Patent Publication Number: US-11031719-B2

Title: Power connector

Description:
RELATED APPLICATIONS 
     This application is a national stage of International Application No. PCT/US2016/059367, filed Oct. 28, 2016, which claims priority to Indian Provisional Application No. 1116/KOL/2015, filed Oct. 29, 2015, both of which are incorporated herein by reference in their entirety. 
     Field of the Invention 
     The present invention relates to field of connectors, more specifically the field of connectors suitable for providing power. 
     Description of Related Art 
     There currently exists a need for wire to wire connector systems, in particular systems that transmit power. A particular issue is that a unique plug and receptacle connector are generally required for the connector system. It is required that the corresponding components in these connectors are assembled properly and correctly. Generally, each of the connectors includes an insulative housing and an electrically conductive terminal that is secured to the end of a cable or wire lead. Connector systems generally include a plug and receptacle with corresponding male and female electrically conductive terminals. 
     Each connector requires a plurality of terminated lead wires inserted into respective cavities in the housing. In some instances, the conductive terminal may not be inserted in the correct manner or the wrong terminal is used resulting in damage to the corresponding terminal and electrical failure. Therefore a power terminal and a connector is desired that eliminates the potential these problems associated with a wire to wire connector system. 
     BRIEF SUMMARY 
     The present disclosure generally relates to an electrical power connector that can be integrated into a connector system and that can provide desirable operation under high current density conditions. In general, connectors are suitable for use as modular components within modular assemblies. For example, modular assemblies can take the form of wire-to-board or wire-to-wire connectors and can, when desired, provide a low-profile connector system. 
     A connector assembly may be provided that includes a hermaphroditic plug connector and a receptacle connector including one or more hermaphroditic blade-type power contacts disposed in each of the connector housings. The plug and receptacle connectors are constructed from an insulative material to form the housing, are slidably mateable with each other and include corresponding molded cavities to receive the electric terminals within the housing. 
     In an embodiment the terminals are constructed with a planar body portion and a planar securing portion with a bent beam contacting portion disposed therebetween. The cavities include a terminal retention slot for securing the planar sections of the terminal within the housing cavity. Additionally the planar portions of the terminal are constructed so that interference exists between the planar portions of the terminal and certain cavity openings and terminal orientations prohibiting incorrect assembly of the terminals to the housing cavities. Additionally, a Terminal Position Assurance, TPA device is used to verify the position and orientation of the terminal with respect to the connector housing. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The present invention 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 a connector system of the present disclosure; 
         FIG. 2  is a perspective view of the connector system of  FIG. 1  wherein the connectors are unmated; 
         FIG. 3  is an exploded view of a connector of the connector system of  FIG. 1 ; 
         FIG. 4  is a perspective view of a lead wire assembly of the connector of  FIG. 3 ; 
         FIG. 5  is a perspective view of the terminal of an embodiment of the present disclosure. 
         FIG. 6  is an alternative perspective view of the terminal of  FIG. 5 . 
         FIG. 7  is a perspective view of the housing of the connector of the present disclosure. 
         FIG. 8  is an alternative perspective view of the housing of  FIG. 7 . 
         FIG. 9  is a section view of the housing of  FIG. 7 . 
         FIG. 10  is an alternative perspective of the section view of  FIG. 9 . 
         FIG. 11  is a partially section view showing a sequence of terminal insertion of the connector of the present disclosure. 
         FIG. 12  is a partially section view showing an additional sequence of terminal insertion of the connector of the present disclosure. 
         FIG. 13  is a partially section view showing an additional sequence of terminal insertion of the connector of the present disclosure. 
         FIG. 14  is an alternative perspective view of  FIG. 13 . 
         FIG. 15  is a perspective view of the TPA device of the connector of the present disclosure. 
         FIG. 16  is a section view of the housing of the connector of the present disclosure. 
         FIG. 17  is a section view showing a sequence of the insertion of a TPA of the connector of the present disclosure. 
         FIG. 18  is a section view showing an additional sequence of the insertion of a TPA of the connector of the present disclosure. 
         FIG. 19  is a section view showing an additional sequence of the insertion of a TPA of the connector of the present disclosure. 
         FIG. 20  is an alternative perspective view of the connector of  FIG. 19 . 
         FIG. 21  is section view of the connector assembly of the present disclosure. 
         FIG. 22  is an additional section view of the connector assembly of the present disclosure. 
         FIG. 23  is a section view of the mated connector assembly system of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     The detailed description that follows describes exemplary embodiments and is not intended to be limited to the expressly disclosed combination(s). Therefore, unless otherwise noted, features disclosed herein may be combined together to form additional combinations that were not otherwise shown for purposes of brevity. 
     The appended figures illustrate an embodiment of the current disclosure and it is to be understood that the disclosed embodiment is merely exemplary of the disclosure, which may be embodied in various forms. Therefore, specific details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present disclosure. 
     As shown in  FIGS. 1-3  a wire to wire connector system  10  is depicted has having a first connector  20  and a second connector  20 ′ that are removeably locked together. The connector system is of the hermaphroditic type, that is, that each connector is a duplicate and can be connected together with itself. As can be appreciated, the electrical terminals are also hermaphroditic and can connect to themselves. Since both the first connector  20  and the second connector  20 ′ are exactly the same, only one of the connectors  20  shall be described. 
     As shown in the  FIG. 2  the hermaphroditic power connector system  10  includes a first connector  20  and a second connector  20 ′ that are mated together about an axis A. The axis A also defines the insertion or mating direction of the connector system  10 .  FIG. 3  shows the connector  20  including an insulative housing  30 , a pair of terminal leads  60  and a terminal position assurance device  120  commonly referred to as a TPA. In the embodiment shown, a two circuit connector system is described, but connector systems having more than two circuits can be appreciated. In operation, the connector system  10  includes an identical connector  20  for respectively mating with each other. As further illustrated in  FIGS. 2 and 7 , each connector includes a housing  30  having a terminal receiving portion  36  and an opening  38 , whereby the opening  38  is configured to accept the terminal receiving portion  36  of the mating or second connector  20 ′. 
     The housing  30  includes a cavity  50  configured for receiving electrically conductive terminals  80  of a terminal lead wire  60  therein. The cavity  50  is formed along the mating axis A of the connector  20  and extends through the housing  30  with a first end corresponding to the terminal mounting portion  36  of the connector  20  and a second end corresponding to the terminal receiving portion  34 . The terminal receiving portion  34  includes an opening for receiving the terminals  80  upon insertion of the terminal lead wire  70 . The terminal receiving portion  36  of the housing  30  includes a window  56  that defines a passage between the cavity  50  and the opening  38 . 
     As depicted in  FIG. 4  the terminal lead wire  60  includes an electrically conductive terminal  80  and a lead wire  70  attached to the terminal  80 . In the embodiment shown, the terminal includes a mating end  100  extending from a body portion  82  and a mounting end  90  also extending from the body  82  as best illustrated in  FIGS. 5 and 6 . The mounting end  90  includes a section for crimping the lead wire  70  to the terminal  80 . A first pair of wings  92  is crimped directly to the conductors of the lead wire  70  and a second pair of wings  94  is crimped to the insulating portion of the lead wire  70 . A terminal securing section  104  is formed at the mating end  100  of the terminal  80  with a contacting portion  102  defined between the body portion  82  and the terminal securing section  104 . The contacting portion  102  is bent and forms a spring beam therebetween. 
     The body  82  of the terminal  80  is formed in the shape of a “U” shaped channel and includes a pair of rails  84  formed along each side of the body  82 . Each rail  84  includes a shoulder  85  formed adjacent the mounting end  100  and a tab  87  having stop surface  88  formed adjacent the mounting end  90 . A locking tang  86  is formed in the body  82  and is bent in a direction so as to be positioned between the rails  84 . 
     As best shown in  FIGS. 7-10 , the housing  30  is formed from an insulative material and includes a terminal receiving end  36  and a mounting end  34 . As previously described, the connector is a hermaphroditic type and therefore the plug connector and receptacle connector are exactly the same and cooperatively mate with each other. In the embodiment shown the connector assembly  10  is shown as a two circuit. As illustrated the connector  20  includes a pair of cavities  50  formed through the housing  30  extending between the mounting end  34  and the terminal receiving end  36  along the mating axis A. As best shown in  FIG. 7 , the housing  30  includes an opening  38  configured to receive the terminal receiving end  36  of a cooperating connector  20  therein. A lock  40  is formed on the exterior of the housing  30  and engages a ramp  44  formed in the opening  38  of a mating connector  20  to secure the connectors together in a mated arrangement. 
     As best shown in  FIG. 8  the mounting end  34  of the housing  30  includes an exterior profile having a generally rectangular shape. In the embodiment shown, a pair of cavities  50  is shown for a two circuit connector system  10 . On the exterior sides of the housing  30  a pair of ramps  42  are formed adjacent the cavities  50 . The profile of the mounting end  34  of the housing  30  includes a guiding surface  47 . 
     As best shown in  FIGS. 9-10 , the housing  30  is shown in section and the cavity  50  is depicted in the cut away view. The cavity  50  is formed in the housing  30  along the mating axis A and includes an opening extending from the mounting end  34  to the terminal receiving end  36 . A center rib or protrusion  58  is defined by a pair of vertical slots  52  formed in the cavity  50  near the receiving end  34  of the housing  30 . The protrusion  58  interposed between the slots  52 . A recess  59  is formed in the protrusion  58  along the mating axis A. A locking ramp  57  is disposed in the recess  59  with the locking ramp  57  further including a stop surface  57 ′ as best shown in  FIG. 21 . As best depicted in  FIG. 10  a window  56  is formed in the housing  30  near the mounting end  36 . The window  56  defines a passage between the opening  38  and the cavity  50 . Horizontal slots  54  are formed on each side of the cavity  50  and extend along the window  56  in the passage. 
     The insertion of the terminal lead wire  70  into the housing  30  is best illustrated in  FIGS. 11-14 .  FIGS. 11-14  depict the sequence that occurs during which the lead wire  70  is inserted into the housing  30 . The terminal lead wire  70  is installed into the connector along an insertion direction that corresponds to the mating axis A. As shown in  FIG. 11  the mating end  100  of the terminal  80  of the terminal lead wire  70  is first inserted into the cavity  50  with the securing section  104  of the terminal  80  aligned with the slots  54  and the rails  84  aligned with the slots  52 . 
     Upon further advance of the terminal  80  into the cavity  50 , the securing section  104  and the rails  84  respectively slide along the slots  54  and slots  52  until the shoulder  85  formed on the rails abuts the interior end or shoulder stop  53  of each channel  52 . As illustrated in  FIG. 21  upon insertion of the terminal  80  to its final position, the tang  86  is guided by recess  59  and is deflected over the locking ramp  57  formed in the protrusion  58 . In this position, the tang  86  snaps back behind the locking ramp  57  and engages the locking surface  57 ′ resisting pull out upon full insertion of the terminal  80 . 
     Once the terminal lead wires  60  are inserted and retained in the cavities  50  that are formed in the housing  30  a terminal position assurance device, TPA  120  is installed on the connector housing  30 . As illustrated in  FIG. 15  the TPA  120  is generally “U” shaped and generally formed from an insulative material and includes a base  122 , a latching arm  124  extending from opposite sides of the base  122  defining a space between the latching arms  124  and a guiding surface  127  defined along each arm  124 . Each arm  124  further includes a cutout formed therein defining an opening  126  with each opening  126  having a stop shoulder  128 . 
     A locking arm  130  extends from the base  122  and corresponds to each cavity  50  formed in the housing  30 . Each securing arm  130  includes a pair of side walls or projections  138  and a connecting wall  132  connecting the side walls  138  that define a “U” shaped beam. A slot  134  is formed in the connecting wall  132  between the side walk of the each securing arm  130  allowing the securing arm  130  to deflect or expand in a lateral direction normal to the mating axis A. With the slot  134 , independent “L” shaped beams are essentially created on each securing arm  130  that can deflect or bend independently of one another. 
     As illustrated in  FIGS. 16-20  the installation of the TPA  120  will now be described.  FIGS. 16-20  depict the sequence in which the TPA  120  are installed on the connector housing  30 . As best shown in  FIGS. 16 and 17 , the TPA  120  is first aligned with the mounting end  34  of the housing  30  by fitting the guiding surface  127  of the TPA  120  with the guiding surface  47  formed on the housing  30 . Each of the locking arms  130  is positioned to enter each respective cavity  50  formed in the housing  30 . Upon further insertion, as best illustrated in  FIG. 18  each of the side walls  138  formed on the securing arms  130  is guided into the respective slots  52 . At this time the side walls  138  engage a side surface of the protrusion  58  allowing the securing arms  130  to be in tight engagement with the protrusion  58 . The locking arm essentially “squeezes” the protrusion  58 . 
     Once aligned, the TPA  120  is further advanced to an installed position as shown in  FIGS. 19 and 20 . At this time the arms  124  are deflected over the ramp  42  with the stop shoulder  128  formed by respective windows  126  positioned behind the ramp  42  locking it in the fully installed positon. A stop surface  133  formed on an end surface of the locking arm  130  abuts the stop surface  88  formed on the end of the tab  87  of the rail  84  of the terminal  80 . As best depicted in  FIG. 22  the stop surface  133  provides a secondary lock to further secure the terminal  80  in the cavity  50  and resist terminal pull out. Additionally, in cases where the terminal  80  is not fully seated in the cavity  50 , the TPA  120  upon insertion, will push the terminal  80  to a fully seated position when it is installed. In instances where the terminal  80  is installed incorrectly, the TPA  120  cannot be advanced to the installed position providing an indication that an incorrectly inserted terminal  80  is present and corrective action is required. 
     As previously stated, a tight fitting arrangement between the locking arm  130  and the protrusion  58  formed in the cavity  50  provides an improvement in positioning the TPA  120 ; the ability of the locking arm  130  of the TPA  120  to flex during installation allows for greater tolerance variation. Stated otherwise, the ability of the locking arms  130  of the TPA  120  to flex can compensate for more variance between the protrusion  58  and securing arm  130 . Additionally, by being biased to the tight fitting arrangement, it will tend to be in the proper locking position even after deflection. By allowing the front portion of the locking arms  130  to flex during loading the locking arms  130  can expand and adjust to the surface of the protrusion  58 . If the securing arm  130  does not deflect, the securing arms  130  may stub and damage the TPA  120  or make it difficult to assemble due to misalignment. 
     As best shown in  FIG. 23  the connectors  20 ,  20 ′ are shown in the mating condition. The contacting sections  102 ,  102 ′ that extend into the respective openings  36 ,  36 ′ engage each other in a direction normal to the mating axis A. The contacting sections  102 ,  102 ′ deflect as they engage each other generating a normal contacting force between them. With the respective engagement of the mating terminals  80 ,  80 ′, the contacting sections  102 ,  102 ′ are deflected upon mutual engagement and tend to flatten out. This causes the each respective securing section  104  of each electrical terminal  80  to translate in the slot  52  allowing for proper electrical engagement between the terminals  80 . Upon full engagement of the connectors  20 , each stop shoulder  128 ,  128 ′ of the housings  30 ,  30 ′ is positioned behind respective lock ramps  42  securing the connectors  20 ,  20 ′ together in mating arrangement. 
     The disclosure provided herein describes features in terms of preferred and exemplary embodiments thereof. Numerous other embodiments, modifications and variations within the scope and spirit of the appended claims will occur to persons of ordinary skill in the art from a review of this disclosure.