Patent Publication Number: US-10312626-B2

Title: Electrical connector with terminal alignment plate and secondary lock detection

Description:
FIELD OF THE INVENTION 
     The invention is directed to an electrical connector assembly with a terminal alignment plate and a secondary lock detection member. In particular, the invention is directed to an electrical connector assembly in which the alignment plate is prevented from moving to a final position when the secondary lock detection member is in a shipping position. 
     BACKGROUND OF THE INVENTION 
     Electrical connectors may be used to transfer data and/or electrical power between different systems or devices. Electrical connectors are often designed to operate in challenging environments where contaminants, shock and/or vibration can disrupt the electrical connection. For example, automobiles and other machinery utilize electrical connectors to communicate data and/or electrical power therein. At least some known electrical connectors include a connector housing that has a cavity configured to receive another electrical connector (hereinafter referred to as a “mating connector”). The cavity opens to a front end of the connector housing and extends a depth into the connector housing. The electrical connector includes an array of electrical contacts, and the mating connector includes a complementary array of electrical contacts (hereinafter referred to as “mating contacts”). As the mating connector is received within the cavity, the electrical contacts are received within corresponding socket openings of the mating connector. Each socket opening may include one of the mating contacts that engages the corresponding electrical contact to establish an electrical connection. 
     Many times harnesses must be assembled and/or preassembled, where one part of the connector is not mated with the corresponding connector until sometime further in the overall assembly process. Thus, this requires a great deal of care for socket connectors of the type having a header and a plurality of upstanding tabs and/or pins. 
     Although the connector housing partially surrounds the electrical contacts within the receiving cavity, the electrical contacts may be exposed to the ambient environment through the open front end. During shipping or handling of the electrical connectors, contaminants may enter the receiving cavity through the front end. In addition, the front end may permit objects to enter the receiving cavity and engage the electrical contacts thereby moving and/or bending the electrical contacts. If an electrical contact is not positioned properly within the receiving cavity, the electrical contact may improperly engage the mating connector, an incident referred to as stubbing, which can damage the electrical contact. In some cases, the damage may require the electrical contact or, potentially, the entire electrical connector to be replaced. 
     In some connection systems, the headers are provided with freestanding pins without any type of support surrounding the pins. In other connection systems, alignment plates may be provided. Such alignment plates have a plurality of holes for receiving the terminal pin portions to maintain the alignment and spacing of the pin portions and prevent bending thereof or damage thereto. The alignment plates may be removed or remain in place before the connector is mated, or it has been known to provide an arrangement whereby the alignment plate moves from an outer protecting position, inwardly along the pin portions to an inner mating position, such as during insertion of the pin portions into holes in a printed circuit board. 
     Although alignment plates can be effective, alignment plates can easily be moved during shipping from an initial position, in which the terminal pins are protected, to a final position, in which the terminal pins are not protected. It would, therefore, be beneficial to provide a terminal alignment plate which cannot be easily moved to a final position during shipping. In particular, it would be beneficial to provide an electrical connector assembly in which the alignment plate is prevented from moving to a final position when a secondary lock detection member is in a shipping position. 
     SUMMARY OF THE INVENTION 
     An embodiment is directed to an electrical connector assembly having a housing, a terminal alignment plate and an independent secondary lock member. The housing has a plurality of terminals mounted in the housing with mating portions projecting therefrom. The terminal alignment plate has a plurality of terminal alignment plate apertures for receiving the mating portions of the terminals. The terminal alignment plate has secondary lock engagement surfaces. The terminal alignment plate is movably mounted on the housing between a protecting position in which the terminal alignment plate is positioned proximate distal ends of the terminals and a fully inserted position in which the terminal alignment plate is positioned away from the distal ends of the terminals. The independent secondary lock member has terminal alignment plate engagement surfaces. The independent secondary lock member being movably mounted on the housing between an open position and a closed position in which the independent secondary lock member engages a primary lock and secures the terminals in the housing. When the independent secondary lock member is in the open position, the terminal alignment plate engagement surfaces engage the secondary lock engagement surfaces of the terminal alignment plate to retain the terminal alignment plate in the protecting position and prevent the terminal alignment plate from being moved to the fully inserted position. When the independent secondary lock member is in the closed position, the terminal alignment plate engagement surfaces do not engage the secondary lock engagement surfaces of the terminal alignment plate, allowing the terminal alignment plate to be moved to the fully inserted position. 
     An embodiment is directed to an electrical connector assembly having a housing with a plurality of terminals mounted in the housing with mating portions projecting therefrom. The housing has recesses for receiving portions of a terminal alignment member. The terminal alignment member has a plurality of terminal alignment member apertures for receiving the mating portions of the terminals. The terminal alignment member has movable member engagement surfaces. The movable member engagement surfaces are positioned in the recesses of the housing. The terminal alignment member is movably mounted on the housing between a protecting position in which the terminal alignment member is positioned proximate distal ends of the terminals and a fully inserted position in which the terminal alignment member is positioned away from the distal ends of the terminals. A movable member is provided and has terminal alignment member engagement surfaces. The movable member is movably mounted on the housing between a first position and a second position. The terminal alignment member engagement surfaces are positioned in the recesses of the housing when the movable member is in the first position. The terminal alignment member engagement surfaces are positioned outside of the recesses of the housing when the movable member is in the second position. When the movable member is in the first position, the terminal alignment member engagement surfaces engage the movable member engagement surfaces of the terminal alignment member to retain the terminal alignment member in the protecting position and prevent the terminal alignment member from being moved to the fully inserted position. 
     An embodiment is directed to a method of mating an electrical connector assembly to a mating connector. The method includes: positioning an independent secondary locking member in a first position; positioning a terminal alignment member in a protecting position in which secondary lock engagement surfaces of the terminal alignment member engage terminal alignment plate engagement surfaces of the independent secondary lock member, wherein the terminal alignment member is prevented from being moved from the protecting position to a fully inserted position; moving the independent secondary locking member to a second position in which the terminal alignment plate engagement surfaces of the independent secondary lock member do not engage the secondary lock engagement surfaces of the terminal alignment member, allowing the terminal alignment member to be moved from the protecting position; and moving the terminal alignment member to a fully inserted position. 
     The method may also include engaging a projection of the independent secondary locking member which extends through the terminal alignment member to move the independent secondary locking member from the first position to the second position; positioning a mating connector in line with the connector assembly; or preventing the insertion of the mating connector into the connector assembly when the mating connector is not in condition for mating, wherein mating connector engaging surfaces of the terminal alignment member engage a portion of a mating connector to prevent the insertion of the mating connector into the electrical connector assembly. 
     Other features and advantages of the present invention will be apparent from the following more detailed description of the preferred embodiment, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of an illustrative electrical connector header assembly of the present invention, with a terminal alignment plate shown in shipping position. 
         FIG. 2  is an exploded perspective view of the header of  FIG. 1 , with the terminal alignment plate exploded therefrom. 
         FIG. 3  is a perspective cross-sectional view of the header assembly of  FIG. 1  taken along line  3 - 3  of  FIG. 1 , the terminal alignment plate and an independent secondary lock member are shown in a first or shipping position. 
         FIG. 4  is a perspective cross-sectional view of the header assembly similar to  FIG. 3 , except the independent secondary lock member is shown in a second or locked position, the terminal alignment plate remains in the first or shipping position. 
         FIG. 5  is a perspective cross-sectional view of the header assembly similar to  FIG. 3 , except the terminal alignment plate is shown in a second or fully inserted position and the independent secondary lock member is shown in a second or locked position. 
         FIG. 6  is a perspective cross-sectional view of the header assembly of  FIG. 1  with a mating connector positioned proximate the header assembly, the terminal alignment plate of the header assembly and the independent secondary lock member of the header assembly are shown in a first or shipping position, an independent secondary lock member of the mating connector is shown in a first position. 
         FIG. 7  is a perspective cross-sectional view of the header assembly of  FIG. 1  with the mating connector fully mated to the header assembly, the terminal alignment plate of the header assembly is shown in a second or fully inserted position, the independent secondary lock member of the header assembly is shown in a second or locked position, and the independent secondary lock member of the mating connector is shown in a second or locked position. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The description of illustrative embodiments according to principles of the present invention is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description. In the description of embodiments of the invention disclosed herein, any reference to direction or orientation is merely intended for convenience of description and is not intended in any way to limit the scope of the present invention. Relative terms such as “lower,” “upper,” “horizontal,” “vertical,” “above,” “below,” “up,” “down,” “top” and “bottom” as well as derivative thereof (e.g., “horizontally,” “downwardly,” “upwardly,” etc.) should be construed to refer to the orientation as then described or as shown in the drawing under discussion. These relative terms are for convenience of description only and do not require that the apparatus be constructed or operated in a particular orientation unless explicitly indicated as such. Terms such as “attached,” “affixed,” “connected,” “coupled,” “interconnected,” and similar refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise. Moreover, the features and benefits of the invention are illustrated by reference to the preferred embodiments. Accordingly, the invention expressly should not be limited to such preferred embodiments illustrating some possible non-limiting combination of features that may exist alone or in other combinations of features, the scope of the invention being defined by the claims appended hereto. 
     As best shown in  FIGS. 3 through 5 , a header assembly  10  includes a housing  12 , a pin or terminal alignment member or plate  14  and a movable member, such as a secondary lock member  16 . Contacts or terminals  20  are provided in the housing. The contacts or terminals  20  may be pin contacts, tabs or other known types of contacts. 
     The housing  12  generally includes a terminal receiving portion  22  with a shroud  24  extending therefrom. The shroud  24  has end walls  30  and side walls  32 . The housing  12  further includes a lower flange portion  34 , which circumscribes the housing  12 . 
     As best shown in  FIGS. 1 through 5 , the terminal receiving portion  22  has alignment plate receiving recesses  40  which extend through at least a portion of the terminal receiving portion  22 . Terminal receiving openings  42  ( FIGS. 3 and 4 ) also extend through the terminal receiving portion  22 . It should be appreciated that the terminal receiving openings  42  are profiled according to the particular contacts or terminals  20  positioned in the housing  12 . 
     The independent secondary locking member  16  is positioned proximate the terminal receiving portion  22 . The independent secondary lock  16  helps to ensure the terminals remain properly positioned within the housing. The independent secondary lock member  16  also cooperates with the primary lock (not shown) to prevent withdrawal of the terminals from the connector. In the illustrative embodiment shown, the independent secondary lock member  16  includes a planar member  44  which extends across a bottom surface of the terminal receiving portion  22 . A projection or rib  46  extends upward from the terminal receiving portion  22  toward the shroud  24 . The projection or rib  46  extends into a cavity  48  in the terminal receiving portion  22 . The rib  46  has one or more terminal alignment plates or terminal alignment member engagement surfaces  50 . In the embodiment shown, the terminal alignment plates or member engagement surfaces  50  extend at an angle relative to the longitudinal axis of the rib  46 . However, other configurations of the terminal alignment plates or member engagement surfaces  50  may be used. 
     An engagement projection  52  (such as, but not limited to a rib or tower) extends upward from the terminal receiving portion  22  toward the shroud  24 . The engagement projection  52  extends through an opening  54  in the terminal receiving portion  22 , such that a free end of the engagement projection  52  is positioned above a top surface of the terminal receiving portion  22 . 
     As best shown in  FIG. 2 , the alignment plate  14  includes a plate portion  60  with a plurality of terminal receiving openings  62  extending therethrough. Projections or walls  64  extend from the terminal receiving portion  22 . Each wall  64  has an upwardly extending portions  66  which extends in a direction toward a mating end  68  of the terminals  20 . Each wall  64  also has an oppositely or downwardly extending portion  68  which extends towards and cooperates with the recesses  40  of the terminal receiving portion  22 . A projection receiving opening  67  is provided in the plate portion  60 . 
     The downwardly extending portion  68  has one or more secondary lock engagement surfaces  70 . In the embodiment shown, the secondary lock engagement surfaces  70  extend at approximately a 90 degree angle relative to the longitudinal axis of the rib  46 . However, other configurations of the secondary lock engagement surfaces  70  may be used. The downwardly extending portion  68  has one or more recesses or slots  72  which cooperate with projections  74  of the terminal receiving portion  22  which extend into the alignment plate receiving recesses  40 . 
     The upwardly extending portion  66  has one or more mating connector engagement surfaces  80 . In the embodiment shown, the mating connector engagement surfaces  80  extend approximately parallel to the secondary lock engagement surfaces  70 . However, other configurations of the mating connector engagement surfaces  80  may be used. The downwardly extending portion  68  has on or more recesses or slots  82  which cooperate with projections  84  of the mating connector  18 . 
     As best shown in  FIGS. 6 and 7 , the mating connector  18  has a projection or rib  90  which extends from the mating face. The rib  90  has one or more terminal alignment plates or terminal alignment member engagement surfaces  92 . In the embodiment shown, the terminal alignment plates or member engagement surfaces  92  extend at an angle relative to the longitudinal axis of the rib  90 . However, other configurations of the terminal alignment plates or member engagement surfaces  92  may be used. 
     Referring to  FIG. 3 , the terminal alignment member  14  is shown in a first, protecting, pre-stage or shipping position. In this position, the plate portion  60  of the terminal alignment member  14  is positioned proximate the mating or distal ends  68  of the terminals  20 . Portions of the downwardly extending portions  68  of the walls  64  of the terminal alignment member  14 , including the secondary lock engagement surfaces  70 , are positioned in the alignment plate receiving recesses  40  of the terminal receiving portion  22  of the housing  12 . The slots  72  of the downwardly extending portions  68  cooperate with the projections  74  to maintain the terminal alignment member  14  in a stable position relative to the housing  12 . 
     In the position shown in  FIG. 3 , the independent secondary lock member or movable member  16  is also positioned in an open or first position. In this position, the terminal alignment plates or terminal alignment member engagement surfaces  50  are positioned in the alignment plate receiving recesses  40 . 
     In the position shown in  FIG. 3 , the terminal alignment plates or terminal alignment member engagement surfaces  50  are positioned in-line and in engagement with the secondary lock engagement surfaces  70  to prevent the movement of the terminal alignment member  14  from the first, protecting, pre-stage or shipping position to a second or fully inserted position. 
     In the first or protecting position, the alignment plate  14  is spaced from the terminal receiving portion  22  of the housing  12 . This allows the alignment plate  14  to be positioned nearer to the free or mating ends  68  of the terminals  20  to provide structural support to the terminals  20  proximate their free or mating ends while still allowing a probe to access the terminals  20 . In so doing, the alignment plate  14  provides protection to the free ends of the terminals  20 , preventing the terminals  20  from being deformed or damaged prior to the insertion of the mating connector  18  into the shroud  24  of the housing  12 . For example, the alignment plate  14  may shield the terminals  20  from objects that inadvertently enter the shroud  24 . In some embodiments, the alignment plate  14  may align and/or hold the terminals  20  in designated positions to reduce the likelihood of stubbing during the mating operation. Optionally, the alignment plate  14  may be configured to function as a cover that reduces the likelihood of contaminants (e.g., dust) entering the shroud  24 . 
     Referring to  FIG. 4 , the terminal alignment member  14  remains in the first, protecting, pre-stage or shipping position. However, the independent secondary lock member or movable member  16  is moved to a second or closed position in which the independent secondary lock member  16  engages the primary lock (not shown) and facilitates the securing of the terminals  20  in the housing  12 . In various embodiments, the independent secondary lock member  16  cannot be fully moved to the second or closed position unless the terminals  20  are properly seated in the terminal receiving portion  22  of the housing  12 . 
     The independent secondary lock member or movable member  16  is moved from the first or open position to the second or closed position by movement of the projection  52 . As the projection  52  extends beyond the terminal receiving portion  22  and the plate portion  60  of the terminal alignment member  14 , an operator can engage and move the projection  52  and the independent secondary lock member or movable member  16  from the first or open position to the second or closed position. 
     In this position, the terminal alignment plates or terminal alignment member engagement surfaces  50  is moved from the alignment plate receiving recesses  40 . Consequently, the terminal alignment plates or terminal alignment member engagement surfaces  50  are no longer positioned in-line and or in engagement with the secondary lock engagement surfaces  70 , allowing the movement of the terminal alignment member  14  from the first, protecting, pre-stage or shipping position to the second or fully inserted position, as shown in  FIG. 5 . 
     The movement of the terminal alignment member  14  from the first, protecting, pre-stage or shipping position to the second or fully inserted position is facilitated by the mating of the mating connector  18  with the connector assembly  10 , as shown in  FIGS. 6 and 7 . 
     In the position shown in  FIG. 6 , the terminal alignment plates or terminal alignment member engagement surfaces  92  of the mating connector  18  are positioned in-line and in engagement with the mating connector engagement surfaces  80  of the terminal alignment member  14  to prevent the proper insertion of the mating connector  18  into the shroud  24  of the housing  12 . 
     Referring to  FIG. 7 , the terminal alignment plates or terminal alignment member engagement surfaces  92  of the mating connector  18  is moved to a position in which the terminal alignment plates or terminal alignment member engagement surfaces  92  are no longer positioned in-line and or in engagement with the mating connector engagement surfaces  80 , allowing the proper insertion of the mating connector  18  into the shroud  24  of the housing  12 . 
     As described herein, the method of mating an electrical connector assembly  10  to a mating connector  18  includes: positioning the independent secondary locking member  16  in a first position; positioning the terminal alignment member  14  in a protecting position in which the secondary lock engagement surfaces  70  of the terminal alignment member  14  engage the terminal alignment plate engagement surfaces  50  of the independent secondary lock member  16 , wherein the terminal alignment member  14  is prevented from being moved from the protecting position to a fully inserted position; moving the independent secondary locking member  16  to a second position in which the terminal alignment plate engagement surfaces  50  of the independent secondary lock member  16  do not engage the secondary lock engagement surfaces  70  of the terminal alignment member  14 , allowing the terminal alignment member to be moved from the protecting position; and moving the terminal alignment member  14  to a fully inserted position. 
     The method may additionally include engaging a projection  52  of the independent secondary locking member  16  which extends through the terminal alignment member  14  to move the independent secondary locking member  16  from the first position to the second position. 
     The method may additionally include: positioning the mating connector  18  in line with the connector assembly  10 ; and preventing the insertion of the mating connector  18  into the connector assembly  10  when the mating connector  18  is not in condition for mating, wherein mating connector engaging surfaces  80  of the terminal alignment member  14  engage a portion of a mating connector  18  to prevent the insertion of the mating connector  18  into the electrical connector assembly  10 . 
     While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the spirit and scope of the invention as defined in the accompanying claims. In particular, it will be clear to those skilled in the art that the present invention may be embodied in other specific forms, structures, arrangements, proportions, sizes, and with other elements, materials and components, without departing from the spirit or essential characteristics thereof. One skilled in the art will appreciate that the invention may be used with many modifications of structure, arrangement, proportions, sizes, materials and components and otherwise used in the practice of the invention, which are particularly adapted to specific environments and operative requirements without departing from the principles of the present invention. The presently disclosed embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being defined by the appended claims, and not limited to the foregoing description or embodiments.