Note: Descriptions are shown in the official language in which they were submitted.
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ATTORNEY DOCKET NO.: 98-2-820
Pagelofl7
Title: CONNECTOR MODULE
TECHNICAL FIELD
The present invention relates to a connector module, that includes internal
latch engagement
members and comprises a first connector housing that mates with a second
connector
housing. A positive assur,ance member is attached to one of the connector
housings in a pre-
locked mode. The positive assurance member assures that the housings are fully
mated, and
contacts therein are fully engaged, in an engaged mode, and that the housings
are locked
together, in a locked mode.
BACKGROUND ART
It is occasionally desirable to provide electrical connectors that may be
mechanically and
electrically connected together but not readily disconnected. For example, the
ability to
easily disconnect an electrical connector module creates a potential safety
hazard in high
voltage applications. Sucli a concern exists in some electrical connections
located under the
hood of a motor vehicle. One known device to deter separation of electrical
connectors
involves the use of mating connector housings that are snap fit together, a
lock disabler
being provided to prevent unsnapping thereof. U.S. patent no. 5,370,550 is an
example of
such a device. However, a device of this type may be disconnected, if desired.
Other
known devices rely upon the use of connector position assurance (CPA) members
such as
described in U.S. patent no. 5,236,373. In structures of this type the CPA
engages mating
connector housings exterior thereof to lock such housings together. Such a CPA
is not
designed for use with connectors having internal latches that are not exposed
to the outside
of the connector. However, when internal latches are provided, use of a CPA is
desirable to
assure that the connector housings and contacts therein are mated, since there
typically is no
visual indication of such niating. This may be a particular concern in view of
the tendency
towards smaller connector bodies that house smaller connector contacts that
make visual
indication less likely. Another concern in view of this tendency is the
requirement that such
smaller connector bodies imeet the same performance requirements as larger
conventional
embodiments. In order to enhance the performance of such smaller connector
bodies, it has
been determined that a pi-eferred material is LCP (liquid crystal polymer) or
a material
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having the same characteristics. Hereinafter, the material will be referred to
as LCP. Connector
bodies fabricated from this material must satisfy performance requirements of
the fmished
product. The performance characteristics of LCP material must also be taken
into
consideration. Another concern is that during fabrication of LCP connector
housings by, for
example, a conventional molding operation, the LCP material presents problems
regarding
weld line strength and filling characteristics of the material. Further, the
flexible yet stiff nature
of the LCP material presents concerns regarding the ability to fabricate a
practical smaller
connector module having a CPA and an internal latch.
DISCLOSURE OF THE INVENTION
It is desirable to provide a connector module that obviates the disadvantages
of the prior art.
It is also desirable to provide a connector module having a connector positive
assurance
member that can only be actuated when the connector module is fully engaged in
an engaged
mode.
It is further desirable to provide a connector module having a connector
positive assurance
member that is preinstalled in a pre-locked mode to one of the connector
housings of the
connector module.
It is desirable to provide a connector module having a connector positive
assurance member
and including a latch engagement member that is hidden from view when fully
engaged in an
engaged mode.
It is desirable to provide a connector module fabricated from LCP that meets
all of the
foregoing objectives.
It is desirable to provide a connector module that may be fabricated from LCP
having the
required weld line strength.
It is desirable to provide a relatively small connector module fabricated from
LCP and having a
CPA that has satisfactory rigidity and resistance characteristics.
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According to one aspect of the present invention, there is provided a
connector module,
comprising: a first connector housing extending from a first end portion to an
opposite second
end portion and comprising a lug extending from a first connector housing
wall; a second
connector housing extending from one end portion to an opposite end portion
and comprising a
resilient locking tongue, the locking tongue comprising a first tongue portion
extending from a
fixed end attached to a second connector housing wall to a first free end and
a second tongue
portion extending from the first free end to an opposite second free end, the
second free end
comprising an engagement member, the second connector housing being slidably
engagable
with the first connector housing in the direction of a longitudinal axis, to
fully engage and
disengage the lug and the engagement member in an engaged and disengaged mode,
respectively, the resilient locking tongue being structured and arranged such
that movement of
the first tongue portion towards the longitudinal axis causes movement of the
engagement
member away from the longitudinal axis in a disengaged mode, and release of
the first tongue
portion permits the engagement member to resile towards the longitudinal axis,
in an engaged
mode; and a positive assurance member movably attached to the second connector
housing and
structured and arranged such that in the engaged mode, movement of the
positive assurance
member in a locking direction causes the engagement member to ride over a
camming surface
of the lug and to resile toward the longitudinal axis and causes an arm of the
positive assurance
member to ride over the engagement member and to resile toward the
longitudinal axis so as to
position the positive assurance member in relation to the locking tongue to
sufficiently resist
the movement of the first tongue portion towards, and the engagement member
away from, the
longitudinal axis to lock engagement of the lug and the engagement member in a
locked mode.
An embodiment of the present invention is a connector module comprising a
first and second
connector housing and a positive assurance member. The first connector housing
extends from
a first end portion to an opposite second end portion and comprises a lug
extending from a first
connector housing surface. The second connector housing extends from one end
portion to an
opposite end portion and comprises a resilient locking tongue. The locking
tongues comprises a
first tongue portion extending from a fixed end, attached to a second
connector housing wall, to
a first free end, and a second tongue portion extending from the first free
end to an opposite
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second free end. The second free end comprises an engagement member. The
second connector
housing is slidably engagable with the first connector housing in the
direction of a longitudinal
axis to fully engage and disengage the lug and the engagement member in an
engaged and
disengaged mode, respectively. The resilient locking tongue is structured and
arranged such
that movement of the first tongue portion towards the longitudinal axis causes
movement of the
engagement member away from the longitudinal axis, in a disengaged mode, and
release of the
first tongue portion permits the engagement member to resile towards the
longitudinal axis, in
an engaged mode. The positive assurance member is movably attached to the
second connector
housing and is structured and arranged such that in the engaged mode, movement
of the
positive assurance member in a locking direction positions the positive
assurance member in
relation to the locking tongue to sufficiently resist the movement of the
first tongue portion
towards, and the engagement member away from, the longitudinal axis to lock
engagement of
the lug and the engagement member in a locked mode.
BRIEF DESCRIPTION OF THE DRAWINGS
This invention may be clearly understood by reference to the attached drawings
in that like
reference numerals designate like parts and in that:
FIG. 1 is an exploded perspective view of one embodiment of the connector
module of the
present invention;
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FIG. 2 is an end view of the connector housing 14 of FIG. 1;
FIG. 3 is a perspective view of the connector housing 14 of FIG. 1 viewed from
the bottom;
FIG. 4 is a cross-sectional view of the connector housing 14 of FIG. 1
illustrating the
positive assurance member of one embodiment of the present invention in a pre-
locked
mode;
FIG. 5 is a cross-sectional view similar to FIG. 4 but illustrating the
positive assurance
member in a locked mode without the connector housing 12 attached to the
connector
housing 14;
FIG. 6 is a bottom perspective view of the positive assurance member of FIG.
1;
FIG. 7 is a top perspective view of the positive assurance member illustrated
in FIG. 6;
FIG. 8 is a plan view of the positive assurance member of FIG. 7 illustrated
within the
connector housing 14 of FIG. 1 in a pre-locked mode;
FIG. 9 is an enlarged view of the detents of the positive assurance member of
FIG. 8; and
FIGS. l 0a to I Od illustrate the operation of the connector module of FIG. 1.
BEST MODE FOR CARRYING OUT THE INVENTION
For a better understanding; of the present invention, together with other and
further objects,
advantages and capabilities thereof, reference is made to the following
disclosure and
appended claims taken in conjunction with the above-described drawings.
The embodiment of this invention that is illustrated in the drawings is
particularly suited for
achieving the objects of this invention. FIGS. 1 to 3 illustrate a connector
module
comprising a first connector housing 12 and a second connector housing 14.
Housings 12
and 14 are slidably engagable with each other as explained herein. The
connector module
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illustrated in FIGS. 1 to 3 also comprises a connector positive assurance
member 16.
The connector housing 12 extends in direction 18 of an axis 20 from an end
portion 22 to an
opposite end portion 24. Housing 12 comprises a cavity 26 therein and a
housing base 28
having holes 30 through that mounting members such as screws (not shown) may
be
inserted for mounting the: housing 12 to a support surface such as an
automobile panel.
Housing 12 comprises a plurality of contacts therein(not shown) each of that
extends
through a respective bore 32 in the base 28 and into cavity 26. The end of
each contact
extending out of cavity 26 from the surface 34 of the base 28 may be connected
to a suitable
conductor in a conventional manner. The contacts within housing 12 may be
conventional
male or female contacts. In the embodiment illustrated in FIGS. 1 to 3, the
contacts within
cavity 26 are male contacts. End portion 24 is structured and arranged to mate
with the
housing 14. To facilitat:e such mating, the housing 12 comprises a key member.
In
particular, housing 12 coniprises an elongated key 36 that extends from
surface 38. Key 36
is directed in the direction 18 of axis 20. The housing 12 comprises a lug 40
extending from
a surface 42. Lug 40 comprises an angular lug camming surface 44 and a lug
abutment
surface 46.
The connector housing 14 extends in the direction 48 of an axis 50 from an end
portion 52
to an opposite end portion 54. Housing 14 comprises a cavity 56 therein and a
cover 58 that
encloses the end portion 52. Housing 14 comprises a plurality of contacts
therein (not
shown). A plurality of conductors extend into housing 14, each conductor being
connected
to a respective contact. In particular, each conductor (not shown) extends
through a
respective bore 60 in cover 58 for conventional electrical and mechanical
attachment to a
respective contact. For example, each conductor may be soldered to a
respective contact in
the usual manner. The contacts within housing 14 may be conventional male or
female
contacts. In the embodim-ent illustrated in FIG. 1, the contacts within cavity
56 are female
contacts. Housing 14 corr.iprises a cover 62 within cavity 56, such cover
having a pluralit.y
of bores 64 that are in alignment with the male contacts within the housing
12. End portion
54 is structured and arranged to mate with the end portion 24 of housing 12.
To facilitate
such mating, housing 14 comprises a key member. In particular, housing 14
comprises an
elongated keyway 66 that extends adjacent wall 68 of cavity 56. Keyway 66 is
directed in
the direction 48 of axis 50.. The key 36 and keyway 66 are structured and
arranged to mate
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with one another to facilit:ate the slidable engagement of the housings 12 and
14. The male
and female contacts in respective housings 12 and 14 are structured and
arranged to mate
with each other in a conventional manner during such slidable engagement to
provide
electrical and mechanical connection between each.
With reference to FIGS. 1 to 5, the connector housing 14 comprises a resilient
locking
tongue 70 comprising a first tongue portion 72 extending from a fixed end 74
attached to a
wall 76 of the housing 14 towards the first end portion to 52. The first
tongue portion 72
extends to a first free end 78. The locking tongue 70 comprises a second
tongue portion 80
that extends from the free; end 78 towards the second end portion 54. The
second tongue
portion 80 extends to a second free end 82. The free end 82 comprises an
engagement
member 84. Such structure provides a latch member in the form of the second
tongue
portion 80 that is connected to the connector housing 14 by a separate flex
member in the
form of the first tongue portion 72 that is located at a finger depression
area. In this manner,
extreme stress concentration is not built up at the pivot point of the locking
tongue 70.
Such structure also allow's for satisfactory deflection of the latch member in
a relatively
small connector module. Further, such structure pennits the desired deflection
at the thumb
pad provided by the first tongue portion 72 thereby creating the desired
deflection of the
second tongue portion 80. Molding of the housing 14 is easier due to the
structured features
of the tongue 70.
The connector housing 12 and its lug 40 are slidably engagable with the
connector housing
14 and engagement meniber 84, in the directions 86 and 86', of a connector
module
longitudinal axis 88 to fuilly engage the lug and the engagement member in an
engaged
mode, and disengage the lug and the engagement member in a disengaged mode,
respectively, as described herein. When the housings 12 and 14 are in the
engaged mode,
the axis 88 will be coincident with axes 20 and 50.
With reference to FIG. 4, the resilient locking tongue 70 is structured and
arranged such that
depression of the first tongue portion 72 in the direction 90 towards axis 50
will urge the
engagement member 84 in the direction 92 away from the axis 50. When the
housings 12
and 14 are attached to each other, such depression permits detachment thereof
in the
disengaged mode as described herein.
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The positive assurance member 16 is movably attached to the connector housing
14. The
positive assurance member 16 is structured and arranged such that in the
engaged mode,
movement of the positive assurance member towards end portion 54 serves to
position the
positive assurance member in a locking mode wherein the positive assurance
member will
sufficiently resist movement of (a) the first tongue portion 72 in direction
90 towards axis
88 and (b) the engagernent member 84 in direction 92 away from axis 88, to
lock
engagement of the lug 40 and engagement member 84 in the engaged mode; that
is, to
prevent disengagement of' the lug and the engagement member. To this end, the
positive
assurance member of the present invention may comprise at least one first
abutment
member and at least one second abutment member. The first and second abutment
members
may be structured and arranged such that when in the locking mode, (a) at
least one first
abutment member surface is positioned relative to the locking tongue 70 to
resist movement
of the tongue portion 72 towards the axis 88, and (b) at least one second
abutment member
surface is positioned relative to the locking tongue to resist movement of the
engagement
member 84 away from axis 88. For example, in the embodiment illustrated in
FIGS. 1, 4
and 5, the second tongue portion 80 of locking tongue 70 comprises a first leg
94 and a
second leg 96 each of that extends in the direction 48 of axis 50 from the
free end 78 to the
engagement member 84. The legs 94 and 96 are spaced from each other to provide
an
opening 98 therebetween. The positive assurance member 16 comprises a base 100
and a
first abutment member in the form of a resilient first arm 102 extending from
the base in the
direction 48 of axis 50 into the opening 98. The first ann 102 is structured
and arranged
such that in the engaged rnode, movement of the positive assurance member 16
in a locking
direction 104 relative to axis 88 serves to position a surface of the first
arm adjacent the
engagement member 84 sa as to sufficiently resist movement of the engagement
member in
direction 92 and out of engagement with the lug 40 as described in more detail
hereinafter.
In the embodiment illustrated in FIGS. 1 and 5-7, the positive assurance
member 16
comprises two second abuitment members in the form of a first region 106 and a
second
region 108. Only region 108 is visible in FIG. 5. The first and second regions
106, 108 are
structured and arranged such that in the engaged mode, movement of the
positive assurance
member 16 in the direction 104 serves to position the regions 106 and 108
relative to the
first and second legs 94, 96 of the locking tongue 70 so as to sufficiently
resist movement of
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the first tongue portion 72 in direction 90 thereby further resisting the
urging of the
engagement member 84 in direction 92.
If desired, the positive assurance member of the present invention may be
structured and
arranged such that in the locking mode a first distal end surface of the first
abutment
member engages a first surface of the engagement member so as to prevent
unlocking of the
positive assurance member. For example, in the embodiment illustrated in FIG.
5, the first
arm 102 comprises a hook-like distal end segment 110 that comprises a first
distal end
surface 112. The resilient first arm 102 is structured and arranged such that
in the locking
mode the surface 112 engages a surface 114 of the engagement member 84 so as
to prevent
movement of the positive assurance member in the direction 104' thereby
preventing
unlocking of the engaged lug 40 and engagement member 84.
If desired, the positive assurance member of the present invention may
comprise at least one
detent, and the second connector housing may comprise at least one detent
abutment
member, the detent being structured and arranged to engage the detent abutment
member to
attach the positive assurance member to the second connector housing in a pre-
locked mode.
For example, in the embodiment illustrated in FIGS. 6 to 8, the positive
assurance member
16 comprises a resilient second arm 116 and an opposite resilient third arm
118 extending
from the base 100 in the clirection 48 of axis 50. Arms 116 and 118 provide
resistance and
rigidity useful in a relatively small connector module. The arms 116 and 118
are spaced
from each other to provide an opening 120 therebetween. The first arm 102
extends into
opening 120 between the second arm 116 and third arm 118. With reference to
FIG. 8, the
arm 116 comprises a detent 122 and the arm 118 comprises a detent 124. The
second
connector housing 14 com;prises a first detent abutment member 126 and an
opposite second
detent abutment member 128 extending from respective walls 68 and 130 of
cavity 56. The
detents 122 and 124 are structured and arranged to engage the detent abutment
members
126 and 128, respectively, to attach the positive assurance member 16 to the
housing 14 in
the pre-locking mode. Such arrangement prevents movement of the positive
assurance
member in directions 104 and 104'.
If desired, the first abutment member of the positive assurance member may
comprise a
second distal end surface lhat engages a second surface of the engagement
member in the
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pre-locking mode. In such embodiment, such second distal end surface and
second surface
of the engagement member, and the detents and the detent abutment members, may
be
structured and arranged to resist movement of the positive assurance member in
the
directions 104 and 104' except in the engaged mode. For example, in the
embodiment
illustrated in FIG. 4, the distal end segment 110 may comprise a second distal
end surface
132 that is opposite the fnst distal end surface 112. The resilient first arm
102 is structured
and arranged such that in the pre-locked mode, the surface 132 engages a
surface 134 of the
engagement member 84. Surface 134 is opposite surface 114. In this embodiment,
surface
132 is structured and arranged relative to the surface 134, and the detent 122
and 124 are
structured and arranged relative to respective detent abutment members 126 and
128, to
provide resistance to movement of the positive assurance member 16 in the
directions 104
and 104' except when the housings 12 and 14 are being slidably engaged as
described
hereinafter.
The embodiment illustrated in the drawings may be fabricated from LCP by
molding.
Heretofore, filling of the inold to form an LCP connector housing 14 created a
weak weld
line that tended to cause the connector housing to split in the direction 48
of axis 50 along
the wall portion 136 and the wall portion 138 that extends therefrom and forms
the first
tongue portion 72. To overcome this problem, the housing 14 may be molded from
LCP in
such a manner that the wall portions 136 and 138 comprise a rib 140 that
extends from end
portion 54 towards end portion 52 in the direction 48 of axis 50. Rib 140
eliminates the
tendency for the housing 14 to split at the surface portions 136 and 138 and
also provides
reinforcement at the first tongue portion 72 that is flexed during use of the
connector
module.
In the embodiment illustrated in FIGS. 6 to 8, the positive assurance member
16 comprises
a bridging member 142 that extends between the first arm 102 and the second
arm 116, and
the first arm 102 and the third arm 118.
The positive assurance member of the present invention may be structured and
arranged to
assure that in the pre-locked mode the positive assurance member remains in a
fixed
position relative to the second connector housing, and in the engaged mode the
positive
assurance member is moveable to a locked mode. For example, with reference to
FIGS. 6 to
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9, the detents 122 and 124 may each comprise a first detent surface 144, and
an opposite
second detent surface 146, extending from a detent base 148. In such
embodiment, the first
and second detent abutnlent members 126 and 128 extend between respective
detent
surfaces 144 and 146 in the pre-locked mode. With reference to FIG. 9, each
first detent
surface 144 extends from the detent base 148 a first length 150 and at a first
angle 152 that
are sufficient to substantially permanently attach the positive assurance
member to the
connector housing 14 in the pre-locked mode. Each second detent surface 146
extends from
the detent base 148 a second length 154 and at a second angle 156 that are
sufficient to
permit movement of the positive assurance member 16 in the direction 104
relative to the
longitudinal axis 88 when the connector module is in the engaged mode, as
described
hereinafter. In the embodiment illustrated in FIGS. 6 to 9, angle 152 is 90
and the length
150 is such that in combination with the 90 orientation of the detent surface
144, once in
the pre-locked position illustrated in FIG. 8, movement of the positive
assurance member 16
in direction 104' is not possible. The angle 156 is an acute angle and the
length 154 is such
that in combination with the acute angular orientation of the detent surface
146, movement
of the positive assurance rnember 16 in direction 104 is possible when the
housings 12 and
14 are in the engaged mode.
The use of the connector module illustrated in the drawings is described
hereinafter. The
connector housing 14 and positive assurance member 16 are first assembled in a
pre-locked
mode. To this end, the positive assurance member 16 is inserted into opening
56 of housing
14 from end portion 52 in direction 104 as best illustrated in FIGS 3 and 8.
In particular, the
ends 82, 158 and 160 of arms 102, 116 and 118, respectively, are inserted into
the opening
56 such that legs 116 and 118 slide along channel surfaces 162 and 164 of
housing 14, and
leg 102 slides within opening 98 between legs 94 and 96 of the locking tongue
70. Sliding
continues until the surface 132 of the end 82 of the arm 102 is adjacent the
surface 134 of
the engagement member 84, and the detent abutment members 126 and 128 engage
respective detents 122 and 124, in the pre-locked mode illustrated in FIG. 8.
In such
position, the positive assurance member 16 is locked to the connector housing
14. In
particular, movement of the positive assurance member 16 in direction 104 will
be
prevented by engagement of surfaces 132 and 134, and movement in the direction
104' will
be prevented by engagement of the detent abutment members 126 and 128 with
respective
detent surfaces 144 of respective detents 122 and 124.
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With reference to FIGS. 1 and l0a to lOc, when it is desired to connect
together the
connector housings 12 anci 14, the key 36 is mated with the keyway 66, and the
end portion
26 of housing 12 is then inserted into opening 56 of housing 14 at end portion
54. As the
housing 12 is inserted into opening 56, the surface 44 of lug 40 engages the
surface 114 of
the engagement member 84 of the locking tongue 70 as illustrated in FIG. 10a.
Continued
movement of the housing 12 into the opening 56 causes the surface 44 to cam
the
engagement member 84 in direction 92 until the engagement member rests upon
the upper
surface 166 of the lug 40 as illustrated in FIG. l Ob. Continued movement of
the housing 12
into the opening 56 causes (a) the engagement member 84 to resile in direction
92' such that
surface 134 of the engagement member 84 is adjacent surface 46 of the lug, and
(b) the
surface 44 to cam the distal end segment 110 of the arm 102 in direction 92
until the
segment 110 rests upon the upper surface 166 of the lug 40 as illustrated in
FIG. l Oc. When
in the position illustrated in FIG. l Oc, the connector housings 12 and 14 are
fully attached to
one another in the engaged mode.
When in the position illustrated in FIG. lOc, the housings 12 and 14 may be
disengaged
from each other by placing the locking tongue 70 in a disengaged mode by
depressing the
first tongue portion 72 of' the locking tongue 70 in direction 90 sufficiently
to cause the
engagement member 84 to move in direction 92 to thereby move surface 134 out
of the path
of the surface 46 of the lug 40. In such position, the lug 40 will no longer
engage the
engagement member 84 when the housings are moved in direction 86' and
therefore will no
longer prevent disengagem.ent of the housings 12 and 14.
With reference to FIGS. 8, 9 and l Od, when it is desired to lock the
connector housings 12
and 14 together after they are in the engaged mode, the positive assurance
member 16 is
urged in direction 104 with sufficient force that the resilient legs 116 and
118 flex
sufficiently to overcome 'the resistance to movement in direction 104 provided
by the
engagement of the detent surfaces 146 with respective detent abutment members
126 and
128. Continued movement of the positive assurance member 16 is direction 104
causes the
distal end segment 110 of' the arm 102 to resile in direction 92' such that
lug 40 enters
opening 98 between legs 94 and 96, and surface 112 is adjacent surface 114 as
illustrated in
FIG. l Od. When in this position the surface 168 of the arm 102 is adjacent a
surface 170 of
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the engagement member 84 of the locking tongue 70, and the regions 106 and 108
of the
positive assurance member 16 are adjacent surfaces 172 of respective legs 94
and 96 of the
locking tongue. In this locked mode illustrated in FIG. 10d, the connector
housings 12 and
14 can not be disconnected because the surface 134 of the engagement member of
the
locking tongue 70 of housing 14 can not be removed from engagement with the
surface 46
of the lug 40 of housing 12. Such removal is prevented because the engagement
of the
regions 106 and 108 with the surfaces 172 prevents depression of the first
tongue portion 72
in direction 90, and engagement of the surface 168 with the surface 170 will
prevent
movement of the engagement member 84 in the direction 92.
The embodiments that have been described herein are but some of several that
utilize this
invention and are set forth here by way of illustration but not of limitation.
It is apparent
that many other embodiments that will be readily apparent to those skilled in
the art may be
made without departing materially from the spirit and scope of this invention.
