Patent Abstract:
A connector apparatus position assurance device ensures that a male connector assembly and a female connector assembly of an in-line sealed electrical connector apparatus of the present invention remain engaged. The connector apparatus position assurance device has contiguous parts that engage various parts of a retention clip of the male connector assembly at different levels of insertion of the connector apparatus position assurance device into the male connector assembly. The insertion of the connector apparatus position assurance device is also accomplished at various stages (i.e., from pre-lock position to final lock position) depending on the insertion level of the female connector assembly into the male connector assembly. Consequently, the effect of the level of insertion of the female connector assembly ensures that the male and female connector assemblies remain engaged.

Full Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention generally relates to an in-line sealed electrical connector apparatus having a connector apparatus position assurance device, and a locking method thereof. More particularly, this invention is directed to the connector apparatus position assurance device having contiguous parts for ensuring the engagement of the male and female connector assemblies of the in-line sealed electrical connector apparatus, and a locking method thereof. 
     2. Discussion of the Relevant Art 
     U.S. Pat. No. 7,465,192 is directed to an inline electrical connector apparatus that has a female connector assembly, the female connector assembly having a female housing, a female wire seal, and a female cover. The in-line sealed electrical connector of U.S. Pat. No. 7,465,192 further has a male connector assembly, the male connector assembly having a male housing, a retention clip, a male housing seal defining a male housing seal opening, a male wire seal, and a male cover. The female connector assembly is inserted within the male connector assembly, the female connector assembly being latched into the male connector assembly. 
     When the in-line electrical connector apparatus is in use, a first wire assembly is connected to the female connector assembly, while a second wire assembly is connected to the male connector assembly. 
     However, in the in-line electrical connector apparatus of U.S. Pat. No. 7,465,192, there is no assurance that the male housing assembly and the female housing assembly remain engaged and locked. 
     SUMMARY OF THE INVENTION 
     To ensure that the male housing assembly and the female housing assembly of the in-line sealed electrical connector apparatus of the present invention remain engaged and locked, a connector apparatus position assurance device is employed. The connector apparatus position assurance device has contiguous parts that engage various parts of the retention clip of the male connector assembly at different levels of insertion of the connector apparatus position assurance device into the male connector assembly. The insertion of the connector apparatus position assurance device is also accomplished at various stages (e.g., from pre-lock position to final lock position) dependent on the insertion level of the female connector assembly into the male connector assembly. For example, the effect of the level of insertion of the female connector assembly on various parts of the retention clip in turn affect the insertion of the connector apparatus position assurance device into the male connector assembly (i.e., from pre-lock position to final lock position). Also, if, e.g., the connector apparatus position assurance device happens to be fully inserted and in the final lock position, without the female connector assembly having been fully mated with the male connector assembly, the female connector assembly cannot be inserted into the male connector assembly. 
     Once fully inserted, the connector apparatus position assurance device ensures the locking engagement of the male and female connector assemblies of the in-line sealed electrical connector apparatus of the present invention. This is accomplished by the connector apparatus position assurance device of this invention ensuring that the retention clip of the male connector assembly fully locks therein the female connector assembly. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is an exploded perspective view of the in-line sealed electrical apparatus having a connector apparatus position assurance device of the present invention. 
         FIG. 2A  is side elevation view showing a first side of the connector apparatus position assurance device of the present invention;  FIG. 2B  is a side elevation view showing a second side, opposite the first side, of the connector apparatus position assurance device of the present invention; and  FIG. 2C  is an elevation view showing an end side of the connector apparatus position assurance device of the present invention. 
         FIG. 3  is a perspective view of a retention clip of the male connector assembly showing the different parts thereof, which affect the insertion of the connector apparatus position assurance device of the present invention. 
         FIG. 4  illustrates a perspective view of the connector apparatus position assurance device, in a pre-lock position, in which a lowered inner retention clip finger and a raised outer retention clip finger Hock the connector apparatus position assurance device from being inserted. 
         FIG. 5  illustrates a perspective view of the connector apparatus position assurance device, still in a pre-lock position, in which the inner retention clip finger is raised, but the raised outer retention clip finger continues to block the connector apparatus position assurance device from being inserted. 
         FIG. 6  illustrates a perspective view of the connector apparatus position assurance device in which the inner retention clip finger is raised, while the outer retention clip finger is lowered for allowing the connector apparatus position assurance device to be finally unblocked and ready to be inserted. 
         FIG. 7  illustrates a perspective view of the connector apparatus position assurance device a fully inserted position and in a final lock position. 
         FIG. 8  is a perspective view of the connector apparatus position assurance device, in a full insertion position and final lock position, for completing the locking of the male and female connector assemblies of the in-line sealed electrical connector apparatus of this invention. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       FIG. 1  is an exploded view showing the in-line sealed electrical connector apparatus of the present invention, generally referred to as reference number  1 . The in-line electrical connector apparatus  1  includes a male connector assembly  3  and a female connector assembly  5 . Mounted within the male connector assembly  3  is a retention clip  7  for receiving therein the female connector assembly  5 . Shown in  FIG. 1  is a connector apparatus position assurance device  8  insertable into the male connector assembly  3  and the retention clip  7 . The male connector assembly  3  has, at an end portion thereof; a cover  10 . A wire assembly (not shown) can be inserted into the male connector assembly  3  through openings (not shown) passing through the cover  10 ; and another wire assembly (not shown) can similarly be inserted into the female connector assembly  5  through openings (not shown) at a free end  6  thereof. 
     The male connector assembly  3  has slots  12 ,  14  passing therethrough for accommodating therein protrusions  20 ,  22  extending from an upper side of the retention clip  7 . Slots  16 ,  18 , opposed to the slots  12 ,  14 , are for accommodating therein protrusions (not shown) extending from a lower side of the retention clip  7 , the lower side of the retention clip  7  being opposed to the upper side of the retention clip  7 . 
     The cover  10  of the male connector assembly  3  has an upper slot  25  passing through an upper side of the cover  10  and a lower slot  27  passing through a lower side of the cover  10 . The upper slot  25  is for accommodating therein a protrusion  30  extending from an upper side of the male connector assembly  3 . While the lower slot  27  is for accommodating therein a protrusion (not shown) extending from a lower side of the male connector assembly  3 . The cover  10  includes an elongated slot  28  extending along an inner surface thereof for accommodating therein an elongated protruding member  29  extending along a side portion of the male connector assembly  3 , the elongated slot  28  being used to slidably guide the elongated protruding member  29  when the cover  10  is slidably mounted on an end portion of the male connector assembly  3 . 
     As also illustrated in  FIG. 1 , the male connector assembly  3  has a lever arm  50  with a fixed end  51  and a free end  52 . The free end  52  of the lever arm  50  includes an inner protruding member  54 , the inner protruding member  54  having an upper substantially inclined surface  55  and a lower substantially flat surface  56 . The fixed end  51  of the lever arm  50  is connected to the lower side of the male connector assembly  3  via a member  53  (generally, an L-shaped member). See, also,  FIG. 8 . 
     The retention clip  7  includes a lower side  32  and an upper side  34 . An inside portion of the lower side  32  of the retention clip  7  includes an elongated slot  30  which accommodates therein an elongated protrusion (not shown) extending from a lower side of the female connector assembly  5 , the elongated slot  30  guiding the elongated protrusion of the female connector assembly  5  when the female connector assembly  5  is inserted into the retention clip  7  once the retention clip  7  is mounted inside the male connector assembly  3 . See, also,  FIG. 3 . 
     Further, as also illustrated in  FIG. 1 , the upper side  34  the retention clip  7  includes a pair of flexible fingers  36 ,  38 ; namely an inner finger  36  and an outer finger  38 , the outer finger  38  having the protrusion  20  thereon (discussed earlier). 
     As later discussed, when the retention clip  7  is fully inserted and mounted within the male connector assembly  3 , the inner protruding member  54  of the free end  52  of the lever arm  50  is placed within a space  60  between end portions of the lower side  32  and the outer finger  38  of the retention clip  7 , the inner protruding member  54  of the lever arm  50  being wedged within the space  60  to prevent the outer finger  38  from moving downward (and the protrusions  20 ,  22  from being dislodged from the slots  12 ,  14 ) and to keep the retention clip  7  fully mounted and locked within the male connector assembly  3 . Also, the lever arm  50  is kept from moving (and therefore the inner protruding member  54  of the lever arm  50  from moving away from the slot  60 ) by a bar  62  connected at a side of the male connector assembly  3 . 
     As further shown in  FIG. 1 , the female connector assembly  5  includes, on an upper surface thereof an elongated slot  40  for accommodating therein the outer finger  38  of the retention clip  7  when the female connector assembly  5  is fully inserted within the retention clip  7 , as more fully discussed later. 
     The connector apparatus position assurance device  8  has leading end members  70 ,  72 ; namely, a first leading end member  70  and a second leading end member  72 , the first leading end member  70  extending longer from the base end  75  of the connector apparatus position assurance device  8  than the second leading end member  72 . As better shown in  FIG. 2B  and  FIG. 2C , the axis of elongation of the second leading end member  72  is positioned below and to the side relative to the axis of elongation of the first leading end member  70 . 
     As further illustrated in  FIG. 1 , the connector apparatus position assurance device  8  also has an elongated aperture  77  passing through a lower portion thereof, a pair of protrusions  79  extending downward from a bottom elongated member  81  thereof (see,  FIG. 2A ), and an elongated protrusion  80  extending from a side thereof. When the apparatus position assurance device  8  is inserted into the male connector assembly  3 , the elongated protrusion  80  is slidably accommodated and partially guided within a corresponding elongated slot (not shown) within an inner surface of the male connector assembly  3  (more particularly, the inner surface of the lever arm  50  of the male connector assembly  3 ). 
     Also, the bottom elongated member  81 , below the elongated aperture  77 , acts as a flexible cantilever, and flexes when the pair of protrusions  79  slide over the generally L-shaped member  53  when the apparatus position assurance device  8  is inserted into the male connector assembly  3 . The pair of protrusions  79 , along with the generally L-shaped member  53 , act as additional assurance for ensuring that the apparatus position assurance device  8  is securely in place, in final lock position, when fully inserted into the male connector assembly  3 . 
       FIGS. 2A ,  2 B, and  2 C illustrate the connector apparatus position assurance device  8  of the invention, in more detail, with  FIG. 2A  being a side elevation view showing a first side of the connector apparatus position assurance device  8 ,  FIG. 2B  being a side elevation view showing a second side, opposite the first side, of the connector apparatus position assurance device  8 , and  FIG. 2C  being an elevation view showing an end side of the connector apparatus position assurance device  8 . Shown in  FIG. 2B  is the second leading end member  72  having the axis of elongation being positioned below and to the side relative to the axis of elongation of the first leading end member  70  resulting in a ledge-like surface  90  on an upper surface of the second leading end member  72  (see,  FIG. 2B ). 
     Further illustrated in  FIG. 2B  is a slot  92  formed on a side surface of the base end  75  of the connector apparatus position assurance device  8 . The slot  92  (see, also,  FIG. 2C ), which accommodates therein the elongated protruding member  29  extending along a side portion of the male connector assembly  3 , the slot  92  being used to slidably guide the connector apparatus position assurance device  8  when the connector position assurance device  8  is slidably inserted into the male connector assembly  3 . 
       FIG. 3  illustrates the retention clip  7  having the inner finger  36  and the outer finger  38 , both fingers  26 ,  28  being flexible. When the retention clip  7  is mounted and locked within the male connector assembly  3 , the protrusions  20 ,  22  of the retention clip  7  are accommodated within slots  12 ,  14 , respectively, of the male connector assembly  3 , while opposing slots  16 ,  18  of the male connector assembly  3  accommodate therein protrusions (not shown) extending from a lower side of the retention clip  7 , the inner protruding member  54  of the lever arm  50  of the male connector assembly  3  being wedged within the space  60  to prevent the flexible outer finger  38  from moving downward for securing the retainer clip  7  within the male connector assembly  3  by ensuring that the protrusions  20 ,  22  remain within the slots  12 ,  14 , respectively. The end portion of the lower side  32  has a substantially flat raised portion  93 , while the end portion of the outer finger  38  has a sloping portion  95 , the substantially flat raised portion  93  and the sloping portion  95  abutting and contacting the lower substantially flat surface  56  and the substantially inclined surface  55 , respectively, of the inner protruding member  54  of the free end  52  of the lever arm  50 , when the retention clip  7  is mounted and locked within the male connector assembly  3 . 
     The free end portion of the inner finger  36  has a ledge-like member  95 , while the free end portion of the outer finger  38  has a ledge-like member  98 . 
     During assembly of the in-line sealed electrical connector apparatus  1 ,  FIGS. 4-7  illustrate the mating of the female connector assembly  5 , the retention clip  7 , and the connector apparatus position assurance device  8 , with the presumption that the retention clip  7  has been mounted within the male connector assembly  3 . For clarification, in  FIGS. 4-7 , the retainer clip  7  is not shown already mounted within the male connector assembly  3  so as to better explain the insertion and locking steps when the female connector assembly  5 , the retention clip  7 , and the connector apparatus position assurance device  8  achieve full mating and in final lock position. That is, to better understand the mating and locking steps of the female connector assembly  5 , the retention clip  7  and the connector apparatus assurance device  8 , the illustration of the male connector assembly  3  has been omitted from  FIGS. 4-7 . In this invention, the retention clip  7  has been pre-mounted and locked, in the manner described above, within the male connector assembly  3  before the female connector assembly  5  is inserted into the retention clip  7  and before the connector apparatus position assurance device  8  is inserted into the male connector assembly  3 . 
     During initial insertion of the connector apparatus position assurance device  8 , in the pre-lock position, as shown in  FIG. 4 , the insertion of the female connector assembly  5  into the retention clip  7  raises the outer finger  38 . The raising of the outer finger  38  results in the first leading end member  70  of the connector apparatus position assurance device  8  to be blocked by the end portion of the outer finger  38 . Further, the inner finger  36  remains in its lowered position; consequently,the second leading end member  72  of the connector apparatus position assurance device  8  is blocked by the end portion of the inner finger  36 . Thus, at initial insertion shown in  FIG. 4 , the connector apparatus position assurance device  8  remains at a pre-lock position and cannot yet be inserted. 
     As shown in  FIG. 5 , when the female connector assembly  5  is further inserted but not yet fully inserted) into the retention clip  7 , the leading end portion of the female connector assembly  5  reaches the inner finger  36  and raises the inner finger  36 . Consequently, the second leading end member  72  of the connector apparatus position assurance device  8  becomes unblocked. However, because the outer finger  38  remains in a raised position, the first leading end portion  70  of the connector apparatus position assurance device  8  remains blocked. Thus, the connector apparatus position assurance device  8  remains at a pre-lock position and cannot yet be inserted. 
     In  FIG. 6 , the female connector assembly  5  has been fully inserted into the retention clip  7 . Consequently, the outer finger  38  has dropped into the elongated slot  40  of the female connector assembly  5 , thereby lowering the outer finger  38 . With the lowered outer finger  38  and with the raised inner finger  36 , the first leading end portion  70  and the second leading end portion  72 , respectively, of the connector apparatus position assurance device  8  become unblocked, and the connector apparatus position assurance device  8  is set and ready to be inserted. 
     With the female connector assembly  5  fully inserted into the retention clip  7 , as shown in  FIG. 7 , the outer finger  38  is lowered when it drops into the elongated slot  40  of the female connector assembly  5  and the inner finger  36  remains raised, thereby unblocking the first and second leading end portions  70 ,  72 , and allowing the connector apparatus position assurance device  8  to be fully inserted to complete the lock position and be at final lock position. 
       FIG. 8  shows the in-line sealed electrical connector apparatus of this invention in which the connector apparatus position assurance device  8  is in final lock position, ready to receive a wire assembly (not shown) to be inserted into the openings (not shown) passing through the cover  10  of the male connector assembly  3  and another wire assembly (not shown) to be inserted into the female connector assembly  5  through openings (not shown) at a free end  6  thereof. As shown in  FIG. 8  and as discussed earlier, the retention clip  7  is mounted and kept locked within the male connector assembly  3  with the protrusions  20 ,  22  of the retention clip  7  being respectively accommodated within the slots  12 ,  14  of the male connector assembly  3 . (Protrusions (not shown) extending from the lower side of the retention clip  7  are similarly accommodated within respective slots  16 ,  18  (see,  FIG. 1 ) of the male connector assembly 
     In order to more clearly illustrate the connector apparatus position assurance device  8  in its fully inserted position and in complete or final lock position, the illustration of the side portion of the male connector assembly  3  containing the lever arm  50  and the bar  62  of the male connector assembly  3  is omitted in  FIG. 8 . (Only a cross-section of the inner protruding member  54  of the lever arm  50 , discussed earlier, is shown in  FIG. 8 , positioned within the space  60  between the end portions of the lower side  32  and the outer finger  38  of the retention clip  7 .) The connector apparatus position assurance device  8 , with its bottom elongated member  81  being seated on the generally L-shaped member  53  extending from the lower side of the male connector assembly  3 , is prevented from sliding out by the protrusions  79  and further prevented from moving laterally by its base end  75  being seated via the slot  92  thereof onto the elongated protruding member  29  extending along the side portion of the male connector assembly  3 . The first leading end member  70  is seated onto the ledge-like member  98  of the free end portion of the outer finger  38 , while the second leading end member  72  abuts a side portion of the free end portion of the outer finger  38 . The cover  10  is slidably mounted onto the male connector assembly  3  and locked thereto with the upper protrusion  30  and the lower protrusion (not shown) of the male connecter assembly  3  being respectively accommodated within the upper slot  25  and the lower slot  27  of the cover  10 . 
     As discussed above, the connector apparatus position assurance device  8  of this invention cannot be inserted past the pre-lock position until the female connector assembly  5  has been fully inserted and mated with the male connector assembly  3 . 
     Also, with the in-line sealed electrical connector apparatus  1  of this invention, if the connector apparatus position assurance device  8  happens to be fully inserted and in the final lock position before the female connector assembly  5  is inserted, the first leading end portion  70  of the connector apparatus position assurance device  8  is positioned on the ledge-like member  98  of the free end portion of the outer finger  38  of the retention clip  7 . Consequently, the outer finger  38  is at a lowered position, and is prevented from being raised by the first leading end portion  70 . Thus, the outer finger  38  blocks the female connector assembly  5  from entering the retention clip  7 . In other words, the female connector assembly  5  will detect its inability to be inserted by the inability of the outer finger  38  to be raised upward, for allowing the female connector assembly  5  to be inserted into the retention clip  7 , when the connector apparatus position assurance device  8  is in the final lock position. 
     Moreover, the female connector assembly  5  can only fully mate or inserted into the male connector assembly  3  when the connector apparatus position assurance device  8  is in the above-discussed pre-set position. If for example, a partial or improper mating is achieved (i.e., if the female connector assembly  5  is partially or improperly inserted into the male connector assembly  3 , as shown in  FIG. 4  or  FIG. 5 ), the connector apparatus position assurance device  8  cannot move forward or inserted because either the inner finger  36  has not been raised for allowing the second leading end member  72  of the retention clip  7  to be unblocked or the outer finger  38  has not been lowered for allowing the first leading end member  70  to be unblocked. Only when the female connector assembly  5  has fully mated or inserted into the male connector assembly  3  has occurred will the connector apparatus position assurance device  8  be allowed to be fully moved forward or inserted because the inner finger  36  has been raised for unblocking the second leading end member  72  of the retention clip  7  and the outer finger  38  has been lowered for unblocking the first leading end member  70  of the retention clip  7 , as shown in  FIGS. 6 ,  7  and  8 ), thereby having the connector apparatus position assurance device  8  to be in final lock position. 
     The present invention is not limited to the above-described embodiments; and various modifications in design, structural arrangement or the like may be used without departing from the scope or equivalents of the present invention.

Technology Classification (CPC): 8