Self-aligning electrical connector assembly for flat power cable terminations

• US 5,080,604 A
• Filed: 11/13/1990
• Issued: 01/14/1992
• Est. Priority Date: 11/13/1990
• Status: Expired due to Term

• Current Assignee: AMP Incorporated (Johnson Controls International plc)
• Original Assignee: AMP Incorporated (Johnson Controls International plc)
• Inventors: Szczesny, David S., Rider, Frederick H.
• Primary Examiner(s): Abrams, Neil
• Assistant Examiner(s): NGUYEN, KHIEM M
• Application Number:
  US07/612,945
• Time in Patent Office: 427 Days
• Field of Search: 439/246, 439/247, 439/248, 439/350, 439/357, 439/358, 439/422, 439/495, 439/493, 439/492, 439/494, 439/496, 439/497, 439/498, 439/677, 439/678, 439/679, 439/680, 439/681 , 439/701
• US Class Current: 439/357
• CPC Class Codes: H01R 12/79 connecting to rigid printed circuits or like structures
• CPC Class Codes: H01R 13/631 for engagement only

Abstract

An electrical connector assembly including integral means for self-alignment and adapted to be used with flat power cable having relatively wide terminals terminated thereonto. A polarizing system is provided complementary to said self-alignment which provides assured mating prevention upon improper connector polarizing orientation. One embodiment is adapted for rack and panel applications where one of the connectors is float mounted. Another embodiment is adapted for delatchably latching together of the connectors with low profile latch arms. A system of polarizing the assembly of terminated dual conductor cables in a housing is provided for control of the electrical connections of the two conductors of each flat cable, by using a polarizing projection on one of the two terminals on each cable, and a corresponding channel along the appropriate one the terminal-receiving cavities of the housing for passing of the projection upon proper cable orientation.

Claims

1. An electrical connector assembly for connecting a plurality of flat power cables each having a pair of flat conductors, with another electrical conductive means along a separable mating interface, comprising:

a first connector having a dielectric first housing including a plurality of first terminal-receiving cavities in communication with a mating face and a hood section forwardly of said mating face, said first connector further having a plurality of first electrical terminals terminated onto ends of respective flat conductors of said plurality of flat power cables and disposed in respective said first terminal-receiving cavities and including wide blade-shaped contact sections extending forwardly of said mating face and within said hood section to leading ends recessed behind a leading edge of said hood section, and said first connector further including a dielectric rear cover member securable onto a rearward face of said first housing after said first terminals have been disposed therein in a manner permitting said plurality of flat power cables to exit said first housing;

a second connector having a dielectric housing including a plurality of second terminal-receiving cavities in communication with a mating face at a forward end of a plug section thereof, said plug section adapted to be received into said hood section of said first connector housing, said second connector further including a plurality of second electrical terminals secured in respective said second terminal-receiving cavities, said second terminals including wide forward contact sections adapted to be electrically engaged with said blade-shaped contact sections of said first terminals upon mating of said first and second connectors, and said second terminals further including rearward contact sections at least exposed along a rearward face of said second housing to be electrically engaged with corresponding conductor means of another electrical article;

at least one of said first and second connectors being mounted on another article in a manner permitting limited transverse movement with respect thereto;

said second housing including blade-receiving apertures into said mating face thereof adapted to receive said blade-shaped contact sections of said first terminals during intermediate stages of connector mating and to engage with and align leading ends of said blade-shaped contact sections; and

said first connector including means for engaging said first terminals terminated onto said respective flat cables proximate respective rearward terminal ends and at said mating face proximate base portions of said blade-shaped contact sections to center and stabilize said first terminals in an axially aligned orientation in a manner permitting incremental adjustment of said blade-shaped contact sections upon receipt into corresponding said blade-receiving apertures of said second connector just prior to electrical engagement of said contact sections of said first and second terminals during mating.

2. The electrical connector assembly as set forth in claim 1 wherein said means for engaging said rearward terminal ends comprise U-shaped bosses extending forwardly from a transverse body section of said rear cover to retain rearward bight sections of said first terminals adjacent lateral edges of said respective flat cables.

3. The electrical connector assembly as set forth in claim 2 wherein said transverse body section of said rear cover is spaced from rearward edges of said first housing along said rearward face thereof to define cable exits extending perpendicularly to axes of said first terminal-receiving cavities, and said U-shaped bosses provide said first terminal rearward ends with relief from strain applied by said flat cables otherwise tending to urge said first terminal rearward ends out of alignment.

4. An electrical connector assembly for connecting a plurality of electrical conductor cables, with another electrical conductive means along a separable mating interface, comprising:

a first connector having a dielectric first housing including a plurality of first terminals secured within first terminal-receiving cavities and including first contact sections extending forwardly of a housing mating face and within a hood section of said first housing to leading ends recessed behind a leading edge of said hood section;

a second connector having a dielectric housing including a plurality of second terminals secured within second terminal-receiving cavities and including second contact sections positioned within a plug section of said second housing and exposed along a mating face thereof and adapted to be electrically engaged with said contact sections of said first terminals upon mating of said first and second connectors, said plug section adapted to be received into said hood section of said first connector housing;

at least one of said first and second connectors being mounted on another article in a manner permitting limited transverse movement with respect thereto, and said first and second connectors including cooperable means for precisely aligning said first and second housings thereof during initial stages of connector mating by urging at least said one of said first and second connectors incrementally transversely upon cooperative engagement of said cooperable alignment means, thereby aligning said contact sections of corresponding ones of said first and second terminals prior to engagement therebetween;

said first and second housings further including cooperable polarizing means, said first housing including polarizing keys selectively positioned angularly about said hood section and extending axially along inside surfaces thereof rearwardly from a substantially transverse leading end recessed from a leading edge of said hood section, and said second housing including keyways defined axially along outside surfaces of said plug section rearwardly from a leading edge thereof and selectively positioned angularly thereabout corresponding to said polarizing keys of said first housing to permit connector mating upon proper polarizing orientation thereof; and

said second housing further having blind keyways extending partially along said outside surfaces of said plug section from a leading edge thereof and selectively positioned angularly thereabout to initially receive thereinto said leading ends of said polarizing keys of said first housing during initial mating stages upon improper polarizing orientation thereof, said blind keyways including substantially transverse rearward ends defining stop surfaces positioned closely to said keyway entrances to assuredly prevent further movement of said first and second connectors toward each other and assuredly indicate improper polarizing orientation prior to engagement said first and second terminals.

5. The electrical connector assembly of claim 4 wherein said second housing includes at least a pair of alignment projections extending forwardly of said mating face thereof to frustoconical leading ends defining bearing surfaces, and said hood section of said first housing includes projection-receiving recesses defined along inside surfaces thereof and extending inwardly from said leading edge thereof adapted to receive thereinto and therealong respective said alignment projections of said second housing upon mating of said first and second connectors, said bearing surfaces engageable with portions of said hood leading edge during initial stages of connector mating to urge said at least one of said first and second connectors incrementally transversely to precisely align said first and second connectors prior to engagement of said first and second terminals during later stages of connector mating;

and

said polarizing keys are defined along said projection-receiving recesses of said hood section, and said polarizing keyways and said blind keyways are defined along said alignment projections with said entrances thereof defined on said frustoconical leading ends thereof.

6. An electrical connector assembly comprising:

a plug connector including a plug housing having a forward plug portion and a receptacle connector including a receptacle housing having a forward hood section adapted to receive said plug portion thereinto during connector mating, and at least said receptacle connector having a rear cover member securable onto the rear face of said receptacle housing;

said rear cover including a pair of latch arms adapted to coextend partially along opposing sides of said receptacle housing upon connector assembly, each said latch arm including a forward free end including an inwardly directed latching projection, and each said latch arm adapted to be deflectable outwardly at said free end;

said receptacle housing including apertures through said opposing sides thereof in communication with a large plug-receiving cavity defined by said forward hood portion, and said latching projections of said latch arm free ends extending inwardly through said apertures and partially into said plug-receiving cavity; and

said plug housing including channels along sides thereof corresponding to said sides of said receptacle housing and aligned with said latch arms, and extending rearwardly from a rearwardly facing latching surface at a location spaced rearwardly from a leading edge of said forward plug portion of said plug housing,

whereby said latching projections of said latch arm free ends of said receptacle housing are adapted to resile into said plug housing channels rearwardly of said latching surfaces and latch said plug connector and receptacle connector together upon mating thereof while not substantially increasing the width of said receptacle connector nor extending forwardly thereof.

7. An electrical connector assembly as set forth in claim 6 wherein said latch arms each include manually grippable sections rearwardly of a hinge about which said latch arm is rotatable during deflection, enabling inward deflection of said manually grippable section to pivot said forward latch arm free end outwardly to delatch said receptacle connector from said plug connector for unmating.

8. An electrical connector assembly for connecting a plurality of flat power cables each having a pair of flat conductors, with another electrical conductive means along a separable mating interface, comprising:

a first connector having a dielectric first housing including a plurality of laterally adjacent pairs of first terminal-receiving cavities in communication with a mating face and a hood section forwardly of said mating face, said first connector further having a plurality of first electrical terminals terminated in laterally adjacent pairs onto ends of respective flat conductors of said plurality of flat power cables with one of each pair of terminals being terminated onto a selected one of said pair of conductors of a respective said flat cable, said first electrical terminals being disposed in respective said first terminal-receiving cavities and including wide blade-shaped contact sections extending forwardly of said mating face and within said hood section to leading ends recessed behind a leading edge of said hood section, and said first connector further including a dielectric rear cover member securable onto a rearward face of said first housing after said first terminals have been disposed therein in a manner permitting said plurality of flat power cables to exit said first housing;

a second connector having a dielectric housing including a plurality of second terminal-receiving cavities in communication with a mating face at a forward end of a plug section thereof, said plug section adapted to be received into said hood section of said first connector housing, said second connector further including a plurality of second electrical terminals secured in respective said second terminal-receiving cavities, said second terminals including wide forward contact sections adapted to be electrically engaged with said blade-shaped contact sections of said first terminals upon mating of said first and second connectors, and said second terminals further including rearward contact sections at least exposed along a rearward face of said second housing to be electrically engaged with corresponding conductor means of another electrical article;

each said pair of first electrical terminals containing a polarizing projection at least proximate the forward end of one of said blade-shaped contact sections associated with a selected one of said pair of conductors of said flat cable, and one of each said pair of terminal-receiving cavities including a corresponding polarizing means cooperable with said polarizing projection of said one contact section to permit complete insertion of said terminated cable end into said housing by permitting said one contact section to be fully inserted through said respective terminal-receiving cavity when said terminated cable end has been positioned in an appropriately polarized orientation prior to assembly while complete insertion of said terminated cable end into said first housing is prevented when said terminated cable end has not been appropriately polarized by disallowing said one contact section to be inserted into the noncorresponding one of said pair of terminal-receiving cavities not containing a polarizing means corresponding to said polarizing projection,

whereby said terminals terminated onto respective said conductors of said flat cable can be secured in said first housing in only one desired arrangement for said conductors to be electrically connected to appropriate conductive means upon mating of said first and second connectors.

9. An electrical connector assembly as set forth in claim 8 wherein said polarizing projection is a lance formed on a leading edge of said one blade-shaped contact section to extend at an angle forwardly and in a selected direction laterally far enough to create a local terminal width larger than the corresponding general width of a said terminal-receiving cavity, and said polarizing means is a channel of said one terminal-receiving cavity aligned with said lance and deep enough to permit passage of said lance during insertion of said one contact section through said one terminal-receiving cavity.

10. An electrical connector assembly as set forth in claim 8 wherein said polarizing projection is located in a position not associated with a corresponding portion of a mating one of said second electrical terminals upon connector mating, and said second housing is adapted to receive said one blade-shaped contact section thereinto without interference.