Patent Description:
Electrical connector assemblies having terminal module frames that are axially loaded into an outer connector housing requires additional clearance between the face of a flexible locking arm of the outer connector housing and the corresponding locking surface of an inner terminal module frame, thereby creating additional axial variation between the outer connector housing the inner terminal module frame, which in turn affects terminal-to-terminal contact overlap of the terminals in the female connector terminal modules and the terminals in a male connector or header pin in the connector assembly. Electrical connector assemblies having terminal modules that are laterally loaded into an outer connector housing reduce the clearance with respect to terminal-to-terminal contact overlap but increases the overall package size of the electrical connector assembly. Flexible locking arms are typically not reinforced so the retention force between the inner terminal module frame and the outer connector housing provided by the flexible locking arms is low. Document <CIT> discloses an electrical connector assembly with an outer housing with cantilevered locking arms to secure a plurality of terminal modules.

According to one or more aspects of the present disclosure, an electrical connector assembly includes a plurality of terminal modules, each configured to contain one or more electrical terminals connected to one or more electrical cables; an inner module frame in which the plurality of terminal modules is secured; and a female outer housing having a plurality of cantilevered locking arms with primary surfaces and secondary surfaces on inner sides of the locking arms configured to secure the inner module frame to the female outer housing. Latch surfaces of the inner module frame engage the primary surfaces when the inner module frame is inserted within the female outer housing. The female outer housing is configured to receive a header having side walls surrounding a plurality of mating electrical terminals. The locking arms define ramp features on outer sides of the locking arms configured to push the locking arms inwardly when the side walls contact the ramp features of the locking arms as the header is inserted within the outer housing, thereby engaging the secondary surfaces with the latch surfaces.

In some aspects of the connector assembly described in the preceding paragraph, the secondary surfaces are arranged closer to free ends of the locking arms than the primary surfaces.

In some aspects of the connector assembly described in any one of the preceding paragraphs, the latch surfaces are substantially parallel to the primary surfaces and nonparallel to the secondary surfaces.

In some aspects of the connector assembly described in any one of the preceding paragraphs, the secondary surfaces are nonparallel with the primary surfaces.

In some aspects of the connector assembly described in any one the preceding paragraphs, a first force applied to the latch surfaces when the primary surfaces engage the latch surfaces is less than a second force applied to the latch surfaces when the secondary surfaces engage the latch surfaces.

In some aspects of the connector assembly described in any one of the preceding paragraphs, a magnitude of the first force is zero.

In some aspects of the connector assembly described in any one the preceding paragraphs, the secondary surfaces are angled and configured to provide the second force on the latch surfaces due to a wedging interface between the secondary surfaces and edges of the latch surfaces when the side walls of the header are in contact with the ramp features.

In some aspects of the connector assembly described in any one of the preceding paragraphs, a first clearance distance between the primary surfaces and the latch surfaces when the side walls of the header are not in contact with the ramp features is greater than a second clearance distance between the secondary surfaces and the latch surfaces when the side walls of the header are in contact with the ramp features.

In some aspects of the connector assembly described in any one of the preceding paragraphs, the second clearance distance is less than <NUM> when the side walls are in contact with the ramp features.

In some aspects of the connector assembly described in any one of the preceding paragraphs, the second clearance distance is <NUM> when the side walls are in contact with the ramp features.

According to one or more aspects of the present disclosure, a method of assembling an electrical connector includes:.

In some aspects of the method described in the preceding paragraph, the method further includes applying a first force to the inner module frame via the locking arms when the primary surfaces engage the latch surfaces and applying a second force to the latch surfaces via the locking arms when the secondary surfaces engage the latch surfaces. The first force is less than the second force.

In some aspects of the method described in any one of the preceding paragraphs, the secondary surfaces are angled and configured to provide the second force on the latch surfaces due to a wedging interface between the secondary surfaces and edges of the latch surfaces when the side walls of the header are in contact with the ramp features.

In some aspects of the method described in any one of the preceding paragraphs, the secondary surfaces are angled and provide the second force on the latch surfaces due to a wedging interface between the secondary surfaces and edges of the latch surfaces when the side walls of the header are in contact with the ramp features.

In some aspects of the method described in any one of the preceding paragraphs, a first clearance distance between the primary surfaces and the latch surfaces of the inner module frame when the side walls of the header are not in contact with the ramp features is greater than a second clearance distance between the secondary surfaces and the latch surfaces of the inner module frame when the side walls of the header are in contact with the ramp features.

<FIG> and <FIG> illustrate a non-limiting example of an electrical connector assembly, hereafter referred to as the connector <NUM>. The connector <NUM> includes a harness connector <NUM> configured to contain a plurality of electrical terminals terminating electrical cables of a wiring harness as shown in <FIG>. Returning to <FIG>, the connector <NUM> also includes a header connector <NUM> containing a plurality of mating electrical terminals. The header connector <NUM> is configured to be mounted to a panel or bulkhead (not shown).

Returning now to <FIG> and <FIG>, the harness connector <NUM> includes a female outer housing <NUM> having a mating assist lever <NUM>. As shown in <FIG>, the mating assist lever <NUM> is made of two piece that snap together to simplify the attachment of the mating assist lever <NUM> to the female outer housing <NUM>. The harness connector <NUM> also includes a terminal module <NUM>, a wire dress cover <NUM> configured to arrange the electrical cables of the wiring harness, and a seal <NUM> between the wire dress cover <NUM> and the female outer housing <NUM> to inhibit entry of environmental contaminants, such as dirt, dust, water, and other fluids into the female outer housing <NUM>.

The terminal module <NUM> includes an inner module frame <NUM> illustrated in <FIG> which is configured to retain a number of electrical connector modules <NUM> containing the electrical terminals <NUM> connected to the electrical cables <NUM>. The inner module frame <NUM> also includes its own terminal cavities that are configured to contain coaxial terminals. The terminal module <NUM> is placed within the female outer housing <NUM> to retain the terminals <NUM> within the harness connector <NUM>.

As shown in <FIG>, the header connector <NUM> includes a shroud <NUM> having side walls <NUM> that surround the mating electrical terminals <NUM>. The side walls <NUM> are received within the harness connector <NUM>. The mating assist lever <NUM> is configured to help overcome the mechanical resistance of mating the plurality of electrical terminals <NUM> in the harness connector <NUM> to the plurality of mating electrical terminals <NUM> in the header connector <NUM>.

As shown in <FIG>, the female outer housing <NUM> defines a number of cantilevered flexible locking arms <NUM> that hold the terminal module <NUM> within the female outer housing <NUM>. As best shown in <FIG>, stop faces <NUM> on inner surfaces <NUM> of each flexible locking arm <NUM> is separated into a primary surface <NUM> and a secondary surface <NUM>. As best shown in <FIG>, the flexible locking arms <NUM> also each have an outer wedge shaped ramp feature <NUM> on their outer surface <NUM>. The secondary surfaces <NUM> are located at the ends of the locking arms <NUM>, i.e., the secondary surfaces <NUM> are arranged closer to the free ends <NUM> of the locking arms <NUM> than the primary surfaces <NUM>.

As illustrated in <FIG>, the terminal module <NUM> is axially inserted into the female outer housing <NUM>. When the terminal module <NUM> is inserted into female outer housing (before header connector <NUM> engagement) as shown in <FIG>, the inner module frame <NUM> contacts an inner ramp feature <NUM> on their outer surface <NUM> on the inner surfaces <NUM> of the flexible locking arms <NUM> and pushes the flexible locking arms <NUM> outwardly until a latch surface <NUM> on the inner module frame clear the stop faces <NUM>.

As illustrated in <FIG>, the primary surface <NUM> of the stop face <NUM> of each flexible locking arm <NUM> contacts an edge <NUM> of the latch surface <NUM> on the inner module frame <NUM> and the primary surfaces <NUM> and apply a first force F1 to the inner module frame <NUM> that holds the terminal module <NUM> within the female outer housing as shown in <FIG>. The primary surfaces <NUM> are arranged substantially parallel to the latch surfaces <NUM>. and the secondary surfaces are nonparallel to both the first surfaces and the latch surfaces.

As the header connector <NUM> is inserted to the female outer housing as shown in <FIG>, the side walls <NUM> of the shroud <NUM> contact the outer wedge shaped ramp feature <NUM> and push the flexible locking arms <NUM> inwardly so that the angled secondary surface <NUM> of the stop face <NUM> of each flexible locking arm <NUM>, rather than the primary surface <NUM>, contacts the latch surface <NUM> on the inner module frame <NUM>. The secondary surfaces <NUM> are nonparallel to both the primary surfaces <NUM> and the latch surfaces <NUM>. The angled secondary surface <NUM> acts as a wedge and applies a second force F2 that pushes the inner module frame <NUM> toward the header connector <NUM>, thereby increasing the terminal overlap of the terminals <NUM> and the mating terminals <NUM> and reducing the likelihood of relative movement between the terminals <NUM> and the mating terminals <NUM> caused by vibration that may degrade the electrical performance of the connector <NUM>.

The second force F2 is greater than the first force F1. The first force F1 may have zero magnitude.

There may be a first clearance distance between the primary surfaces <NUM> and the latch surfaces <NUM> when the side walls <NUM> of the shroud <NUM> are not in contact with the outer wedge shaped ramp features <NUM>. This first clearance distance is greater than a second clearance distance between the secondary surfaces <NUM> and the latch surfaces <NUM> when the side walls <NUM> of the shroud <NUM> are in contact with the outer wedge shaped ramp feature <NUM>. The second clearance distance may be less than <NUM> when the side walls <NUM> are in contact with the outer wedge shaped ramp feature <NUM> and is preferably <NUM>, meaning there is no clearance between the secondary surfaces <NUM> and the latch surfaces <NUM>.

<FIG> is a flowchart of an example method <NUM> for assembling an electrical connector <NUM>, comprising the steps of:.

The connector <NUM> provides at least following benefits:.

While the example presented herein is directed to an electrical connector assembly, alternative embodiments of the connector assembly may be envisioned that are configured to interconnect fiber optic cables, pneumatic tubes, hydraulic tubes, or a hybrid connector assembly having a combination of any of these types of conductors.

While the invention has been described with reference to an exemplary embodiment(s), it is intended that the invention is not limited to the disclosed embodiment(s), but that the invention will include all embodiments falling within the scope of the appended claims.

As used herein, 'one or more' includes a function being performed by one element, a function being performed by more than one element, e.g., in a distributed fashion, several functions being performed by one element, several functions being performed by several elements, or any combination of the above.

It will also be understood that, although the terms first, second, etc. are, in some instances, used herein to describe various elements, these elements should not be limited by these terms. For example, a first contact could be termed a second contact, and, similarly, a second contact could be termed a first contact, without departing from the scope of the various described embodiments. The first contact and the second contact are both contacts, but they are not the same contact.

The terminology used in the description of the various described embodiments herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used in the description of the various described embodiments and the appended claims, the singular forms "a", "an", and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will also be understood that the term "and/or" as used herein refers to and encompasses any and all possible combinations of one or more of the associated listed items. It will be further understood that the terms "includes," "including," "comprises," and/or "comprising," when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

As used herein, the term "if" is, optionally, construed to mean "when" or "upon" or "in response to determining" or "in response to detecting," depending on the context. Similarly, the phrase "if it is determined" or "if [a stated condition or event] is detected" is, optionally, construed to mean "upon determining" or "in response to determining" or "upon detecting [the stated condition or event]" or "in response to detecting [the stated condition or event]," depending on the context.

Claim 1:
An electrical connector assembly (<NUM>), comprising:
a plurality of terminal modules (<NUM>), each configured to contain one or more electrical terminals (<NUM>) connected to one or more electrical cables (<NUM>);
an inner module frame (<NUM>) in which the plurality of terminal modules (<NUM>) is secured; and
a female outer housing (<NUM>) having a plurality of cantilevered locking arms (<NUM>) with primary surfaces (<NUM>) and secondary surfaces (<NUM>) on inner sides of the locking arms (<NUM>) configured to secure the inner module frame (<NUM>) to the female outer housing (<NUM>), wherein latch surfaces (<NUM>) of the inner module frame (<NUM>) engage the primary surfaces (<NUM>) when the inner module frame (<NUM>) is inserted within the female outer housing (<NUM>), wherein the female outer housing (<NUM>) is configured to receive a header having side walls (<NUM>) surrounding a plurality of mating electrical terminals (<NUM>), wherein the locking arms (<NUM>) define ramp features on outer sides of the locking arms (<NUM>) configured to push the locking arms (<NUM>) inwardly when the side walls (<NUM>) contact the ramp features of the locking arms (<NUM>) as the header is inserted within the outer housing (<NUM>), thereby engaging the secondary surfaces (<NUM>) with the latch surfaces (<NUM>).