Patent Description:
Electrical connector assemblies utilized for cabin applications in commercial aerospace and other applications often comprise separate connectors that mate together to form a secure physical and electrical connection. In particular, the electrical connector assemblies for aerospace application shall meet altitude immersion requirements.

To achieve an effective, properly aligned and sealed electrical connection of the connectors, it is common to employ a mating assistance device for connecting the electrical connectors together, as shown in <CIT>.

The mating assistance devices known in the art are usually made of several parts which are assembled by screwing, welding and/or bonding when the connection between the connectors is achieved. Consequently, the mating assistance devices as known in the art require the use of tools, e.g. a screwdriver for the assembly. Furthermore, notwithstanding that the mating assistance device provided with machined parts are known to be a costly solution, they are also not particularly adapted in term of lightness and weight reduction for cabin applications in commercial aerospace.

The utility model <CIT> discloses using a U-shaped frame member with a pushable wedge for coupling two connectors.

Therefore, it is an object of the present invention to provide a light, easy-to-use, tool-free and inexpensive mating assistance device for a connector assembly.

The above-mentioned problem is addressed by mating assistance device for electrical connectors according to claim <NUM>. The displacement of the connector pushing element between the unlocked position to the locked position allows to move the electrical connectors towards the inside of the housing. As a result, thanks to the displacement of the connector pushing element in the direction of insertion of the electrical connector, the sealing of the electrical connectors is facilitated and realized without the need of using external tools. Therefore, the assembly of the electrical connectors inside the mating assistance device is simplified and the assembly cost can be reduced.

The mating assistance device can be further improved according to various advantageous embodiments.

According to an embodiment, the trajectory of the at least one connector pushing element from the unlocked position to the locked position can be inclined with respect to the normal of the direction of insertion of the electrical connector into the housing. In particular, the trajectory of the at least one connector pushing element from the unlocked position to the locked position is inclined at an angle comprised between <NUM>° and <NUM>° with respect to the normal of the direction of insertion of the electrical connector into the housing. The inclined trajectory of the connector pushing element can exercise a force onto the electrical connector to move it further into the housing and to achieve the necessary sealing.

According to another embodiment, the at least one locking device can have the form of a bracket, in particular, the form of a U-shaped bracket having a configuration conforming to the shape of the housing. When using a bracket, the force can be applied on two sides of the electrical connector and in addition, the same shape of locking device can be used on the left and the right side of the housing when connecting two electrical connectors.

According to another embodiment, the U-shaped bracket can have a central portion provided with an inner surface from which extends two arms in the same direction such that the direction of the arm's length is inclined with respect to a direction extending normally from the inner surface of the central portion. The central portion can be used by the user to push the bracket from the unlocked to the locked position. By providing an inclined direction of the arms the desired movement of the connector pushing element can be obtained.

According to the invention, the housing is a one-piece housing, in particular made of a molded plastic or a polymer material, and has the shape of a hollow beam with two opened-ends for receiving a terminal of the electrical connector. The simple design of the housing and the lightweight material used provide a light device with no loose parts. In addition, the overall assembly costs can be reduced compared with a screw-together design in the art.

According to another embodiment, the at least one connector pushing element of the locking devices can be provided with one or more protrusions, in particular two protrusions, protruding towards the inside of the housing when in the locked position. The protrusions of the connector pushing element allow guiding and forcing the electrical connector to further move inside the housing when the locking device is moved from the unlocked position to the locked position.

According to another embodiment, the shape of the one or more protrusions of the locking devices can be complementary to latch means provided on an interface of the electrical connector. With the complementary shapes, an efficient transmission of the pushing force can be obtained.

According to another embodiment, the mating assistance device can further be provided with two retentions means configured to hold the at least one locking device respectively in the unlocked position and in the locked position respectively relative to the housing. This feature allows preventing an involuntary locking or unlocking of the locking device, in particular during the transportation of the mating assistance device.

According to another embodiment, the retention means can be configured to provide a form-fit connection between the housing and the at least one connector pushing element in the unlocked position and in the locked position. In particular, the retentions means can comprise two recesses or grooves on the at least one connector pushing element, in particular longitudinal grooves, configured to fit to a protruding element of the housing, the protrusion element protruding towards the at least one connector pushing element. The form-fit connection in the unlocked and locked position can be realized without any external tool, and only by means of the retentions means integral with the mating assistance device. This allows simplifying the assembly step while reducing the assembly cost.

According to another embodiment, the locking devices and/or the housing can comprise at least one handle for pulling the locking device from the locked position to the unlocked position. Hence, the mating of the electrical connectors can be reversed, therefore allowing an easy versatile use in comparison with a soldered or a bonded assembly which have to be destroyed to disassemble the connection.

According to another embodiment, the locking devices and/or the housing further can comprise at least one opening with an undercut configured for allowing an unmating of the electrical connectors, in particular by using an external tool. In case a user's manual forces are not sufficient to move the locking device from the locked to the unlocked position, it still remains possible to decouple the connector again.

According to another embodiment, a center region of the housing can be provided with flanges or a flange receiving region. Thus, the device can be easily mount to other parts.

The object of the present invention is also achieved with a method for connecting electrical connectors according to claim <NUM>. With the inventive method sealed electrical connections satisfying the high requirements of the aerospace industry, can be achieved without using external tools.

Additional features and advantages will be described with reference to the drawings. In the description, reference is made to the accompanying figures that are meant to illustrate preferred embodiments of the invention. It is understood that such embodiments do not represent the full scope of the invention.

The present invention will now be described with reference to the attached figures. Various structures, systems and devices are schematically depicted in the drawings for purposes of explanation only and so as to not obscure the present disclosure with details, which are well known to those skilled in the art. Nevertheless, the attached drawings are included to describe and explain illustrative examples of the present disclosure. The words and phrases used herein should be understood and interpreted to have a meaning consistent with the understanding of those words and phrases by those skilled in the relevant art. No special definition of a term or phrase, i.e., a definition that is different from the ordinary or customary meaning as understood by those skilled in the art, is intended to be implied by consistent usage of the term or phrase herein.

<FIG> represent a mating assistance device <NUM> according to the present invention. The mating assistance device <NUM> comprises a housing <NUM> and two locking devices <NUM>, <NUM> movable with respect to the housing <NUM>. In <FIG>, the locking devices <NUM>, <NUM> are illustrated in the unlocked position relative to the housing <NUM>.

The housing <NUM> is a one-piece housing, made of a molded plastic or a polymer material, and has the shape of a hollow beam with two opened-ends <NUM>, <NUM> for receiving a terminal of an electrical connector (not represented in <FIG>) according to a direction of insertion of the electrical connectors inside the housing <NUM> and represented by the arrow A.

In another embodiment, not illustrated, a center region <NUM> of the housing <NUM> may be provided with flanges or a flange receiving region.

According to the first embodiment of the present invention, the locking devices <NUM>, <NUM> are identical and are mounted on the housing <NUM> with mirror symmetry with respect to the center region <NUM>. In another embodiment, the locking devices <NUM>, <NUM> may be different from each other.

Each locking device <NUM>, <NUM> has the form of a U-shaped bracket having a complementary shape to the housing <NUM>, as it can be seen in <FIG>. Each U-shaped locking device <NUM>, <NUM> is provided with a central portion having an inner surface <NUM> from which extends two arms <NUM>, <NUM> providing respectively two connector pushing elements <NUM>, <NUM>. The central portion <NUM> of each locking device <NUM>, <NUM> can be used as a pushing-button by an operator for moving the locking devices <NUM>, <NUM> from the unlocked to the locked position according to the locking direction represented by the arrow B. The locking direction B is perpendicular to the direction of insertion A.

As can be seen in <FIG> which illustrates a top view of the locking device <NUM>, the direction L1 of the length l1 of each arm <NUM>, <NUM> (accordingly of each connector pushing elements <NUM>,<NUM>) is inclined with respect to a direction N1 extending normally from the inner surface <NUM> of the central portion <NUM>. According to the first embodiment of the present invention, the inclination between the direction L1 and the direction N1 forms an angle α comprised between <NUM>° and <NUM>°.

The direction N1 of the normal extending from the inner surface <NUM> of the central portion <NUM> of the locking device <NUM> and the locking direction B are parallel, as illustrated in <FIG>.

Accordingly, the direction L1 of the length l1 of the connector pushing element <NUM>, <NUM> is inclined with respect to the locking direction B with the angle α. Therefore, the trajectory of each connector pushing element <NUM>, <NUM> from the unlocked position to the locked position is inclined with respect to the locking direction B according to the angle α.

The locking device <NUM> is mounted on the housing <NUM> such that when the locking device <NUM> moves from the unlocked to the locking position according to the locking direction B, the inclination of the connector pushing elements <NUM>, <NUM> forming the angle α is oriented towards the center region <NUM> of the housing <NUM>. As a consequence, the inclination of the connector pushing elements <NUM>, <NUM> can provide the effect of moving and compressing each electrical connector towards the center region <NUM> of the housing <NUM> for sealing the electrical connectors together when inserted into the housing. Thus, the altitude immersion requirement can be satisfied. The same applies for the second locking device <NUM>.

Furthermore, the connector pushing elements <NUM>, <NUM> of each locking device <NUM>, <NUM> are respectively provided with inner surfaces <NUM>, <NUM> facing each other. The surfaces <NUM>, <NUM> of the connector pushing elements <NUM>, <NUM> are provided with two protrusions <NUM>, <NUM> protruding towards the inside <NUM> of the housing <NUM> when the locking devices <NUM>, <NUM> are mounted to the housing <NUM>. The shapes of the first and second protrusions <NUM>, <NUM> of the locking devices <NUM>, <NUM> are complementary to an interface of an electrical connector. The interface of the electrical connector will be further in <FIG>.

The mating assistance device <NUM> is further provided with retentions means <NUM>, <NUM>, <NUM> configured to hold the locking device <NUM>, <NUM> in the unlocked position and in the locked position respectively relative to the housing <NUM>. The retentions means <NUM>, <NUM> of each connector pushing element <NUM>, <NUM> are longitudinal grooves <NUM>, <NUM> provided on the surface <NUM>, <NUM>. The longitudinal groove <NUM>, <NUM> are dimensioned to fit to a mating protruding element <NUM> of the retention means <NUM> of the housing <NUM>, the protruding element <NUM> protruding towards the connector pushing element <NUM>, <NUM>. The retention means <NUM>, <NUM>, <NUM> are configured to provide a form-fit connection between the housing <NUM> and each of the connector pushing element <NUM>, <NUM> in the unlocked position and in the locked position. In the unlocked position, as illustrated in <FIG>, the locking device <NUM>, <NUM> is hold by form-fit connection between the retention means <NUM>, <NUM> and the retention means <NUM>, <NUM> of the housing <NUM>. In the locked position, the locking device <NUM>, <NUM> is hold by form-fit connection between the retention means <NUM>, <NUM> and the retention means <NUM>, <NUM> of the housing <NUM>.

Each locking device <NUM>, <NUM> and the housing <NUM> respectively comprise a handle <NUM>, <NUM> for pulling the locking device <NUM>, <NUM> from the locked position to the unlocked position. Hence, the mating of the electrical connectors can be reversed, therefore allowing an easy versatile use in comparison with a soldered or a bonded assembly for which have to be destroyed to disassemble.

Each locking device <NUM>, <NUM> and the housing <NUM> further respectively comprise an opening with an undercut <NUM>, <NUM> configured to allow an unmating of the electrical connectors, in particular by using an external tool.

The successive steps of the method for connecting electrical connectors with the mating assistance device <NUM> according to the prevent invention, are illustrated in <FIG>. Elements with the same reference numeral already used in <FIG> and <FIG> will not be described in detail again but reference is made to their description above.

<FIG> illustrates a state wherein two electrical connectors <NUM>, <NUM> have been partially introduced into the mating assistance device <NUM> and the locking device <NUM>, <NUM> are in the unlocked position - as further illustrated in <FIG>.

The electrical connectors <NUM>, <NUM> are inserted into the housing <NUM> of the mating assistance device <NUM> by the open-ends <NUM>, <NUM> according to the direction of insertion A. At the step illustrated in <FIG>, the electrical connectors <NUM>, <NUM> are not yet in contact and are separated by air <NUM> inside the housing <NUM>.

In the step of <FIG> and further illustrated in <FIG>, the locking device <NUM> is hold in the unlocked position by form-fit connection between the retention means <NUM>, <NUM> of the connection pushing element <NUM> and the retention means <NUM>, <NUM> of the housing <NUM>.

As it can be seen in <FIG>, each electrical connector <NUM>, <NUM> is provided with latch means <NUM> on an interface <NUM>. The latch means <NUM> comprises a ramp <NUM> and two protrusions <NUM>, <NUM>, here in the form of wedges <NUM>, <NUM> adjacent each side of the ramp <NUM> perpendicular to the slope 51a of the ramp <NUM>.

In <FIG>, the electrical connectors <NUM>, <NUM> have been further inserted into the housing <NUM> such that they are now in contact with each other. Consequently, the air volume <NUM> is reduced compared to <FIG>. The locking devices <NUM>, <NUM> are still in an unlocked position.

The displacement of the electrical connectors <NUM>, <NUM> in the insertion direction A has moved the latch means <NUM> such that the second protrusion <NUM> of the connection pushing element <NUM> slides over the surface of interface <NUM> and is guided to the ramp <NUM>. In particular, the dimensions of the first and second protrusions <NUM>, <NUM> are adapted with respect to the dimensions of the latch means <NUM> of the electrical connectors <NUM>, <NUM>.

At the step of <FIG>, and as it can be seen in <FIG>, the second protrusion <NUM> is then positioned between the wedges <NUM>, <NUM> of the latch means <NUM>. In this configuration, the locking device <NUM>, <NUM> can still not be moved into the locked position in the locking position B, as the first and second protrusions <NUM>, <NUM> are blocked by the wedges <NUM>, <NUM>.

At the step illustrated in <FIG>, the electrical connectors <NUM>, <NUM> have been further inserted into the housing <NUM> according the direction of insertion A by pushing the locking devices into the direction B. The air gap <NUM> is further reduced in comparison to the one illustrated in <FIG>.

The second protrusion <NUM> of the connector pushing element <NUM> slides further and partially behind the wedges <NUM>, <NUM> on the side of the open-end <NUM>, <NUM> of the housing <NUM>.

Thus, by applying a force in the locking direction B on the central portion <NUM> of the locking devices <NUM>, <NUM> the connectors <NUM> and <NUM> can be moved closer together without the need of an external tool.

As mentioned, the inclination of the direction L1 of the connector pushing element <NUM> with respect to the locking direction B allows a displacement of the connector pushing element <NUM> in the direction of insertion A when the locking device <NUM>, <NUM> is moved from the unlocked to the locked position. According to this embodiment, the trajectory of the connector pushing element <NUM> from the unlocked position to the locked position is inclined with respect to the locking direction B, preferentially at an angle α comprised between <NUM>° and <NUM>°. The inclination of the connector pushing elements <NUM>, <NUM> of each locking devices <NUM>, <NUM> are oriented towards the center region <NUM> of the housing <NUM> with respect to the normal direction N1 and the locking direction B. As a consequence, the inclination of the connector pushing elements <NUM>, <NUM> provides the effect of moving each electrical connector <NUM>, <NUM> towards the center region <NUM> of the housing <NUM> by means of the protrusions <NUM>, <NUM> so that they can be compressed together to achieve the desired sealing. Indeed, the inclined trajectory of the protrusions <NUM>, <NUM> with respect to the normal direction N1 and the locking direction B, have the effect of compressing the electrical connectors <NUM>, <NUM> inwards the housing <NUM>. At the step illustrated in <FIG>, the latch means <NUM> of each electrical connectors <NUM>, <NUM> are separated by a distance X.

In <FIG>, the electrical connectors <NUM>, <NUM> are mated and the locking devices <NUM>, <NUM> are in their locked position.

By pressing on the central portion <NUM> (see <FIG>) of the locking devices <NUM>, <NUM> in the locking direction B, the locking devices <NUM>, <NUM> can be moved into the housing <NUM> such that the electrical connectors <NUM>, <NUM> are mated together. A little air <NUM> remains between the connectors <NUM> and <NUM>. Only the elastomeric sealing cone devices from the male connector <NUM> are compressed into the front opposite cone recesses of the female connector <NUM>. In comparison with the step illustrated in <FIG>, it can be seen in <FIG> that the latch means <NUM> of each electrical connectors <NUM>, <NUM> are now separated by a distance X-d, the distance d corresponding to the necessary dimension for having an efficient sealing between the two electrical connectors <NUM>, <NUM>. In this situation, the first and second protrusions <NUM>, <NUM> are positioned behind the wedges <NUM>, <NUM> on the interface <NUM>. Thanks to the complementary shapes of the wedges <NUM>, <NUM> and the protrusions <NUM>, <NUM>; the connector pushing elements <NUM>, <NUM> and the latch means <NUM> realize a form-fit connection. As a result, the electrical connector <NUM>, <NUM> cannot move against the direction A as it abuts against protrusions <NUM> and <NUM>.

In this locked position of <FIG> and as it can be seen in <FIG>, the locking device <NUM> is hold in the locked position by form-fit connection between the retention means <NUM>, <NUM> of the connection pushing element <NUM> and the retention means <NUM>, <NUM> of the housing <NUM>.

Claim 1:
A mating assistance device for connecting electrical connectors together comprising:
a housing (<NUM>) for receiving electrical connectors (<NUM>, <NUM>), wherein the housing (<NUM>) is a one-piece housing, in particular made of a molded plastic or a polymer material, and has the shape of a hollow beam with two opened-ends (<NUM>, <NUM>) for receiving a terminal of the electrical connectors (<NUM>, <NUM>), and
two locking devices (<NUM>, <NUM>) movable between an unlocked and a locked position with respect to the housing (<NUM>), each locking device (<NUM>, <NUM>) further comprising at least one connector pushing element (<NUM>, <NUM>),
wherein each locking device (<NUM>, <NUM>), when moved from the unlocked to the locked position, is configured such that the at least one connector pushing element (<NUM>, <NUM>) is displaceable in the direction of insertion (A) of an electrical connector (<NUM>, <NUM>) into the housing (<NUM>).