Electrical connection system

• US 7,601,019 B2
• Filed: 06/22/2007
• Issued: 10/13/2009
• Est. Priority Date: 06/22/2007
• Status: Active Grant

• Current Assignee: Aptiv Technologies AG (Aptiv PLC)
• Original Assignee: Delphi Technologies, Inc. (BorgWarner Incorporated)
• Inventors: Hsieh, Shao C., McCall, Mark D.
• Primary Examiner(s): Leon; Edwin A.
• Application Number:
  US11/821,248
• Publication Number:
  US 20080318460A1
• Time in Patent Office: 844 Days
• Field of Search: 439/345, 439/845, 439/851, 439/855, 439/587, 439/589, 439/857, 439/224, 439/356, 439/595, 439/752, 439352-355, 439/357, 439/358, 439/488, 439/489
• US Class Current: 439/345
• CPC Class Codes: H01R 13/113 co-operating with pins or blades having a rectangular transverse section
• CPC Class Codes: H01R 13/187 with spring member in the socket
• CPC Class Codes: H01R 13/426 Securing by a separate resilient retaining piece supported by base or case, e.g. collar or metal contact-retention clip
• CPC Class Codes: H01R 13/5205 Sealing means between cable and housing, e.g. grommet H01R13/5221 takes precedence
• CPC Class Codes: H01R 13/5219 Sealing means between coupling parts, e.g. interfacial seal
• CPC Class Codes: H01R 13/5812 the cable clamping being achieved by mounting the separate part on the housing of the coupling device
• CPC Class Codes: H01R 13/641 by indicating incorrect coupling; by indicating correct or full engagement

Abstract

A connection position assurance retainer may include mechanisms for retaining connectors. For example, a female connector and a male connector may be mated and retained. Male and female terminals, the female terminal including a terminal insert, may also be provided.

Claims

1. A connection position assurance system, comprising a connection position assurance retainer that includes:

a dovetail tab configured to mechanically engage a dovetail slot;

a pair of back tabs on either side of, and substantially parallel to, the dovetail tab, each back tab having a back stop protruding downwardly therefrom;

a pair of side tabs that are substantially parallel to one another;

forward stops protruding upwardly from each of the side tabs, the side tabs extending beyond the forward stops;

forward bumps protruding downwardly from a tip of each side tab; and

a hook arm extending between, and substantially parallel to, the side tabs.

2. The system of claim 1, further comprising a female connector including a top side that includes:

a pair of grooved arms flexibly extending in a substantially parallel fashion from a back side of the female connector, each grooved arm including a groove that has an edge that is spaced away from an end of the grooved arm;

a slot formed by a space between the grooved arms;

a hook bar that extends between the grooved arms and is substantially perpendicular thereto, the hook bar bounding one end of the slot, whereby the hook bar may serve as a forward stop for the connection position assurance retainer in a pre-stage position and as a back stop for the connection position assurance retainer in a final stage position;

a pair of side walls, each side wall extending substantially perpendicularly from an end portion of one of the grooved arms, the hook bar extending between the end portions; and

connector position assurance protector traps extending from the top side to form substantially right angles, the traps limiting movement of the grooved arms in an upward direction.

3. The system of claim 2, wherein the dovetail tab is inserted in the slot, and the back stops and the forward bumps are seated in respective ones of the grooves, the connection position assurance retainer further including a pair of lower guide tabs extending below and within, and substantially parallel to, the side tabs, wherein the lower guide tabs are also being inserted within the slot, the hook arm is engaged with the hook bar, the side tabs are inserted in respective spaces between the grooved arms and the traps, and each of the forward stops abuts one of the traps.

4. The system of claim 3, further comprising a male connector including a top side having a locking bump protruding therefrom.

5. The system of claim 4, wherein the male connector is inserted into the female connector, and the locking bump is engaged by the hook bar.

6. A connection system, comprising:

a female connector including a top side that includes;

a pair of grooved arms flexibly extending in a substantially parallel fashion from a back side of the female connector, each grooved arm including a groove that has an edge that is spaced away from an end of the grooved arm;

a slot formed by a space between the grooved arms;

a hook bar that extends between the grooved arms and is substantially perpendicular thereto, the hook bar bounding one end of the slot, whereby the hook bar may serve as a forward stop for a connection position assurance retainer in a pre-stage position and as a back stop for the connection position assurance retainer in a final stage position;

a pair of side walls, each side wall extending substantially perpendicularly from an end portion of one of the grooved arms, the hook bar extending between the end portions; and

connector position assurance protector traps extending from the top side to form substantially right angles, the traps limiting movement of the grooved arms in an upward direction; and

the connection position assurance retainer, including;

a dovetail tab configured to mechanically engage a dovetail slot;

a pair of back tabs on either side of, and substantially parallel to, the dovetail tab, each back tab having a back stop protruding downwardly therefrom;

a pair of side tabs that are substantially parallel to one another;

forward stops protruding upwardly from each of the side tabs, the side tabs extending beyond the forward tabs;

forward bumps protruding downwardly from a tip of each side tab; and

a hook arm extending between, and substantially parallel to, the side tabs.

7. The system of claim 6, further comprising a male connector including a top side having a locking bump protruding therefrom.

8. The system of claim 7, wherein the male connector is inserted into the female connector, and the locking bump is engaged by the hook bar.

9. The system of claim 7, further comprising

a male terminal inserted within the male connector, and

a female terminal inserted within the female connector.

10. The system of claim 7, the male connector further including a pair of male cylinders and the female connector further including a pair of female cylinders, the system further comprising:

a first pair of cables including a first set of wires that are electrically engaged with the male terminal; and

a second set of cables including a second set of wires that are electrically engaged with the female terminal.

11. The system of claim 10, further comprising at least one terminal position assurance lock disposed around one of the cables and securing the one of the cables to one of the female cylinders or one of the male cylinders, the terminal position assurance lock including:

a circumferential portion that surrounds the one of the cables,

one or more lock aims engaged with one or more lock bumps on the one of the cylinders;

index ribs located about the circumferential portion and inserted into slots in the one of the cylinders; and

a plurality of fingers extending from the circumferential portion and securing the one of the cables.

12. The system of claim 6, the female connector further including a top brace extending between the side walls, the top brace being further from the back side of the female connector than the hook bar.

13. The system of claim 6, wherein the dovetail tab is inserted in the slot, and the back stops and the forward bumps are seated in respective ones of the grooves.

14. The system of claim 13, the connection position assurance retainer further including a pair of lower guide tabs extending below and within, and substantially parallel to, the side tabs, the lower guide tabs also being inserted within the slot.

15. The system of claim 13, wherein the hook arm is engaged with the hook bar.

16. The system of claim 15, wherein the side tabs are inserted in respective spaces between the grooved aims and the traps.

17. The system of claim 15, wherein each of the forward stops abuts one of the traps.

18. The system of claim 6, the female terminal including a terminal insert that includes:

a pair of opposing side panels, each side panel having a plurality of flexibly indented contact arms and a set of dimples;

a pair of opposing side contact arms, each side contact arm having an inwardly curved tip; and

a pair of top flanges, each top flange extending curvilinearly from a top edge of one of the side panels.

19. The system of claim 6, wherein the female connector is one of a right-angle connector and an in-line connector.

20. A terminal insert, comprising:

a pair of opposing side panels, each side panel having a plurality of flexibly indented contact arms and a set of dimples;

a pair of opposing side contact, each side contact positioned between said side panels at opposite sides thereof having an inwardly curved tip extending between said side panels;

a pair of top flanges, each flange extending curvilinearly from a top edge of one of the side panels; and

a pair of side tabs, each side tab extending from one of the side panels at one side of said terminal insert and at a substantially right angle in a direction opposing a direction of the other one of the side tabs, said pair of side tabs positioned above said side contacts at said one side of said terminal insert.