mentioned above, the edge  238  on the near side N of the window  23   a  relative to the turning shaft portion  231  has a section  238   b  in which the interval Lwb between it and the edge  237  on the far side F is larger than the maximum diameter Lc of the cam shaft portion  411 , the cam shaft portion  411  can pass through the window  23   a  in section  238   b.    
     However, as mentioned above, because the distance Lr from the turning shaft portion  231  to the edge  237  on the far side F of the window  23   a  is smaller than the distance Ln from the turning shaft hole  41   a  to the end of the hook portion  415  on the far side F, the cam shaft portion  411  cannot be inserted into the window  23   a  and the turning shaft portion  231  cannot be inserted into the turning shaft hole  41   a  as long as the arm portion  41  remains straight. 
     Therefore, as shown in  FIG. 13B , the rear side of the cam shaft portion  411  of each arm portion  41  is pushed inward in the second direction using a finger. 
     In this way, the portion of each arm portion  41  between the cam shaft portion  411  and the turning shaft hole  41   a  becomes elastically deformed, and the cam shaft portion  411  is pushed into the cam groove  3   a . At this time, when the hook portion  415  pass through the window  23   a  and reaches the cam groove  3   a , the arm portion  41  moves from the turning shaft portion  231  to the far side F only by the protruding length of the hook portion  415 , and the turning shaft portion  231  can be inserted into the turning shaft hole  41   a.    
     As a result, and as shown in  FIG. 13C , the cam shaft portion  411  can be inserted into the window  23   a , and the turning shaft portion  231  can be inserted into the turning shaft hole  41   a.    
     The hook portion  235  of the turning shaft portion  231  protrudes on the side opposite that of the hook portion  415  of the cam shaft portion  411 . The turning shaft hole  41   a  also extends on the opposite side. Thus, when the arm portion  41  moves to the far side F from the turning shaft portion  231  by the protruding length of the hook portion  415  and the turning shaft portion  231  is inserted into the turning shaft hole  41   a , insertion by the hook portion  235  can be inhibited. 
     An embodiment of the present disclosure was explained above, but the present disclosure is not restricted to this embodiment. It should be clear to a person of skill in the art that many other embodiments are possible.