Electrical connector assembly

• US 7,094,081 B1
• Filed: 03/24/2005
• Issued: 08/22/2006
• Est. Priority Date: 03/24/2005
• Status: Active Grant

• Current Assignee: Aptiv Technologies AG (Aptiv PLC)
• Original Assignee: Delphi Technologies, Inc. (BorgWarner Incorporated)
• Inventors: Reedy, Patrick J., Senk, Joseph M., Blasko, Raymond J., Daggett, Barry M.
• Primary Examiner(s): Gilman, Alexander
• Application Number:
  US11/088,420
• Time in Patent Office: 516 Days
• Field of Search: 439/157, 439/160, 439/310, 439/342, 439/372, 361/752, 361/776, 361/791
• US Class Current: 439/157
• CPC Class Codes: H01R 13/447 Shutter or cover plate
• CPC Class Codes: H01R 13/62938 Pivoting lever comprising own camming means
• CPC Class Codes: H01R 13/6295 Pivoting lever comprising means indicating incorrect coupling of mating connectors
• CPC Class Codes: H01R 13/62955 Pivoting lever comprising supplementary/additional locking means
• CPC Class Codes: H01R 13/62966 Comprising two pivoting levers
• CPC Class Codes: H01R 2201/26 for vehicles
• CPC Class Codes: H01R 9/2425 Structural association with built-in components for coupling parts H01R13/66
• CPC Class Codes: H01R 9/2458 Electrical interconnections between terminal blocks
• CPC Class Codes: H01R 9/2491 Terminal blocks structurally associated with plugs or sockets

Abstract

The present invention provides an electrical connector assembly and a method of mating the same. The electrical connector assembly includes a panel sub-assembly which mates to at least one electrical connector body. Preferably two cam leveraging devices which rotate in opposing directions are mounted rotatably to the panel sub-assembly for sliding engagement of respective cam studs engaged rigidly to the electrical connector body. Opposing rotations of the cam leveraging devices along respective and parallel rotation axes causes the panel sub-assembly to move linearly along a mating axis disposed orthogonally to the rotation axes and toward the electrical connector body to a staged position. During linear panel sub-assembly movement from the disconnected position to the staged position, the cam studs slide against a first portion of a track carried by respective cam levers and which generally spirals radially inward toward the rotation axis. Reversing rotation of both cam leveraging devices causes the panel sub-assembly to continue linear movement toward the electrical connector body from the staged position and to a mated position. During linear panel sub-assembly movement from the staged position to the mated position, the cam stud lifts off of the first portion, and is caught by and slides along a second portion of the track to a mated end.

Claims

1. An electrical connector assembly comprising:

an electrically insulating connector body;

an electrically conductive first terminal engaged rigidly to the connector body;

an electrically insulating panel sub-assembly constructed and arranged to mate with the electrical connector body along a mating axis;

an electrically conductive second terminal engaged rigidly to the panel sub-assembly and constructed and arranged to mate with the first terminal along the mating axis;

a first cam stud engaged to the electrical connector body;

a second cam stud engaged to the electrical connector body;

a first cam lever attached rotatably to the panel sub-assembly about a first rotation axis disposed orthogonally to the mating axis, wherein the first cam lever is in sliding contact with the first cam stud and rotates clockwise to move the panel sub-assembly linearly along the mating axis toward the electrical connector body; and

a second cam lever attached rotatably to the panel sub-assembly about a second rotation axis disposed orthogonally to the mating axis and parallel to the first rotation axis, wherein the second cam lever is in sliding contact with the second cam stud and rotates counter-clockwise to move the panel sub-assembly linearly along the mating axis toward the electrical connector body and to counter a moment created by the generally simultaneous rotation of the first cam lever;

the first cam lever having a cam track for sliding contact with the first cam stud;

the cam track having;

a first portion extending gradually radially inward toward the first rotation axis from a receiving end for initial contact of the cam stud to a staging end; and

a second portion being in disconnected relationship to the first portion and extending gradually radially inward toward the first rotation axis from a catch end to a mated end;

wherein the first portion spirals radially inward toward the first rotation axis generally in a first circumferential direction and the second portion spirals radially inward toward the rotation axis generally in an opposite circumferential direction.

2. The electrical connector assembly set forth in claim 1 further comprising:

a cam track carried by each of the first and second levers for sliding contact with the respective first and second cam studs; and

wherein the cam tracks generally spiral toward the respective first and second rotation axes.

3. The electrical connector assembly set forth in claim 1 wherein the first rotation axis is spaced laterally away from the second rotation axis.

4. The electrical connector assembly set forth in claim 3 further comprising an imaginary plane disposed orthogonally to the central mating axis and containing the first and second rotation axes.

5. The electrical connector assembly set forth in claim 1 further comprising:

an arm of each of the first and second cam levers projecting radially outward with respect to the respective first and second rotation axes; and

a flexible flap projecting tangentially outward from each of the arms with respect to the respective first and second rotation axes, the flap being snap locked to the panel sub-assembly when the electrical connector assembly is mated.

6. The electrical connector assembly set forth in claim 5 further comprising:

an exterior shelf carried by the panel sub-assembly and facing axially toward the electrical connector body with respect to the mating axis; and

a ramped tab carried by the respective flaps and snap locked to the exterior shelf when the electrical connector assembly is mated.

7. The electrical connector assembly set forth in claim 1 further comprising:

a first and an opposite second side wall of the panel sub-assembly disposed substantially orthogonally to the first and second rotation axes;

a third cam stud engaged to the electrical connector body and aligned to the first cam stud along a first centerline disposed substantially parallel to the first rotation axis;

a fourth cam stud engaged to the electrical connector and aligned to the second cam stud along a second centerline disposed substantially parallel to the second rotation axis;

a first leveraging device engaged rotatably to the panel sub-assembly and about the first rotation axis, the first leveraging device having the first cam lever and a third cam lever; and

a second leveraging device engaged rotatably to the panel sub-assembly and about the second rotation axis, the second leveraging device having the second cam lever and a fourth cam lever.

8. The electrical connector assembly set forth in claim 7 further comprising:

first and third arms of the respective first and third cam levers projecting radially outward with respect to the first rotation axis;

second and fourth arms of the respective second and fourth cam levers projecting radially outward with respect to the second rotation axis;

a first handle of the first leverage device extending between the first and third arms; and

a second handle of the second leverage device extending between the second and fourth arms.

9. The electrical connector assembly set forth in claim 8 wherein the first handle is parallel to the first rotation axis and the second handle is parallel to the second rotation axis.

10. An electrical connector assembly comprising:

an electrically insulating connector body;

an electrically conductive first terminal engaged rigidly to the connector body;

an electrically insulating panel sub-assembly constructed and arranged to mate with the electrical connector body along a mating axis;

an electrically conductive second terminal engaged rigidly to the panel sub-assembly and constructed and arranged to mate with the first terminal along the mating axis;

a first cam stud engaged to the electrical connector body;

a second cam stud engaged to the electrical connector body;

a first cam lever attached rotatably to the panel sub-assembly about a first rotation axis disposed orthogonally to the mating axis, wherein the first cam lever is in sliding contact with the first cam stud and rotates clockwise to move the panel sub-assembly linearly along the mating axis toward the electrical connector body;

a second cam lever attached rotatably to the panel sub-assembly about a second rotation axis disposed orthogonally to the mating axis and parallel to the first rotation axis, wherein the second cam lever is in sliding contact with the second cam stud and rotates counter-clockwise to move the panel sub-assembly linearly along the mating axis toward the electrical connector body and to counter a moment created by the generally simultaneous rotation of the first cam lever; and

a cam track carried by each of the first and second levers for sliding contact with the respective first and second cam studs;

wherein the cam tracks generally spiral toward the respective first and second rotation axes;

wherein the first and second studs each have a diameter and a centerline disposed substantially parallel to the respective first and second rotation axes;

wherein a first portion of the cam tracks generally face the respective first and second rotation axes and have a radially outward receiving end for initial receipt of the respective first and second studs and an opposite, radially inward, staging end;

wherein a second portion of the cam tracks are in disconnected relationship to the first portion and generally face the respective first and second rotation axes, the second portion having a radially outward catch end and an opposite, radially inward, mated end; and

wherein the catch end generally faces the rotational center and faces the staging end, and is spaced from the staging end by a distance which is greater than the diameter of the respective first and second studs.

11. The electrical connector assembly set forth in claim 10 wherein the first and second cam studs are disposed at the respective receiving ends when the panel sub-assembly is in a disconnected position, and wherein clockwise rotation of the first cam lever and counter clockwise rotation of the second cam lever causes the panel sub-assembly to move linearly along the mating axis from the disconnected position and to a staged position as the first and second studs slide along the respective first portions from the receiving end to the staging end.

12. The electrical connector assembly set forth in claim 11 wherein the counter-clockwise rotation of the first cam lever and clockwise rotation of the second cam lever when the panel subassembly is initially in the staged position causes the panel sub-assembly to move linearly along the mating axis to a mated position as the first and second studs lift off the staging end, contact the catch end and slide along the second portion to the mated end.

13. An electrical connector assembly comprising:

an electrical connector body;

an electrical panel sub-assembly matable with the electrical connector body along a mating axis, the electrical panel sub-assembly having a rotation axis disposed orthogonally to the mating axis;

a cam stud engaged to the electrical connector body and extending along a centerline disposed parallel to the rotation axis, the cam stud having a diameter; and

a cam lever attached rotatably to the electrical panel sub-assembly about the rotation axis, the cam lever having a cam track for sliding contact with the cam stud;

the cam track having;

a first portion extending gradually radially inward toward the rotation axis from a receiving end for initial contact of the cam stud, and to a staging end;

a second portion being in disconnected relationship to the first portion and extending gradually radially inward toward the rotation axis from a catch end to a mated end;

a third portion of the cam track extending gradually radially outward from the mated end and toward the staged end; and

an inner blind slot communicating through the cam lever and defined laterally between the second and third portions;

wherein the catch end generally faces the rotation axis and faces the staging end, and is spaced from the staging end by a distance which is greater than file stud diameter.

14. The electrical connector assembly set forth in claim 13 further comprising:

the cam stud being disposed at the receiving end when the electrical panel sub-assembly is in a disconnected position, and wherein clockwise rotation of the cam lever causes the electrical panel sub-assembly to move along the mating axis from the disconnected position and to a staged position as the cam stud slides along the first portion from the receiving end to the staging end;

wherein counter-clockwise rotation of the cam lever when the electrical panel sub-assembly is initially in the staged position causes the electrical panel sub-assembly to move along the mating axis to a mated position as the cam stud lifts off the staging end, contacts the catch end and slides along the second portion to the mated end; and

wherein clockwise rotation of the cam lever when the electrical panel sub-assembly is initially in the mated position causes the electrical panel sub-assembly to move along the mating axis to the staged position as the cam stud slides along the third portion to the staged end of the first portion.

15. The electrical connector assembly set forth in claim 13 further comprising a concave face at the staged end of the first portion which faces radially outward with respect to the rotation axis for removably seating the cam stud.

16. The electrical connector assembly set forth in claim 15 further comprising:

a second stud engaged to the electrical connector body and orientated along a second centerline spaced laterally from and parallel to the centerline;

a second rotation axis spaced laterally from and parallel to the rotation axis;

a second cam lever engaged rotatably to the electrical panel sub-assembly at the second rotation axis; and

wherein the second cam lever rotates opposite to the cam lever.

17. The electrical connector assembly set forth in claim 13 wherein the cam stud is disposed at the receiving end when the shroud is in a disconnected position, and wherein clockwise rotation of the cam lever causes the electrical panel to move along the mating axis from the disconnected position and to a staged position as the cam stud slides along the first portion from the receiving end to the staging end.

18. The electrical connector assembly set forth in claim 17 wherein the counter-clockwise rotation of the cam lever when the electrical panel sub-assembly is initially in the staged position causes the electrical panel sub-assembly to move along the mating axis to a mated position as the cam stud lifts off the staging end, contacts the catch end and slides along the second portion to the mated end.

19. The electrical connector assembly set forth in claim 18 wherein the first and second portions of the cam track extend radially inward in a spiral fashion.

20. The electrical connector assembly set forth in claim 19 further comprising a concave face at the staged end of the first portion which faces radially outward with respect to the rotation axis for seating the cam stud when the electrical connector assembly is in the staged position, and forms congruently into the third portion at an apex.

21. An electrical connector assembly comprising:

an electrical connector body;

an electrical panel sub-assembly matable with the electrical connector body along a mating axis, the electrical panel sub-assembly having a rotation axis disposed orthogonally to the mating axis;

a cam stud engaged to the electrical connector body and extending along a centerline disposed parallel to the rotation axis, the cam stud having a diameter; and

a cam lever attached rotatably to the electrical panel sub-assembly about the rotation axis, the cam lever having a cam track for sliding contact with the cam stud;

the cam track having;

a first portion extending gradually radially inward toward the rotation axis from a receiving end for initial contact of the cam stud, and to a staging end; and

a second portion being in disconnected relationship to the first portion and extending gradually radially inward toward the rotation axis from a catch end to a mated end;

wherein the catch end generally faces the rotation axis and faces the staging end, and is spaced from the stage end by a distance which is greater than the stud diameter; and

wherein the first portion spirals radially inward toward the rotation axis generally in a first circumferential direction and the second portion spirals radially inward toward the rotation axis generally in an opposite circumferential direction.

22. A method for mating an electrical connector assembly comprising the steps of:

placing an electrical panel sub-assembly over an electrical connector body;

aligning a first cam stud to a disconnect end of a first portion of a track of a first cam lever engaged rotatably to the electrical panel sub-assembly;

rotating the first cam lever in a clockwise direction about a first rotation axis causing the first cam stud to slide along the first portion as the electrical panel sub-assembly moves in a linear direction toward the electrical connector body;

abutting the first cam stud to a staged end of the first portion placing the electrical panel sub-assembly in a staged position;

rotating the first cam lever in a counter-clockwise direction about the first rotation axis causing the first cam stud to lift off of the staged end and slideably engage a radially outward catch end of a second portion of the track and causing the first cam stud to slide along the second portion, the second portion being in disconnected relationship to the first portion and generally facing the first rotation axis; and

abutting the first cam stud against a radially inward mated end of the second portion placing the electrical connector assembly in a mated position.

23. The method for mating an electrical connector assembly set forth in claim 22 comprising the additional steps of:

aligning a second cam stud to an initial contact end of a first portion of a track of a second cam lever engaged rotatably to the electrical panel sub-assembly;

rotating the second cam lever in a counter-clockwise direction as the first cam lever is rotated in the clockwise direction, causing the second cam stud to slide along the first portion of the second cam lever as the electrical panel sub-assembly moves in the linear direction toward the electrical connector body;

abutting the second cam stud to a staged end of the first portion of the second cam lever placing the electrical panel sub-assembly in the staged position;

rotating the second cam lever in a clockwise direction as the first cam lever is rotated in the counter-clockwise direction causing the second cam stud to lift off of the staged end of the second cam lever and slideably engage a catch end of a second portion of the track of the second cam lever and causing the second cam to slide along the second portion of the second cam lever; and

abutting the second cam stud against a mated end of the second portion of the second cam lever placing the electrical connector assembly in the mated position.

24. The method for mating the electrical connector assembly set forth in claim 22 compirsing the additional step of unmating the electrical connector assembly by rotating the first cam lever in a clockwise direction causing the first cam stud to lift off of the mated end of the second portion and slide along a third portion of the track which extends gradually radially outward to the staged end of the first portion, and stopping the rotation when the first cam stud reaches the staged end thus placing the electrical panel sub-assembly back into the staged position.