Patent Description:
Electrical stabilizers are used to stabilize free ends of electrical terminals as those terminals receive complimentarily-shaped terminals of another mating electrical connector. The stabilizer is provided in a pre-staged position in which the free ends of the terminals are received in slots of the stabilizer.

Publication <CIT> discloses an electrical distribution center assembly including a housing having a connector shroud. The shroud defines a shroud cavity adapted for receiving a mating electrical connector body. A blade stabilizer is formed integral with the shroud in a first position within the shroud cavity. The blade stabilizer has blade apertures formed therein. Bladed terminals extend from the housing into the blade apertures. In this position, the blade stabilizer protects the terminal blades from being bent away from a terminal axis. The blade stabilizer is movable to a second position to enable female terminals of the mating electrical connector to electrically connect to the blade terminals.

In one example configuration, the stabilizer is supported in the pre-staged position by the surrounding housing of the electrical connector assembly. A mating connector is used to push the stabilizer against a lower housing floor, which exposes the free ends to the mating connector such that the terminals make an electrical connection.

One problem with prior art arrangements is that the stabilizer does not return to its pre-staged position once the electrical connector is removed from the electrical connector assembly. The stabilizer also may not move evenly from the pre-staged position to the assembled connector position, which causes the stabilizer to bind and become stuck within the housing. As a result, a subsequent attempt to connect the electrical terminals may result in the terminals being knocked out of position.

An electrical connector assembly is disclosed according to claim <NUM>. The electrical connector assembly includes an electrical terminal that is mounted to a support structure, wherein the support structure is a printed circuit board. The assembly also includes a stabilizer that has a slot that receives a free end of the electrical terminal. The assembly includes a housing that includes first and second housing portions. The printed circuit board is arranged within the housing, and the first housing portion includes a window exposing the stabilizer and the terminal. The assembly further includes a first spring that operatively supports the stabilizer relative to the support structure. The stabilizer is secured to the printed circuit board with the first spring being intermediate the stabilizer and the printed circuit board. The first spring biases the stabilizer away from the support structure to a pre-staged position. The first spring is configured to flex from the pre-staged position to an assembled connector position in which more of the free end protrudes through the slot than in the pre-staged position. The first spring extends from each of opposing sides of a first post which is arranged at a first lateral edge of the stabilizer. A second post and a second spring are arranged at a second lateral edge of the stabilizer opposite the first lateral edge. The first housing portion has a contour that corresponds to a spring contour of the first and second springs in the pre-staged position. The contour is configured to limit the return of the stabilizer to the pre-staged position by abutting the first and second springs against the contour.

In a further embodiment of any the above, the first and second posts are secured to the support structure.

In a further embodiment of any the above, the first and second posts each have a barb that is received in a hole in the support structure in a snap-fit relationship.

In a further embodiment of any the above, the first and second springs are S-shaped and each include a first end that is secured to its respective post and a second end that is secured to the stabilizer. The first and second springs each include a trough that extends from the first end to a peak that extends to the second end.

In a further embodiment of any the above, the first and second springs are integral with the stabilizer.

In a further embodiment of any the above, the first and second lateral edges of the stabilizer are spaced apart from one another. The first and second springs are spaced apart from the first and second lateral edges. The first and second springs are movable in a plane that is normal to the stabilizer.

In a further embodiment of any the above, the electrical terminal is a male terminal.

In a further embodiment of any the above, the stabilizer has a stop that extends toward the printed circuit board. The stop is spaced a distance from the printed circuit board equal to a distance between the stabilizer and the printed circuit board in the pre-staged position. The stop is configured to limit movement of the stabilizer to the assembled connector position.

In a further embodiment of any the above, the first and second posts are secured to the support structure. The first and second springs are S-shaped and include a first end secured to its respective post and a second end secured to the stabilizer. The first and second springs include a trough that extends from the first end to a peak that extends to the second end. The electrical terminal is a male terminal.

A method of assembling an electrical connector assembly is disclosed according to claim <NUM>. The method of assembling an electrical connector assembly includes a stabilizer that is secured to a printed circuit board with a first spring element intermediate the stabilizer and the printed circuit board. The stabilizer has a slot that receives a free end of an electrical terminal that is mounted to the printed circuit board. The first spring operatively supports the stabilizer relative to the printed circuit board. The first spring biases the stabilizer away from the printed circuit board to a pre-staged position. The first spring is configured to flex from the pre-staged position to an assembled connector position in which more of the free end protrudes through the slot than in the pre-staged position, wherein the first spring extends from each of opposing sides of a first post which is arranged at a first lateral edge of the stabilizer. A second post and a second spring are arranged at a second lateral edge of the stabilizer opposite the first lateral edge. The method further includes the printed circuit board and stabilizer that are mounted within a housing. The housing includes first and second housing portions, the first housing portion includes a window exposing the stabilizer and the terminal, wherein the first housing portion has a contour that corresponds to a spring contour of the first and second springs in the pre-staged position. The method also includes limiting the return of the stabilizer to the pre-staged position by abutting the first and second springs against the contour of the first housing portion.

In a further embodiment of any the above, the stabilizer has a wall that includes the slot. The method includes a step of engaging the wall with a connector. The connector has another terminal that is aligned with the electrical terminal and includes a step of pushing the stabilizer from a pre-staged position with the connector to overcome a force generated by the first spring and the second spring and electrically couple the electrical terminal and the another terminal by moving the stabilizer to an assembled connector position.

In a further embodiment of any the above, the securing step includes a barb inserted on each of the posts into corresponding holes in the printed circuit board in a snap-fit relationship.

The embodiments, examples and alternatives of the preceding paragraphs, the claims, or the following description and drawings, including any of their various aspects or respective individual features, may be taken independently or in any combination. Features described in connection with one embodiment are applicable to all embodiments, unless such features are incompatible.

An electrical connector assembly <NUM> is illustrated in <FIG> and <FIG>. The electrical connector assembly <NUM> may be a component of an electrical distribution center as shown in <FIG> and <FIG> or in other embodiments may be a standalone electrical connector assembly. The assembly <NUM> includes a housing <NUM> having first and second housing portions <NUM>, <NUM> secured to one another. A first housing portion <NUM> has multiple windows <NUM> configured to each receive one or more electrical connectors (not shown). A printed circuit board (PCB) <NUM> is arranged within the housing <NUM> and is retained by the second housing portion <NUM> by supports <NUM>. Multiple terminals <NUM>, typically male terminals, extend from the PCB <NUM> for connection with electrical connectors that are in electrical communication with various components distributed throughout the vehicle.

In the example, a stabilizer <NUM> is provided within each window <NUM>. Each stabilizer <NUM> includes a wall <NUM> having slots <NUM> each circumscribed by a protrusion <NUM>, for example. A free end <NUM> of each terminal <NUM> is received within a corresponding slot <NUM>. The free end <NUM> may be contained within the slot <NUM> or extend partially from the slot <NUM>. The stabilizer <NUM> provides support to the terminals <NUM> such that they do not become inadvertently bent during handling or misaligned with respect to the mating electrical connectors during the assembly process.

<FIG> illustrates the stabilizer at <NUM> in a pre-staged condition prior to installation of a mating connector and subsequent to removal of that mating connector. <FIG> illustrates an assembled connector position in which the stabilizer <NUM> has been moved toward the PCB <NUM> in response to pushing another electrical connector <NUM> into engagement with the stabilizer <NUM> to electrically connect the terminals <NUM> with terminals <NUM>.

Referring to <FIG> and <FIG>, the wall <NUM> of the stabilizer <NUM> has spaced apart lateral edges <NUM> (best shown in <FIG>). Multiple springs <NUM> are configured to bias the stabilizer <NUM> away from the PCB <NUM> to the pre-staged position illustrated in <FIG>. In one example, a post <NUM> next to each lateral edge <NUM> is secured to the PCB <NUM>. In the example, each post has a barb <NUM> received in a hole <NUM> (<FIG>) in the PCB, which is best illustrated in <FIG> and <FIG>.

One of the springs <NUM> extends from each of opposing sides of the post <NUM> such that a pair of springs <NUM> is used to support each lateral edge <NUM> with respect to its corresponding post <NUM>, as best shown in <FIG>. The springs <NUM> are S-shaped, i.e. having a serpentine or sinusoidal shape. Each spring <NUM> includes a first end <NUM> secured to its respective post <NUM> and a second end <NUM> secured to its respective lateral edge <NUM>. The spring <NUM> includes a trough <NUM> extending from the first end <NUM> to a peak <NUM> that extends to the second end <NUM>. The housing portion <NUM> includes a contour <NUM> that corresponds to the S-shape when the stabilizer <NUM> is in the pre-staged condition, as shown in <FIG>. This contour <NUM> maintains desired alignment and positioning of the stabilizer <NUM> with respect to the housing <NUM> via the springs <NUM>.

Referring to <FIG>, and <FIG>, the wall <NUM> supports upper and lower stops <NUM>, <NUM> at each corner. The upper stop <NUM> is in close proximity to or in contact with an inner surface of the first housing <NUM> when the stabilizer <NUM> is in the pre-staged condition, as shown in <FIG>. Each upper stop <NUM> may be slideably received in a slot <NUM> in the first housing <NUM> to provide further stability to the stabilizer <NUM> during movement within the housing <NUM>. The lower stop <NUM> is spaced from the PCB <NUM> in the pre-staged condition, but come in close proximity to or contact with the PCB <NUM> when the stabilizer is moved to the assembled connector position shown in <FIG>. In this manner, the upper and lower stops <NUM>, <NUM> limit the range of motion of the stabilizer <NUM> respectively to the pre-staged position and the assembled connector position.

In operation, the electrical connector assembly is assembled by securing the stabilizer <NUM> to the printed circuit board <NUM> by the springs <NUM>. The stabilizer <NUM> has a wall <NUM> that includes a slot <NUM> that receives a free end <NUM> of an electrical terminal <NUM> (typically a male terminal). The wall is provided in the pre-staged position relative to the PCB <NUM> by the springs <NUM>. The PCB <NUM> and the stabilizer <NUM> are mounted within the housing <NUM>. A connector <NUM> engages the wall <NUM> such that another terminal <NUM> (typically a female terminal) is aligned with the electrical terminal <NUM>. The stabilizer <NUM> is pushed with the connector <NUM> to overcome the springs <NUM> and electrically couple the electrical terminal <NUM> and the other terminal <NUM> in the assembled connector position.

Claim 1:
An electrical connector assembly (<NUM>) comprising:
an electrical terminal (<NUM>) mounted to a support structure, wherein the support structure is a printed circuit board (<NUM>);
a stabilizer (<NUM>) having a slot (<NUM>) receiving a free end (<NUM>) of the electrical terminal (<NUM>);
a housing (<NUM>) that includes first and second housing portions (<NUM>, <NUM>), wherein the printed circuit board (<NUM>) is arranged within the housing (<NUM>), the first housing portion (<NUM>) includes a window (<NUM>) exposing the stabilizer (<NUM>) and the terminal; and
a first spring (<NUM>) operatively supporting the stabilizer (<NUM>) relative to the support structure, the stabilizer (<NUM>) is secured to the printed circuit board (<NUM>) with the first spring (<NUM>) being intermediate the stabilizer (<NUM>) and the printed circuit board (<NUM>), the first spring (<NUM>) biasing the stabilizer (<NUM>) away from the support structure to a pre-staged position, the first spring (<NUM>) configured to flex from the pre-staged position to an assembled connector position in which more of the free end (<NUM>) protrudes through the slot (<NUM>) than in the pre-staged position, wherein the first spring (<NUM>) extends from each of opposing sides of a first post (<NUM>) which is arranged at a first lateral edge (<NUM>) of the stabilizer (<NUM>), and a second post (<NUM>) and a second spring (<NUM>) are arranged at a second lateral edge (<NUM>) of the stabilizer (<NUM>) opposite the first lateral edge (<NUM>),
characterized in that
the first housing portion (<NUM>) has a contour (<NUM>) that corresponds to a spring contour of the first and second springs (<NUM>) in the pre-staged position, and the contour (<NUM>) is configured to limit the return of the stabilizer (<NUM>) to the pre-staged position by abutting the first and second springs (<NUM>) against the contour (<NUM>).