Electrical connector with scoop proof dome

[0001] 1. Field of the Invention

[0002] The invention relates to an electrical connector and, more particularly, to a scoop proof electrical connector.

[0003] 2. Brief Description of Prior Developments

[0004] U.S. Pat. No. 6,726,495, which is hereby incorporated by reference in its entirety, discloses a squib, scoop proof electrical connector. The connector is used for an air bag system in a vehicle, and the scoop proof feature prevents scoop-proof insertion of the plug connector into the socket connector. U.S. Pat. No. 6,997,750 discloses a squib electrical connector with a ferrite tube surrounding portions of contacts. U.S. Pat. No. 5,993,230 discloses a co-axial squib electrical connector with a ferrite block surrounding portions of electrical wires.

[0005] A problem exists with conventional squib electrical connectors used as vehicle air bag connectors in that the height size of the connectors are limited due to the limited size of the area they are used in (vehicle space limitations), and the height of ferrite tubes at contact areas of plug connectors is desired to be larger for better filtering or attenuating. These two diametrically opposite factors have prevented a small size squib air bag connector from having adequate ferrite filtering at its contacts. There is a desire for a squib air bag electrical connector with an increased height ferrite member(s) at its contacts.

[0006] In accordance with one aspect of the invention, a socket electrical connector is provided which is adapted to receive a portion of a mating plug electrical connector. The socket electrical connector includes a housing, at least two electrical contact terminals, and a contact shorting member. The housing includes a first housing member and a second housing member. The second housing member is located in the first housing member and forms a scoop proof dome having a height extending above a top side of the first housing member. The second housing member forms at least one receiving area for receiving the portion of the mating plug electrical connector. The electrical contact terminals are connected to the first housing member and extend into the at least one receiving area of the second housing member. The contact shorting member is mounted on the second housing member and contacts the electrical contacts.

[0007] In accordance with another aspect of the invention, a squib electrical connector assembly is provided comprising a plug electrical connector and a socket electrical connector connected to the plug electrical connector. The plug electrical connector comprises a plug housing, female electrical contacts and at least one ferrite tube. The socket electrical connector comprises a socket housing, male electrical contacts and a contact shorting member. The socket housing comprises a first housing member and a second housing member. The second housing member is located in the first housing member and forms a scoop proof dome having a height extending above a top side of the first housing member. The second housing member forms at least one receiving area having a portion of the plug housing mounted therein. The portion of the plug housing comprises an extended height plug portion to accommodate a height of the scoop proof dome. The at least one ferrite tube comprises an extended height which extends above a top plane of the scoop proof dome at least about 30 percent of the height of the ferrite tube.

[0008] In accordance with another aspect of the invention, a method of assembling a squib electrical connector is provided comprising providing a first housing member; connecting an electrical contact shorting member to a second housing member, wherein the second housing member comprises an elevated height scoop proof dome portion; connecting electrical male contact terminals to the first housing member; inserting the second housing member into the first housing member wherein the elevated height scoop proof dome portion extends above a top side of the first housing member; and electrically connecting the male contact terminals to each other by the electrical contact shorting member.

[0019] Referring to FIG. 1, there is shown a perspective view of a squib electrical connector assembly 10 incorporating features of the invention. Although the invention will be described with reference to the exemplary embodiment shown in the drawings, it should be understood that the invention can be embodied in many alternate forms of embodiments. In addition, any suitable size, shape or type of elements or materials could be used.

[0020] The assembly 10 generally comprises a plug electrical connector 12 and a socket electrical connector 14. Referring also to FIGS. 2-4, the socket electrical connector 14 generally comprises a socket housing 16, male electrical contacts or terminals 18 and a contact shorting member 20. The socket housing 16 generally comprises a first housing member 22 and a second housing member 24. In an alternate embodiment, the socket housing 16 could be a one-piece member, or could comprise more than two housing members. The first housing member 22 comprises a receiving area 26 and keying slots 28, 29 in its top side 30. The male electrical contacts 18 are mounted in the first housing member 22 and extend upward from the base of the first housing member into the receiving area 26. The first housing member 22 includes a latch receiving annular recess 32 in its side wall at the receiving area 26. In alternate embodiments, more than one latch receiving recess could be provided, and any suitable shape could be provided.

[0021] The second housing member 24 is mounted in the receiving area 26 of the first housing member 22. The second housing member 24 generally comprises two generally annular wall sections 34, 36 connected to each other by a base section. The wall sections 34, 36 for an inner receiving area 38 and an outer receiving area 40. The outer wall section 34 comprises two latch slots 42 to allow latches 44 (see FIG. 1) of the plug connector 12 to latch into the recess 32. The outer wall section 34 also comprises outwardly projecting, cantilevered key sections 46, 47. The key sections 46, 47 are received in the keying slots 28, 29 of the first housing member 22 to properly orientate the second housing member 24 relative to the first housing member 22.

[0022] The outer receiving area 40 has a general annular shape. The inner receiving area 38 has a general hour-glass type of shape or “8” type of shape. The inner wall section 36 has an elevated height which forms a scoop proof dome 48 that extends above the top side 30 of the first housing member 22. The inner wall section 36 also comprises a shorting member retainer section 50 having the contact shorting member 20 mounted thereon. The shorting member 20 extends through the shorting member retainer section 50 between an inner side of the inner wall section 36 and an outer side of the inner wall section 36. The inner wall section 36 also comprises a ramp section 52 above the shorting member 20 adapted to move a portion of the mating plug electrical connector 12 when the mating plug electrical connector is inserted into the socket connector 14.

[0023] The shorting member 20 comprises a formed sheet metal member with a first section 54 and two second sections 56. The second sections 56 have ends 58 which respectively contact the male contact terminals 18. The shorting member 20, thus, electrically connects the terminals 18 to each other. As seen in FIG. 5, the ends 58 are adapted to be resiliently deflected away from the male terminals 18 when the plug connector 12 is inserted into the socket connector 14.

[0024] As seen in FIGS. 1, 5 and 6, the plug connector 12 generally comprises a plug housing 60, female electrical contacts 62, and ferrite members 64. In this embodiment the ferrite members 64 are tubes. However, in alternate embodiments any suitable shape(s) could be provided. The plug housing 60 is a right angle housing in this embodiment. However, in an alternate embodiment the plug housing could be a non-right angle connector housing. The housing 60 houses the two contacts 62 in a side-by-side configuration. The contacts 62 have rear ends connected to two respective wires 66. Front ends 68 of the contacts 62 form female receiving areas for receiving the male contacts 18. The front ends 68 are located inside the ferrite tubes 64. The plug housing 60 has portions 74, 76 which are adapted to be inserted into the receiving areas of the second housing member 24.

[0025] The plug connector 12 also comprises a connector position assurance (CPA) member 70. The CPA member 70 is shown in its down or locked position in FIGS. 1 and 5. The CPA member 70 is prevented from moving to its locked position unless the plug connector 12 is properly connected to the socket connector 14. More specifically, referring also to FIGS. 7-9, the plug housing 60 has a CPA latch 72. The latch 72 is part of the plug housing; not part of the CPA member 70. More specifically, latch 72 is part of the portion 76 and extends upward in a general cantilever fashion. The latch 72 includes a top stop surface 78 and a cam surface 80.

[0026] FIGS. 7-8 show the CPA member 70 in its up, unlocked position. The CPA member 70 includes a blocking section 82 with a stop surface 84. As seen in FIG. 7, before the plug connector 12 is fully inserted into the socket connector 14, the latch 70 is positioned in the path of the blocking section 82 such that the two stop surfaces 78, 84 engage each other and prevent the CPA member 70 from being moved to its locked position on the plug housing 60. As seen in FIG. 8, as the plug connector 12 is further inserted into the socket connector 14 to its fully inserted position, the ramp section 52 of the second housing member 24 contacts the cam surface 80, and resiliently cams the latch 72 outward. This moves the stop surface 78 out of the path of the stop surface 84. Thus, the scoop proof dome 48 has an engagement feature (the ramp section 52 of the shorting member retainer section 50) that moves the flexible arm (the CPA latch 72) of the plug connector 12. The CPA latch 72 is moved to allow the CPA member to latch. The user can then push the CPA member 70 downward as shown in FIG. 9 to its final locked position.

[0027] With the invention, the scoop proof dome 48 prevents the male contact pins 18 from being bent during connection of the connectors 12, 14 to each other. This is because of the extended height of the second housing member 24. The extended height insures that the plug connector 12 is substantially completely aligned with the center axis of the receiving area 38 before the plug connector 12 can make contact with the top ends of the pins 18. Thus, by preventing the pins 18 from becoming inadvertently bent, this helps to insure that the pins 18 properly connect with the contacts 62. In a preferred embodiment, at least one ferrite tube comprises an extended height which extends above a top plane of the scoop proof dome at least about 20 percent of the height of the ferrite tube, and preferably at least about 30 percent.

[0028] It should be understood that the foregoing description is only illustrative of the invention. Various alternatives and modifications can be devised by those skilled in the art without departing from the invention. Accordingly, the invention is intended to embrace all such alternatives, modifications and variances which fall within the scope of the appended claims.