Abstract
The present disclosure provides a connector assembly. The connector assembly includes a connector housing adapted to engage with a corresponding counter-connector housing. A lever including a first lever arm and a second lever arm is pivotably and sealingly mounted to the connector housing. Each lever arm includes interlocking means for connecting the first lever arm to the second lever arm at a first location. The interlocking means of each of the first lever arm and the second lever arm are configured to define complementary symmetrical surfaces that interlock with one another when the lever arms are pivotably mounted to the connector housing. On mounting the lever arms to the connector housing, the lever is configured to move about the connector housing between an open state and a closed state to secure the counter-connector housing to the connector housing.
Claims
1. A connector assembly comprising; a connector housing adapted to engage with a corresponding counter-connector housing; and a lever comprising a first lever arm and a second lever arm, each lever arm comprising interlocking means for connecting the first lever arm to the second lever arm at a first location, each lever arm comprising at a second location a first mounting member configured to cooperate with a complementary second mounting member on the connector housing for pivotably and sealingly mounting each lever arm to a corresponding location on the connector housing; wherein the interlocking means of each of the first lever arm and the second lever arm are configured to define complementary symmetrical surfaces that interlock with one another when the lever arms are pivotably mounted to the connector housing and, wherein on mounting the lever arms to the connector housing, the lever is configured to move about the connector housing between an open state and a closed state to secure the counter-connector housing to the connector housing.
2. The connector assembly according to claim 1, wherein a sealing member is provided in sealing contact with corresponding sealing surfaces on the lever arms and the connector housing.
3. The connector assembly according to claim 2, wherein the sealing member is integrally formed on each of the lever arms and/or the connector housing.
4. The connector assembly according to claim 3, wherein the sealing member is formed using a 2K injection molding process.
5. The connector assembly according to claim 1, wherein the connector housing comprises two apertures provided on opposing sides of the connector housing, each aperture configured to receive a locking member of a lever arm.
6. The connector assembly according to claim 5, wherein the locking member comprises a locking element which is configured to cooperate, when the lever moves to the closed state, with a mating surface of the counter-connector housing to secure the counter-connector housing to the connector housing.
7. The connector assembly according to claim 6 wherein the locking element is in the form of a gear comprising at least one gear tooth configured to engage with a recess on the counter-connector housing.
8. The connector assembly according to claim 1, wherein the first and second mounting members comprise one of a retaining member and a notch adapted to cooperate with one another for mounting each lever arm to opposing locations on the connector housing.
9. The connector assembly according to claim 8, wherein the notch defines a substantially circular rim configured to engage with a corresponding retaining latch.
10. The connector assembly according to claim 1, wherein the counter-connector housing comprises one or more engagement surfaces adapted to cooperate with one or more corresponding engagement surfaces on the connector housing or the lever arms.
11. The connector assembly according to claim 10, wherein the one or more engagement surfaces comprise at least one boss.
12. The connector assembly according to claim 1, wherein the interlocking means of each lever arm comprise a locking element and a guiding element.
13. The connector assembly according to claim 12, wherein the guiding element comprises a protruding elongate member and a corresponding slot configured for receiving an elongated member of the first or second lever arm.
14. The connector assembly according to claim 12, wherein the locking element comprises a protruding locking member and a corresponding resilient member which defines a locking aperture configured for receiving and securing a protruding locking member of the first or second lever arm.
15. The connector assembly according to claim 1, wherein the lever comprises first connecting means configured to cooperate with corresponding second connecting means on the connector housing for releasably securing the lever on the connector housing, when the lever is in the closed state, wherein the first connecting means and second connecting means comprising interconnecting elements configured to engage with one another.
16. The connector assembly of claim 15, wherein the connector assembly comprises a connector position assurance (CPA) member, the CPA member being movable from a start position to an end position, wherein at the end position the CPA member is adapted to prevent the interconnecting elements from disengaging.
17. The connector assembly according to claim 1, wherein the first lever arm and the second lever arm are substantially symmetrical.
18. The connector assembly according to claim 1, wherein the lever arms are made of a glass fiber reinforced thermoplastic material comprising between 20% to 50% of fiber content.
19. A method for assembling an electrical connector, the electrical connector comprising a connector housing, a corresponding counter-connector housing, and a lever comprising a first lever arm and a second lever arm, each lever arm comprising interlocking means configured to define complementary symmetrical surfaces that interlock with one another when the lever arms are pivotably mounted to the connector housing for connecting the first lever arm to the second lever arm at a first location, the method comprising the steps of: presenting the first lever arm and the second lever to the connector housing on opposite sides thereof; biasing the interlocking means of each lever arm towards the interlocking means of another lever arm to effect an interlock of the first and second lever arms, the interlock effecting a sealed connection of the lever arms to the connector housing; engaging the connector housing with the corresponding counter-connecting housing; and pivoting the lever relative to the connector housing to effect a locking of the connector housing with the corresponding counter-connecting housing.
20. A method according to claim 19, further comprising pivoting the lever arm to the closed state until an audible sound is generated from an engagement of corresponding connecting means provided on the lever arm and the connector housing.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The present invention will now be described, by way of example with reference to the accompanying drawings, in which:
(2) FIG. 1 illustrates a perspective view of a sealed electrical connector assembly with a symmetrical split lever according to an embodiment of the present disclosure;
(3) FIG. 2 illustrates a perspective view of a lever arm according to an embodiment of the present disclosure;
(4) FIG. 3a illustrates a perspective view of an interlocking means of the lever arm;
(5) FIG. 3b illustrates a perspective view of an alternative embodiment of the interlocking means of the lever arm;
(6) FIG. 4 illustrates a perspective view of the symmetrical split lever in the interlocked position;
(7) FIG. 5 illustrates a perspective view of a connector housing;
(8) FIG. 6a illustrates a perspective view of the first lever arm, the second lever arm and the connector in the unassembled position;
(9) FIG. 6b illustrates a perspective view of the first lever arm and second lever arm which are interlocked to form a lever and mounted on the connector housing;
(10) FIG. 7a illustrates a perspective view of the interlocking means in the interlocked position;
(11) FIG. 7b illustrates a perspective cross section view of a gear tooth engaged with a protruding surface of the connector housing 2 in the pre lock position;
(12) FIG. 7c illustrates a perspective cross section view of a retention feature in the form of an elongate arm and corresponding rim;
(13) FIG. 7d illustrates a perspective cross section view of the lever to connector housing mounting means;
(14) FIG. 8a illustrates a perspective view of a sealed electrical connector assembly in an unmated configuration wherein the counter-connector housing has not been inserted into the connector housing;
(15) FIG. 8b illustrates a perspective view of a sealed electrical connector assembly in a mated configuration wherein the counter-connector has been inserted into the connector housing;
(16) FIG. 9a illustrates a perspective cross section view of a boss of the counter-connector and a corresponding mating surface;
(17) FIG. 9b illustrates a perspective cross section view of the boss which is engaged in an internal mating surface of a gear member;
(18) FIG. 10a illustrates a perspective view of a sealed electrical connector assembly with a symmetrical split lever wherein the CPA member is in the pre lock position;
(19) FIG. 10b illustrates a perspective view of a sealed electrical connector assembly with a symmetrical split lever wherein the CPA member is in the lock position;
(20) FIG. 11a illustrates a perspective cross section view of a CPA member and a corresponding element in the connector housing in a pre-lock position;
(21) FIG. 11b illustrates a perspective cross section view of the CPA member and the corresponding element in the connector housing in a lock position;
(22) FIG. 12a illustrates a perspective cross sectional view of first connecting member of the lever which is engaged by a second connecting member of the connector housing;
(23) FIG. 12b illustrates a perspective cross sectional view of the first connecting means of the lever which is engaged at an intermediate position with the connector housing;
(24) FIG. 12c illustrates a perspective cross sectional view of the first connecting means of the lever which is engaged with the second connecting means of the connector housing, which in turn is engaged with the CPA member.
(25) FIG. 12d illustrates a further perspective cross sectional view of the three engaged elements of FIG. 12c;
(26) FIG. 12e illustrates a further perspective cross sectional view of the three engaged elements of FIGS. 12c and 12d; and
(27) FIG. 13 illustrates an enlarged perspective cross sectional view of the gear when the lever is in the final-lock position such that the gear tooth engages with a recess on a mating surface of the connector housing.
DETAILED DESCRIPTION
(28) The following discussion provides many exemplary embodiments of the inventive subject matter. Although each embodiment represents a single combination of inventive elements, the inventive subject matter is considered to include all possible combinations of the disclosed elements. Thus, if one embodiment includes elements A, B, and C, and a second embodiment includes elements B and D, then the inventive subject matter is also considered to include other remaining combinations of A, B, C, or D, even if not explicitly disclosed.
(29) For simplicity and clarity of illustration, reference numerals may be repeated among the figures to indicate corresponding or analogous elements. Numerous details are set forth to provide an understanding of the examples described herein. The examples may be practiced without these details. In other instances, well-known methods, procedures, and components are not described in detail to avoid obscuring the examples described. The description is not to be considered as limited to the scope of the examples described herein.
(30) Referring now to FIGS. 1 to 13 of the accompanying drawings, there is illustrated an example of an electrical connector assembly 100 with symmetrical split lever 5 which is designed to easily and efficiently connect and secure two electrical components in an environment which may be subject to dust and/or moisture. The electrical connector assembly 100 may be used as a door-to-body connector in automotive applications.
(31) As shown in FIG. 1, the electrical connector assembly 100 includes a connector housing 2 and a counter-connector housing 4 which may engage together in a male-female connection. More particularly, the connector housing 2 may include a female connector housing and the counter-connector housing 4 may include a male connector housing.
(32) The electrical connector assembly 100 is provided with a two-part lever 5. The lever 5 includes a first lever arm 6 and a second lever arm 7, wherein the lever arms 6,7 may be provided with symmetrical features. For example, the lever arms 6, 7 may be provided with interlocking means 8 including symmetrical complementary surfaces. The lever arms 6,7 may be made from the same mould or made on the same manufacturing line. Preferably, the lever arms 6,7 are substantially identical, and as such may be interchangeable with one another. It should be appreciated that the term substantially identical implies that the lever arms 6,7 are identical in terms of relevant technical features but may include negligible irrelevant dissimilarities which do not affect the functioning of the lever arms 6,7 such as for example manufacturing imperfections etc. As shown in FIG. 1, the lever arms are pivotably mounted on opposing sides of the connector housing 2.
(33) As shown in FIG. 2, each lever arm 6, 7 includes an interlocking means 8 which may be located at an end of the lever arm 6, 7 and a mounting means 9, 10 which may be located at an opposite end of the lever arm 6, 7. The interlocking means 8 of the lever arms 6, 7 include symmetrical features which form complementary interlocking surface that are configured to interlock with one another when the lever arms 6, 7 are connected. For example, the interlocking means 8 of the first lever arm 6 interlocks with the interlocking means 8 of the second lever arm 7 when the lever arms 6,7 are arranged about a central axis of rotation of the lever 5, in other words, when both the interlocking surfaces are in contact with each other. Each interlocking means 8 may include a guiding element 30 and a locking element 28.
(34) The guiding element 30 includes a protruding elongate member 32 and a corresponding slot 34. As the protruding elongate member 32 includes a major longitudinal axis which is parallel to the direction in which the interlocking means 8 are pushed together, the protruding elongate member 32 ensures the correct alignment of the two interlocking means 8. In use, the protruding elongate member 32 of the first lever arm 6 moves into the corresponding slot 34 of the second lever arm 7, and in parallel the protruding elongate member 32 of the second lever arm 7 moves into the corresponding slot 34 of the first lever arm 6. It will be appreciated that the protruding elongate member 32 and corresponding slot 34 may be configured in a variety of geometries for example two alternative forms for the guiding element 30 are illustrated in FIGS. 3a and 3b. The guiding element 30 in FIG. 3a includes a protruding elongated member 32 of square cross section and a slot 34 in the form of a substantially square aperture in a contacting surface of the guiding element 30. The guiding element 30 of FIG. 3b includes a protruding elongated member 32 in the form of a cruciform extrusion and a slot 34 in the form of a substantially circular hole in the contacting surface of the guiding element 30.
(35) The locking element 28 of the interlocking means 8 may also be provided with protruding locking member 36 and a resilient member 38 which defines a locking aperture. The guiding element 30, depending on their positions on the interlocking means 8, may be activated prior to the activation of the locking element 28. The resilient member 38 may be configured for providing a locking aperture. In use, the resilient member 38, may be adapted to resiliently deform in order to allow the resilient member 38 to slide over the protruding locking member 36, so that the protruding locking member 36 engages with the aperture defined in the resilient member 38. An example of the interlocked configuration of the first lever arm 6 and the second lever arm 7 is shown in FIG. 7a.
(36) As shown in FIG. 2, each lever arm 6 and 7 may be provided with a first mounting member 9, which is configured to cooperate with a complementary second mounting member 10 provided on the connector housing 2. For example, the first mounting means 9 may be a retaining member e.g., in the form of a retaining latch, which is configured to cooperate with a complementary second mounting member 10 provided on corresponding mounting locations on the connector housing 2. The second mounting means 10 may be in the form of a notch 26 that defines a rim 31 on the mounting locations of the connector housing 2. The notch 26 may be in the form of an indentation that defines a channel. The notch 26 is configured to cooperate with the retaining latch 9 of the corresponding lever arm 6 and 7. The second mounting means 10 may be provided in any other desirable form e.g., an opening adapted to engage with a corresponding retaining latch. It should also be noted that in the context of the present application, the first and second mounting means 9 and 10 are interchangeable. As such the second mounting means 10 may be provided on the lever arms 6 and 7 and the first mounting means 9 may be provided on the corresponding mounting locations on the connector housing. Each lever arm, 6 and 7, may be provided with corresponding locking member 16a and 16b including a gear mechanism 18 provided with at least one gear tooth 22. The locking members 16a and 16b may have a desired shape e.g., a cylindrical shape. As shown in FIG. 2, the gear mechanism 18 may be symmetrical about an axis of rotation of the lever 5. As shown in FIG. 2, the sealing surface 11 may be provided around the locking members 16a and 16b. The sealing surface 11 may be surrounded by a raised edge 13 defining a space.
(37) According to an embodiment, the lever arms 6,7 are identical, and as such may be interchangeable with one another, which eliminates the potential for confusion with regards to how the levers arms 6,7 are connected and how they should be orientated on the connector housing.
(38) FIG. 4 illustrates a view of the first lever arm 6 interlocked with the second lever arm 7 such that they form a U-shaped lever 5. It will be appreciated that, FIG. 4 shows the lever arms 6 and 7 in the interlocked state without the connector housing 2 for illustrative purposes, however, in use, the first lever arm 6 may be assembled directly onto the connector housing 2 prior to being interlocked with the second lever arm 7.
(39) As shown in FIG. 5, the connector housing 2 may be provided with two apertures 14a and 14b located on opposing sides of the connector housing 2. Each aperture 14a and 14b is configured to receive a cylindrical locking member 16a and 16b. Around each aperture 14a and 14b, a sealing surface 21 may be provided with a raised edge 27 for receiving a sealing member 12. The sealing member 12, may be provided in sealing contact with corresponding sealing surfaces 11 and 21 on each of the lever arms 6 and 7 and the connector housing 2 as shown in FIGS. 7c and 7d. According to the embodiment shown in FIGS. 7c and 7d, the raised edge 13 of the sealing surface 11 is configured to be received, when the levers 6 and 7 are mounted on the connector housing 2, at corresponding openings 29 on the connector housing 2, and the raised edge 27 is configured to be received together with the sealing member 12 at the space defined by the raised edge 13. As such, when the lever 5 is mounted on the connector housing 2, water and dust are prevented from entering the connector housing 2. The sealing member 12 may be integrally formed on one of the sealing surfaces 11 and 21 e.g., using a 2K injection molding process. Furthermore, the sealing member 12 may be provided in the form of an independently O ring seal. In use, the sealing member 12 is positioned between each lever arm 6 and 7 and the connector housing 2 such that it prevents moisture and/or dust from entering the interior of the connector housing 2. As shown in FIGS. 5 and 7c the sealing member 12 may be provided at locations around the apertures 14a and 14b. As shown in FIGS. 5 and 7d, the second mounting member 10, which is configured to cooperate with the first mounting member 9 of a lever arm 6 and 7, may be in the form of a notch 26 defining a rim 31 provided substantially around each aperture 14a and 14b. As shown in FIGS. 7c and 7d, the notch 26 is configured to engage with a corresponding engagement surface of the retaining latch 9 of a lever arm 6 and 7. Once the retaining latch 9 is engaged, the notch 26, is configured to retain the retaining latch 9 within the channel, due to the profile of the retaining latch 9, as the lever 5 rotates between the open and closed states.
(40) As shown in FIG. 7b, when the lever 5 is in the open position, also referred to as pre-lock position, the gear tooth 22 is configured to engage with a protruding member 41 e.g., a node, on surface 50 of the connector housing 2. It will be appreciated that the term engages means that the lever arms 6,7 may be mounted on the connector housing 2, such that the gear mechanism 18 is provided at an orientation to the protruding member 41 as shown in FIG. 7b. In order for the gear mechanism 18 to rotate, such that the lever moves from the pre-lock position to the final-lock position, a suitable force is applied to the gear mechanism 18 via the lever 5 causing the gear tooth 22 to move over the protruding member 41 towards the closed position. The surface 50 may be provided with a concave surface, thus allowing the gear mechanism 18 to rotate to the closed position, whereby the gear tooth 22 is configured to engage with a corresponding mating surface of the counter-connector housing 4, and the protruding member 41 engages with a corresponding surface 23 of the gear mechanism 18 as shown in FIG. 13.
(41) FIGS. 9a and 9b illustrate the mating sequence of the connector 2 and the counter-connector 4. As shown, the counter-connector 4 is configured to engage with the connector housing 2 via a boss 24 and corresponding engagement surfaces 25. For example, the counter-connector 4 may be provided with one or more bosses or protrusions, which are configured to engage with corresponding mating surfaces 25 e.g., openings, channels and the like, provided on the connector housing 2 and/or the locking member 16a and 16b of the lever arms 6 and 7, as shown in FIGS. 9a and 9b.
(42) FIGS. 10a and 10b illustrate the connector assembly with the lever 5 in the closed position, also referred to as the final-lock position. A shown, a connector position assurance (CPA) member 48 may be provided and secured in a location between the lever 5 and the connector housing 2. The CPA member 48 is configured to be activated after the lever 5 has been rotated from the open to the closed position. The insertion of the CPA member 48 ensures that the lever 5 is prevented from accidentally rotated away from the closed position during use. Should the need arise to reverse the mating of the connector housing 2 and the counter-connector housing 4 the CPA must be purposefully removed from the electrical connector assembly 100 in order to enable the rotation of the lever 5.
(43) The CPA member 48 includes geometrical features 62 which are configured to engage with corresponding features 47 in the lever 5 as shown in FIGS. 11a to 12e. In use, the CPA member 48 is slotted into the geometrical features 62 formed between the second connecting means 42 of the connector housing 2 and the main body of the connector housing 2. For example, behind the second connecting means 42, an opening may be provided for inserting the CPA member 48. As shown, the CPA member includes engagement members 61 configured to engage with corresponding features 47 of first connecting means 40 of the lever 5. The CPA member 48 is movable between a start position, and a stop position.
(44) As shown in FIGS. 12a and 12b, with the CPA member in the start position, when the lever is positioned at the closed state, the first connecting means 40 and the second connecting means 42 are configured to engage. For example, the first and second connecting means 40, 42 may be provided with corresponding engagement elements 44, e.g., in the form of a latch and a corresponding mating surface. Once, the first and second connecting means are engaged, the CPA member 48 is moved from the start position to the end position as shown in FIGS. 12c to 12e. At the end position, the CPA member 48 exerts a retaining force on the second connecting mechanism 42, and such as accidental movement of the lever is prevented.
(45) FIG. 13 shows a cross-sectional perspective view of the connector assembly with the lever 5 in the closed position. As shown, the gear tooth 22 of the gear mechanism engages with a recess on a mating surface 54 of the counter-connector housing 4. As such, the counter-connector housing 4 is securely connected to the connector housing 2.
(46) An exemplified method for the connector assembly is described below to illustrate the sequence of activation of the features of the connector assembly with references to FIGS. 6a, 6b, 8a, and 8b:
(47) As shown in FIG. 6a, the lever arms 6 and 7 are presented at opposing mounting locations on the connector housing 2. Each lever arm 6 and 7 is mounted to the connector housing 2 via the respective first and second mounting means 9, 10 as described above and the corresponding interlocking means 8 are connected to one another, thereby forming the lever 5. With the lever 5 mounted on the connector housing 2, the retaining latch 9 is engaged with a notch 26 in the connector housing 2 as shown in FIG. 6b. As the notch 26 in the connector housing 2 forms an arcuate path as described above, the retaining latch 9 is free to rotate without accidentally becoming disengaged, for example to move along the arcuate notch. The sealing member 12 is located on the connector housing 2.
(48) In use, when the lever 5 is mounted on the connector housing 2, the sealing member 12 is in sealing contact with both the lever 5 and the connector housing 2. As the sealing member 12 is ring shaped and it sits within a sealing surface 11 in the mounting means 8, it does not prohibit rotational movement of the lever 5 in relation to the connector housing 2. As shown in FIG. 8a, the counter-connector 4 is presented to the connector housing 2. The connector housing 2 and the counter-connector housing 4 may be brought into engagement such that a portion of the counter-connector housing 4 is located inside a portion of the connector housing 2 as shown in FIG. 8b. The boss 24, or another engagement element, may be provided on the counter connector housing 4 which cooperates with a corresponding mating surface 25 of the gear as shown in FIGS. 9a and 9b. The geometry of the mating surface 25 is such that it allows the boss 24 to rotate within the space defined by the mating surface 25 without disengaging from the mating surface 25. As the lever 5 is rotated from the open position, in which it is assembled on the connector housing 2, to a closed position, the connector housing 2 and the counter-connector housing 4 are coupled to one another via the rotatable gear mechanism 18 provided by each lever arm 6 and 7.
(49) As such, the lever 5 acts as a mate-assist device, as it is known in the art, configured to coupling the two connector housings 2 and 4. When the lever 5 reaches the closed position, the at least gear tooth 22 engages with a mating surface 54 such that further motion of the gear mechanism 18, either clockwise or counterclockwise, is discouraged. In addition, when the lever 5 reaches the closed position a first connecting means 40 on the lever engages with a second connecting means 42 on the connector housing, further strengthening the engagement between the lever 5 and the connector housing 2. A CPA member 48 is additionally inserted at this point, which is wedged between the second connecting means 42 and the connector housing 2 such that the first connecting means 40 and the second connecting means 42 cannot disengage from one another.
