Patent ID: 12244086

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now to the drawings, there is illustrated inFIG.1an electrical connector assembly, indicated generally at10. The electrical connector assembly10includes a first connector, indicated generally at12, and a second connector, indicated generally at14. InFIG.1, the first connector12is shown mated with the second connector14. The illustrated electrical connector assembly10is an inline connector assembly and is adapted to electrically connect a first cable16to a second cable18. In the illustrated embodiment, there are two first cables16and two second cables18. However, the electrical connector assembly10may connect any desired number of cables16and18. Additionally, the electrical connector assembly10may be any desired type of connection and may be adapted to connect any desired conductors.

Referring now toFIG.2, there is illustrated an exploded perspective view of the first connector12. The first connector12includes a housing20. The illustrated housing20is molded from plastic, but may be made from any desired material and by any desired process. The housing20extends from an insert end22to a contact end24. The insert end22is adapted to accommodate the first cables16, as described below, and the contact end24is adapted to engage the second connector14. The housing20of the first connector12includes two terminal cavity bays26that extend from the insert end22toward the contact end24. The illustrated first connecter12includes two terminal cavity bays26, but may include any desired number of terminal cavity bays26. A connector axis28also extends from the insert end22toward the contact end24.

The first connector12includes a plurality of first electrical terminals30that are adapted to be retained in the terminal cavity bays26, as described below. The illustrated first connector12includes six of the first electrical terminals30, but may include any desired number of first electrical terminals30. The first electrical terminals30are described in detail below.

FIG.3is an enlarged perspective view of the insert end22of the housing20, andFIG.4is an end elevational view of the insert end22. The housing20includes a plurality of terminal catches32in the insert end22. Each of the illustrated terminal catches32is a recess that extends into the housing20and is parallel to the connector axis28. The illustrated first connector12includes six terminal catches32, but may include any desired number of terminal catches32.

Referring now toFIG.5, there is illustrated a perspective view of the first connector12shown partially assembled.FIG.6is a cross-sectional view taken along line6-6ofFIG.5. As shown, the first electrical terminals30are inserted into the housing20. Each of the illustrated first electrical terminals30is the same, and only one will be described in detail.

The illustrated first electrical terminal30is made from sheet metal folded into the illustrated shape, but may be made from any material and any desired process. The first electrical terminal30includes a conductor portion, indicated generally at34, that is adapted to engage the first cable16, as described below, and a contact portion, indicated generally at36, that is adapted to engage a second electrical terminal (not shown) that is located in the second connector14. The illustrated contact portion36is a male blade, but may be any desired type of contact.

To install the first electrical terminal30in the first connector12, the first electrical terminal30is initially positioned parallel to the connector axis28, with the connect portion36facing the terminal cavity bay26. The first electrical terminal30is then moved in an insertion direction38parallel to the connector axis28so that the first electrical terminal30is moved into the terminal cavity bay26.

The terminal cavity bay26extends from the insert end22to a housing stop40. As best shown inFIG.4, the illustrated housing stop40is a wall that extends across the terminal cavity bay26perpendicular to the connector axis28. The terminal cavity bay26includes a plurality of terminal openings42extending parallel to the connector axis28past the housing stop40and opening into a contact area44provided in the contact end24of the housing20. The first electrical terminal30is moved in the insertion direction38so that the contact portion36extends through one of the terminal openings42and at least partially into the contact area44. The terminal cavity bay26including the terminal opening42provides a terminal cavity adapted to accommodate the first electrical terminal30. In the illustrated embodiment, the terminal cavity bay26includes three terminal openings42and defines three terminal cavities. However, the terminal cavity bay26may include any desired number of terminal openings42and may define any desired number of terminal cavities.

The first electrical terminal30includes a terminal tab46that is located on an end of the conductor portion34opposite the contact portion36. The terminal tab46is a portion of the first electrical terminal30that extends in the insertion direction38. When the first electrical terminal30is installed in the terminal cavity bay26, the terminal tab46is received in one of the terminal catches32. Each terminal catch32is adapted to receive a terminal tab46of one of the first electrical terminals30so as to retain the respective first electrical terminal30in place relative to the housing20. The first electrical terminal30engages the housing20at the terminal catch32and at the housing stop40to limit movement of the first electrical terminal30relative to the housing20. This limits movement of the first electrical terminal30relative to the housing20in the insertion direction38and also movement in any direction perpendicular to the connector axis28.

The first connector12includes a terminal lock48that is adapted to retain the first electrical terminals30in their respective positions in the terminal cavity bays26. The illustrated terminal lock48is molded from plastic, but may be made from any desired material using any desired process. The terminal lock48includes a terminal lock body50. A plurality of terminal lock tabs52extend from the terminal lock body50in the insertion direction38. The illustrated terminal lock48includes four terminal lock tabs52, but may include any desired number of terminal lock tabs52.

To attach the terminal lock48to the housing20, the terminal lock48is initially positioned with the terminal lock tabs52facing the insert end22. The housing20includes a plurality of terminal lock latches54in the insert end22. The illustrated housing20includes four terminal lock latches54, one for each terminal lock tab52. The terminal lock48is then moved in the insertion direction38relative to the housing20so that each of the terminal lock tabs52engages one of the terminal lock latches54. The terminal lock tabs52cooperate with the terminal lock latches54to retain the terminal lock48in the illustrated lock position relative to the housing20. However, the first connector12may use any other desired lock to retain the terminal lock48in the lock position relative to the housing20.

The terminal lock48includes terminal lock openings56that extend through the terminal lock body50parallel to the connector axis28. The illustrated terminal lock48includes two terminal lock openings56. When the terminal lock48is in the lock position, the terminal lock openings56are aligned with the terminal cavity bays26in the insertion direction38.

Additionally, when the terminal lock48is in the lock position, the terminal lock48is located opposite the insertion direction38of a portion of the first electrical terminal30. As best shown inFIG.6, part of the terminal lock body50is located opposite the insertion direction38from the terminal tab46. Thus, when the terminal lock48is in the lock position, it prevents the first electrical terminal30from being moved opposite the insertion direction38relative to the housing20and prevents the first electrical terminal30from being removed from the terminal cavity bay26.

The terminal cavity bay26extends from the insert end22of the housing20to the housing stop40. As previously described, the illustrated housing20includes two terminal cavity bays26. As best shown inFIGS.3and4, each terminal cavity bay26is adapted to accommodate multiple first electrical terminals30. In the illustrated embodiment, each terminal cavity bay26can accommodate three of the first electrical terminals30. However, the terminal cavity bays26can accommodate any desired number of first electrical terminals30.

The two terminal cavity bays26are similar, and only one will be described in detail. Referring toFIG.4, the terminal cavity bay26has a width W and a height H.FIG.4is a view taken perpendicular to the connector axis28and the width W is also perpendicular to the connector axis28while the height H is perpendicular to the connector axis28and perpendicular to the width W. In the illustrated embodiment, the width W of the terminal cavity bay26is greater than the height H in order to accommodate the first cable16, as described below. However, the terminal cavity bay26may have any desired relative dimensions.

As best shown inFIG.6, the terminal cavity bay26includes a first cavity wall58and a second cavity wall60that is on an opposite side of the terminal cavity bay26from the first cavity wall58. The distance between the first cavity wall58and the second cavity wall60defines the height H of the terminal cavity bay26. The first cavity wall58extends at an angle relative to the second cavity wall60so that the height H of the terminal cavity bay26changes between the insert end22the housing stop40. A first height H1at the insert end22is greater than a second height H2near at the housing stop40. In the illustrated embodiment, the first cavity wall58extends parallel to the connector axis28and the second cavity wall60extends at an angle to the connector axis28. However, the first cavity wall58and the second cavity wall60may have any desired relative orientations.

As previously described, the conductor portion34of the first electrical terminal30is adapted to engage the first cable16. The conductor portion34is located in the terminal cavity bay26. The conductor portion34engages the first cavity wall58at both a first support62located near the insert end22and a second support64located near the housing stop40. The conductor portion34includes a compression portion66between the first support62and the second support64. The illustrated compression portion66is a part of the first electrical terminal30that is generally arcuate in shape and is spaced apart from the first cavity wall58between the first support62and the second support64.

The first electrical terminal30includes a terminal stop68between the second support64and the contact portion36. The illustrated terminal stop68is a portion of the first electrical terminal30that extends substantially perpendicular to the connector axis28. The terminal stop68is located near the housing stop40, but a space is provided between the housing stop40and the terminal stop68when the first electrical terminal30is installed in the terminal cavity bay26, as shown inFIG.6.

Referring now toFIG.7, there is illustrated a view similar toFIG.5showing a cable lock70attached to the housing20in a pre-load position.FIG.8is a cross-sectional view taken along line8-8ofFIG.7. The cable lock70is adapted to hold the first cable16in place relative to the housing20.

The illustrated cable lock70is molded from plastic, but may be made of any desired material and by any desired process. The cable lock70includes a cable lock body72. A plurality of lock tongues74extends from the cable lock body72in the insertion direction38. The illustrated cable lock70includes two lock tongues74, but may include any desired number of lock tongues74.

To attach the cable lock70to the housing20, the cable lock70is initially positioned with the lock tongues74facing the insert end22. The cable lock70is then moved in the insertion direction38relative to the housing20so that each of the lock tongue74passes through one of the terminal lock openings56and enters into one of the terminal cavity bays26. Each of the lock tongues74extends between one of the first electrical terminals30and the respective second cavity wall60.

Referring back toFIG.5, the housing20includes a plurality of cable lock tabs76. The illustrated housing includes four cable lock tabs76(two are visible inFIG.5), but may include any desired number of cable lock tabs76.FIG.9is a cross-sectional view taken along line9-9ofFIG.8and shows two of the cable lock tabs76. The cable lock70includes a plurality of pre-load latches78that engages the cable lock tabs76. The illustrated cable lock70includes four pre-load latches78(two are visible inFIG.9), but may include any desired number of pre-load latches78. When the cable lock70is moved in the insertion direction38relative to the housing20to the illustrated pre-load position, each of the pre-load latches78engages an associated one of the cable lock tabs76to limit movement of the cable lock70relative to the housing20. The cable lock tabs76cooperate with the pre-load latches78to retain the cable lock70in the pre-load position relative to the housing20.

The cable lock70includes cable lock openings80that extend through the cable lock body72. When the cable lock70is in the pre-load position, the cable lock openings80are aligned with the terminal cavity bays26in the insertion direction38and provide access to the terminal cavity bays26through the cable lock body72. The illustrated cable lock70includes two cable lock openings80, but may include any desired number of cable lock openings80.

Referring back toFIG.7, there is also shown an enlarged view of a portion of the first cable16. The first cable16is a flat flexible cable. The illustrated first cable16includes an insulator82that is formed from a plastic material, but any desired material may be used. The first cable16also includes an electrical conductor84. The illustrated electrical conductor84is a relatively thin, solid layer of copper that is bonded to or otherwise supported on the insulator82, but may be any desired material. The illustrated first cable16includes three electrical conductors84, but may include any desired number of electrical conductors84. The ratio of the height to the width of the electrical conductor84and the first cable16are significantly different from a typical round wire or a bundle of wires, which typically define an electrical conductor having a generally circular cross-section.

The insulator82surrounds the electrical conductors84along most of the length of the first cable16. The first cable16includes a stripped portion, indicated generally at86, where portions of the electrical conductors84are not covered by the insulator82. The stripped portion84may be created by removing a portion of the insulator82that would otherwise cover the electrical conductors84. Each of the electrical conductors84can be engaged with one of the first electrical terminals30by inserting the first cable16into the terminal cavity bay26.

The first connector12includes a polarizer88that restricts the insertion of the first cable16into the terminal cavity bay26. The illustrated polarizer88is located on the cable lock70, but may be on any desired part of the first connector12. The polarizer is a stop that extends across a portion of the cable lock opening80. The illustrated polarizer88is a physical stop that limits the first cable16from being inserted into a portion of the terminal cavity bay26in the insertion direction38. As best shown inFIG.8, the illustrated polarizer88extends parallel to the height H. The illustrated polarizer88extends in a stop direction90that is the same direction as the direction between the first cavity wall58and the second cavity wall60.

Referring back toFIG.7, the first cable16includes a notch92in the stripped portion86. The notch92extends through the complete thickness of the insulator82. The illustrated notch92is located between two of the electrical conductors84, but the notch92may be in any desired location on the first cable16. The illustrated notch92extends parallel to the insertion direction38.

To insert the first cable16into the first connector12, the first cable16is initially positioned with the stripped portion86adjacent to the insert end22. The first cable16is then moved in the insertion direction38relative to the first connector12so that the first cable16passes through the cable lock opening80. As previously described, the polarizer88is positioned in the cable lock opening80and, therefore, prevents the insertion of the first cable16into the terminal cavity bay26unless it is properly oriented relative to the polarizer88. As shown inFIG.10, when the first cable16is properly aligned and oriented with the first connector12, the polarizer88is aligned in the insertion direction38with the notch92in the first cable16. Thus, the first cable16can be moved in the insertion direction38, through the cable lock opening80and the terminal lock opening56, and into the terminal cavity bay26.FIG.10shows the first cable16in a loaded position, where at least part of the stripped portion86is located adjacent to the compression portion66of the first electrical terminal30. The first cable16is oriented with the insulator82facing the lock tongue74and with the electrical conductor84facing the first electrical terminal30. Also, the polarizer88is located in the notch92in in the first cable16.

As previously described, the illustrated first connector12includes two terminal cavity bays26. Referring back toFIG.7, the illustrated first connector12also includes two cable lock openings80, each of which has one of the polarizers88. The polarizer88in each of the cable lock openings80is in a different relative position, which prevents the first cables16form being inserted into the wrong terminal cavity bays26. Each of the illustrated cable lock openings80includes a single polarizer88, but the cable lock openings80may have multiple polarizers88if desired, and each may have a different number of polarizers88.

Referring back toFIG.10, the first connector12is shown with the first cable16in the loaded position and the cable lock70in the pre-load position. As previously described, the cable lock tabs76cooperate with the pre-load latches78to retain the cable lock70in the pre-load position relative to the housing20. An operator may apply additional force to the cable lock70in order to release the pre-load latches78from the cable lock tabs76and move the cable lock70in the insertion direction38relative to the housing20to a locked position, shown inFIG.11. The cable lock70includes a plurality of lock latches94that engage the cable lock tabs76to limit movement of the cable lock70relative to the housing20. The illustrated cable lock70includes four lock latches94(two are visible inFIG.11), but may include any desired number of lock latches94. Each of the lock latches94is located opposite the insertion direction38from one of the pre-load latches78so that the pre-load latch78is released from one of the cable lock tabs76and the respective lock latch94engages that cable lock tab76.

Referring toFIG.12, there is illustrated a perspective view similar toFIG.7, showing the first connector12with the cable lock70in the locked position.FIG.13is a cross-sectional view taken along line13-13ofFIG.12.

As previously described, the illustrated cable lock70includes two lock tongues74. The two lock tongues74are the same, and only one will be described in detail. When the cable lock70is moved from the pre-load position to the locked position, the lock tongue74is moved in the insertion direction38relative to the housing24. The lock tongue74is located between the first electrical terminal30and the second cavity wall60. The lock tongue74includes a first tongue surface96that faces the first electrical terminal30and a second tongue surface98that faces the second cavity wall60. The first tongue surface96extends at an angle relative to the second tongue surface98, and the second tongue surface98is parallel to the second cavity wall60. As a result, a first thickness of the lock tongue74between the first tongue surface96and the second tongue surface98is greater near the cable lock body72than a second thickness at an outer end of the lock tongue74.

When the cable lock70is attached to the housing24, there is a terminal space, indicated generally at100, between the first cavity wall58and the first tongue surface96. At least part of the conductor portion34is located in the terminal space100. When the first cable16is in the loaded position, at least a part of the stripped portion86is located in the terminal space100.

When the cable lock70is moved from the pre-load position to the locked position, the second tongue surface98engages the second cavity wall60and is pushed toward the first cavity wall58. This causes the first tongue surface96to also be moved toward the first cavity wall58and the terminal space100to become smaller. When the first tongue surface96is moved toward the first cavity wall58, the first electrical cable16is pressed against a portion of the first electrical terminal30. In particular, the electrical conductor84is pressed against the compression portion66of the conductor portion34. This deflects the compression portion66toward the first cavity wall58. The terminal tab46on the illustrated first electrical terminal30is held in the terminal catch32by the terminal lock48and is restrained from moving relative to the housing24. However, the terminal stop68is able to move relative to the housing24. Thus, when the compression portion66is deflected toward the first cavity wall58, the terminal stop68is displaced in the insertion direction38toward the housing stop40. When the cable lock70is retained in the locked position by the cooperation of the lock latches94and the cable lock tabs76(as shown inFIG.11), the lock tongue74is retained pressing the electrical conductor84against the first electrical terminal30and deflecting the compression portion66. This maintains a mechanical connection between the first connector12and the first cable16, and also an electrical connection between the first electrical terminal30and the electrical conductor84.

When the cable lock70is moved to the locked position, the lock tongue74is moved relative to the lock body72by the engagement of the second tongue surface98and the second cavity wall60. As shown inFIG.13, when the cable lock70is in the locked position a portion of the first cable16is pressed against the first support62. This further maintains the mechanical connection between the first connector12and the first cable16, and also the electrical connection between the first electrical terminal30and the electrical conductor84.

The principle and mode of operation of this invention have been explained and illustrated in its preferred embodiment. However, it must be understood that this invention may be practiced otherwise than as specifically explained and illustrated without departing from its spirit or scope.