Patent Publication Number: US-9853391-B2

Title: Wire connector with integrated coaxial connection and front loaded terminal position assurance structures

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority of U.S. Provisional Application No. 62/212,914 filed Sep. 1, 2015, the contents of which are incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     The invention relates to terminal connectors and with more particularity to multi-cavity terminal connectors including coaxial and terminal cavities. 
     BACKGROUND OF THE INVENTION 
     In the prior art, coaxial connections are separate from terminal connections in connector assemblies. Typically, the male coaxial component gets locked into a female component and then connects to a clip slot that may attach to a connector or a wire harness. There is therefore a need for a wiring connector that has a compact packaging space requirement that includes both terminal connectors and a coaxial terminal connection. There is also a need for a wiring connector that includes both terminal connectors and a coaxial terminal connection with a terminal position assurance structure that locks both the terminal and coaxial connections. 
     SUMMARY OF THE INVENTION 
     In one aspect, there is disclosed a connector assembly that includes a male housing having at least one coaxial cavity and terminal cavities. At least one female housing is shaped to be disposed in the male housing when in a connected position. The at least one female housing includes a corresponding coaxial cavity relative to the male housing and corresponding terminal cavities relative to the male housing. At least one front loaded male terminal position assurance structure is disposed in the male housing. At least one front loaded female terminal position assurance structure is connected to the at least one female housing. The front loaded male and female terminal position assurance structures lock coaxial connections and terminal connections within the male and female housings when in the connected position. 
     In another aspect, there is disclosed a connector assembly that includes a male housing having at least one coaxial cavity and terminal cavities. At least one female housing is shaped to be disposed in the male housing when in a connected position. The at least one female housing includes a corresponding coaxial cavity relative to the male housing and corresponding terminal cavities relative to the male housing. The coaxial cavity of the male and female housing includes a cam structure formed thereon aligning and holding a coaxial terminal within the coaxial cavity. 
     In another aspect, there is disclosed a connector assembly that includes a male housing including at least one coaxial cavity and terminal cavities. The male housing includes lance structures formed about the coaxial cavity. At least one female housing is shaped to be disposed within the male housing when in a connected position. The at least one female housing includes a corresponding coaxial cavity relative to the male housing and corresponding terminal cavities relative to the male housing. The female housing includes lance structures formed about the coaxial cavity. At least one front loaded male terminal position assurance structure is disposed in the male housing. The male terminal position assurance structure includes wedges formed therein corresponding to a position of the coaxial cavity. At least one front loaded female terminal position assurance structure is connected to the at least one female housing. The female terminal position assurance structure includes wedges formed therein corresponding to a position of the coaxial cavity. When a coaxial terminal is inserted into the coaxial cavity of the male or female housing the lances of the male or female housing and the wedges of the male or female terminal position assurance structure interact locking the coaxial terminal into position. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is an exploded perspective view of a connector assembly; 
         FIG. 2  is a cutaway side view of a connector assembly; 
         FIG. 3A  is an end view of a female housing; 
         FIG. 3B  is an end view of a female housing; 
         FIG. 4A  is partial perspective view of the male terminal position assurance structure detailing the wedges formed thereon; 
         FIG. 4B  is partial perspective view of the female terminal position assurance structure detailing the wedges formed thereon; 
         FIG. 5  is an end view of a male housing; 
         FIG. 6  is an end view of the female housing structure detailing the lance structures; 
         FIG. 6A  is a sectional view of  FIG. 6 ; 
         FIG. 6B  is a partial end view of the female housing structure detailing the lance structures; 
         FIG. 6C  is a sectional view of  FIG. 6B ; 
         FIG. 7  is an end view of the male housing structure detailing the lance structures; 
         FIG. 8  is a partial sectional view detailing the coaxial cavity and insertion of a coaxial terminal; 
         FIG. 9  is a top view of a male terminal position assurance structure including slots formed therein; 
         FIG. 10A  is a view detailing insertion of a coaxial terminal and the interaction between the lance and wedges of the housing and terminal position assurance structure; 
         FIG. 10B  is a view detailing insertion of a coaxial terminal and the bending of the lance; 
         FIG. 10C  is a view detailing insertion of a coaxial terminal and the interaction between the lance and wedges of the housing and terminal position assurance structure when locked; 
         FIG. 11  is a partial perspective view of a male housing including panel lock members and a bridge and sidewall structure of the male housing; 
         FIG. 12 a    is a partial perspective view of a male housing including panel lock members and a bridge and sidewall structure of the male housing; 
         FIG. 12 b    is a view of  FIG. 12 a    taken from the opposite side; 
         FIG. 13  is a partial perspective view of a female housing detailing the connector lock member including a bridge structure and sidewalls. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring to the various figures, there is detailed a connector assembly  12  that may be utilized for wire routing through vehicle openings particularly through vehicle doors. The connector assembly  12  may include a male housing  14  that includes at least one coaxial cavity  16  and terminal cavities  18 . At least one female housing  20  is shaped to be disposed in the male housing  14  when in a connected position. The at least one female housing  20  includes a corresponding coaxial cavity  16  relative to the male housing  14  and corresponding terminal cavities  18  relative to the male housing  14 . At least one front loaded male terminal position assurance structure  24  is disposed in the male housing  14 . At least one front loaded female terminal position assurance structure  26  is connected to the at least one female housing  20 . The front loaded male and female terminal position assurance structures  24 ,  26  lock coaxial connections  28  and terminal connections  30  within the male and female housings  14 ,  20  when in the connected position. 
     In the depicted embodiments of  FIGS. 1-3 , the at least one female housing  20  includes two female housings  20 . The female housings  20  may have differing numbers of terminal connections  30  with one including a coaxial cavity  16  in the depicted embodiment. The male housing  14  may be formed of a unitary structure and receives the two female housings  20 . In this manner, the male housing  14  may be utilized in various vehicle platforms by switching the number of terminals within the female housings  20  while reusing the common male housing  14 . Additionally, in the depicted embodiments of  FIGS. 1-2 and 4 , two male and female terminal position assurance structures  24 ,  26  are provided. It should be realized that various numbers of terminal connections or terminals  30  may be provided in the female housing  20  which will also have a corresponding male housing  14  and will also include a corresponding number of terminal position structures in the male and female terminal position assurance structures  24 ,  26 . In one aspect, the connector assembly  12  may further include a grommet  32  attached to the male housing  14 , as best seen in  FIGS. 1 and 2 . 
     In the depicted embodiments, the connector assembly  12  includes a coaxial cavity  16  and additional terminal cavities  18 . The terminals may include various types of systems such as a Tyco Gen Y and FCI Apex type terminals. Additionally, in the depicted embodiments the two female housings  20  allow potential flexibility in design with differing numbers of terminals. In the depicted embodiment of  FIG. 3A  there is detailed an 18-terminal connector including a coaxial cavity  16  for receiving a coaxial terminal or connection  28  and 18 terminal connections  30  while in  FIG. 3B , there is depicted a 25-terminal connector that does not include a coaxial cavity  16 . It should be realized that various numbers of terminal connections  30  and coaxial connections  28  may be included. 
     Referring to  FIG. 5 , the male housing  14  includes a corresponding number of coaxial cavities  16  and terminal cavities  18  that align with the female housing  20  cavities as described above. 
     Referring to  FIGS. 6 and 6A , the female housing  20  includes lance structures or lances  34  formed about the coaxial cavity  16 . In one aspect, the lance structures  34  extend from a face  36  of the female housing  20  and are positioned radially about the coaxial cavity  16 . In the depicted embodiment, two lance structures  34  are formed on the female housing  20 . Similarly, as shown in  FIG. 7 , the male housing  14  includes lance structures  34  formed radially about the coaxial cavity  16  and again two lance structures  34  are shown in the depicted embodiment. 
     Referring to  FIGS. 6B and 6C  there is shown another position of the lances  34  on the female housing  20 . The lances  34  as shown are positioned so as to be diametrically opposed to each other wherein the biasing force of one lance  34  is countered by the biasing force of the opposing lance  34 . Accordingly, the coaxial terminal  28  is centered in the coaxial cavity  16 , which helps ensure the coaxial terminal  28  is retained therein. 
     Referring to  FIGS. 4A and 4B , the male terminal position assurance structures  24  and the female terminal position assurance structures  26  include wedges  38  formed thereon that correspond to a position of the coaxial cavity  16 . In the depicted embodiment, the terminal position assurance structures  24 ,  26  include two wedges  38  formed thereon and extend from a face  40  of the terminal position assurance structures  24 ,  26 . In one aspect, the wedges  38  interact with the lances  34  of the housings  14 ,  20  as will be described in more detail below. 
     Referring to  FIG. 8 , the coaxial cavity  16  of the male and female housings  14 ,  20  includes a cam structure  42  formed thereon that facilitates insertion and location of a coaxial terminal  28  into the coaxial cavity  16  and provides a temporary positioning of the coaxial terminal  28  before the terminals are locked in position as will be described in more detail below. As shown in the figure, the cam structure  42  may include at least one or multiple ramps or angles  44  formed on the surface  46  of the cavity  16  to facilitate insertion and location of the coaxial terminal  28  even when the terminal position assurance structures  24 ,  26  are in a pre-staged or removed position. As the coaxial terminal  28  is inserted into the cavity, it travels on the surface  46  and continues to a first ramp  44   a  which aligns and temporarily holds the coaxial terminal  28  in position within the cavity  16 . As the coaxial terminal  28  is further inserted into the cavity it contacts a second ramp  44   b  that further aligns the coaxial terminal  28  within the cavity and temporarily holds the coaxial terminal in position. 
     Referring to  FIG. 9 , the male terminal position assurance structure  24  includes notches  48  formed thereon that control an insertion force connecting the male terminal position assurance structure  24  to the male housing  14 . In this manner, a force can be regulated for connecting the male terminal position assurance structure  24  to the male housing  14  to assure fatigue or other types of failures do not occur. 
     Referring to  FIGS. 10A-C , there is shown views of the interaction of a coaxial terminal  28  and housing  14  and terminal position assurance structure  24 . When a coaxial terminal  28  is inserted into the coaxial cavity  16  of either the male or female housing  14 ,  20 , the lances  34  of the housing  14 ,  20  and the wedges  38  of the terminal position assurance structures  24 ,  26  interact locking the coaxial terminal  28  into position. When the coaxial terminal  28  is inserted into the coaxial cavity  16  of the male or female housing  14 ,  20 , the lances  34  begin in a starting position ( FIG. 10A ) and then bend allowing the terminal  28  to be pushed into the cavity ( FIG. 10B ). Next the lances  34  return to the starting position as the wedges  38  of the terminal position assurance structure  24 ,  26  slide beneath the lances  34  preventing the lance  34  from bending and locking the coaxial terminal  28  into position ( FIG. 10C ). 
     Referring to  FIG. 11 , the connector assembly  12  includes a male housing  14  having a plurality of panel lock members  50  locking the male housing  14  into an opening formed in a panel. The male housing  14  includes a bridge structure  52  formed thereon proximate the panel locks  50  preventing breakage of the panel locks  50 . Additionally, the male housing  14  includes sidewalls  54  formed thereon proximate the panel locks  50  preventing deflection of the panel locks  50 . Further, as best shown in  FIGS. 12 a  and 12 b   , the panel locks  50  extend toward a rear face  56  of the housing  14  less than flush relative to the rear face  56  to minimize snagging of the panel lock members  50 . 
     Referring to  FIG. 13 , the female housing  20  includes a connector lock  58  locking the female and male housings  14 ,  20 . The female housing  20  includes a bridge structure  60  formed thereon proximate the connector lock  58  preventing breakage of the connector lock  58 . Additionally, the female housing  20  includes sidewalls  62  formed thereon proximate the connector lock  58  to prevent deflection of the connector lock  58 . Additionally, the connector lock  58  extends toward a rear face  64  of the female housing  20  less than flush relative to the rear face  64  minimizing snagging of the connector lock  58 . 
     The above examples and embodiments are for illustrative purposes only and changes, modifications, and the like will be apparent to those skilled in the art and yet still fall within the scope of the invention. As such, the scope of the invention is defined by the claims.