Connector position assurance device and connector assembly incorporating the same

[0001] The present invention relates to a connector position assurance device and a connector assembly that incorporates the connector position assurance device.

[0002] Many different types of connector position assurance devices used with electrical connectors are well known in the art. One such connector position assurance device is described in U.S. Pat. No. 6,261,116 to Ceru. This connector position assurance element includes a horizontal base portion, a stem, a finger-graspable crossbar, deflectable side arms and a shoulder. The horizontal base portion has an insertion end and a withdrawal end. The stem extends vertically from the withdrawal end of the base portion. The finger-graspable crossbar is positioned on an end of the stem distal from the base portion. The deflectable side arms extend from the withdrawal end of the base portion at an upward acute angle and terminate in a free end adjacent and above the insertion end. The shoulder is located between the stem and the deflectable side arms with the shoulder defining a horizontal seat above the base portion and below the crossbar.

[0003] A drawback regarding the connector assurance device of Ceru is that permanent stress is applied to the side arms when the connector position assurance device is engaged.

[0004] Another connector position assurance device known in the art is described in U.S. Pat. No. 6,435,895 to Fink et al. This connector position assurance device is provided with a connector position assurance channel into which a connector position assurance slide is located. The connector position assurance slide interacts with the connector position assurance channel snappingly at two sliding positions of the connector position assurance slide assurance slide interacts with the connector position assurance channel snappingly at two sliding positions of the connector position assurance slide relative to the channel, namely a pre-staged position and a staged position. A connector position assurance actuation lock is provided. The connector position assurance channel includes a pair of channel abutments and the connector position assurance slide has a pair of resilient arms, the ends of which abut, respectively, the channel abutments when the connector position assurance slide is at the pre-staged position. The abutting interaction of the channel abutments with respect to the resilient arms prevents the connector position assurance slide from being snappingly slid to the staged position.

[0005] A drawback associated with the connector position assurance device of Fink et al. is that there is no guide channel on the connector housing to assure stable position of the connector position assurance device when it is engaged with the connector housing.

[0006] It would be beneficial to provide a connector position assurance device that is not permanently stressed when it is engaged with a connector housing. It would also be beneficial to provide a connector position assurance device that can be stably positioned within the connector housing when connector position assurance device is engaged therewith. The present invention provides these benefits.

[0007] One exemplary embodiment of the present invention is a connector position assurance device that includes a base panel member and a latch assembly. The latch assembly is connected to and extends generally perpendicularly from the base panel member. The latch assembly has a tongue part and a pair of rails disposed apart from and extending parallel to one another. The tongue part is positioned between and is disposed apart from the pair of rails to define a pair of open-ended stop-receiving channels between the tongue part and respective ones of the pair of rails.

[0008] Another exemplary embodiment of the present invention is a connector assembly that includes a first connector housing, a second connector housing and a connector position assurance device. The first connector housing has a first connector opened end, a first connector inner cavity and a first connector locking protrusion extending from a first connector upper wall into the first connector inner cavity. The second connector housing is sized and adapted to be received by the first connector inner cavity through the first connector opened end. The second connector housing has a second connector opened end, a second connector inner cavity, a second connector latch assembly with a cross-bar locking element and a second connector latch hole defined in part by the cross-bar locking element, a second connector bottom wall facing the second connector latch assembly, a pair of facially opposing second connector side walls, at least one stop element disposed between the second connector latch assembly and the second connector bottom wall and a second connector upwardly projecting locking protrusion projecting upwardly from the second connector bottom wall. The second connector housing includes a joist structure disposed within the second connector inner cavity. The joist structure has a pair of joists disposed apart from one another and extends in the insertion direction. A respective one of the pair of joists is disposed apart from a respective one of the second connector side walls and the second connector bottom wall to form a rail-receiving channel therebetween. The second connector latch assembly is operative to move to and between a normal, relaxed condition and a downward flexed condition with the second connector latch assembly being resiliently biased to the normal relaxed condition.

[0009] The connector position assurance device is sized and adapted to be received by the second connector inner cavity. The connector position assurance device has a base panel member and a latch assembly connected to and extending generally perpendicularly from the base panel member. The latch assembly has a tongue part with a forward portion and a pair of rails disposed apart from and extending parallel to one another. The tongue part is positioned between yet disposed apart from the pair of rails to define a pair of open-ended stop-receiving channels between the tongue part and respective ones of the pair of rails. The tongue part is formed with a slot and a follower projection connected to the tongue part forward of the base panel member and the slot. The tongue part is movable, in an upward direction, to and between a relaxed normal position and an upward flexed position and, in a downward direction, to and between the relaxed normal position and a downward flexed position being opposite the upward flexed position with the tongue part being resiliently biased to the relaxed normal position.

[0010] With respective ones of the pair of rails of the connector position assurance device aligned with respective ones the rail-receiving channels of the second connector housing in order to slidably receive the pair of rails in a close-fitting relationship, the connector position assurance device is inserted into the second connector inner cavity in the insertion direction at a first insertion force sufficient to cause the tongue part to slide over the second connector upwardly projecting locking protrusion thereby moving the tongue part from the relaxed normal position to the upward flexed position while the tongue part is in sliding contact with and slides over the second connector upwardly projecting locking protrusion and then the tongue part moves from the upward flexed position to the relaxed normal position when a forward end of the tongue part loses sliding contact with the second connector upwardly projecting locking protrusion. The follower projection confronts the cross-bar locking element and the slot receives the second connector locking protrusion at a forward end portion of the slot to render the connector position assurance device in a pre-set stage partially within the second connector inner cavity.

[0011] Thereafter the second connector housing with the connector position assurance device in the pre-set stage is inserted into the first connector inner cavity in the insertion direction by being received in the first connector inner cavity such that the first connector locking protrusion in sliding contact with the cross-bar locking element pushes downwardly on the cross-bar locking element thereby moving the second connector latch assembly from the normal relaxed condition to the downward flexed condition and the second connector latch assembly returns to the normal relaxed condition as the first connector locking protrusion loses sliding contact with the cross-bar locking element and the first connector locking protrusion in sliding contact with the follower projection pushes downwardly on the follower projection thereby moving the tongue part from the relaxed normal position to the downward flexed position so that the forward portion of the tongue part in sliding contact with the at least one stop element slides underneath the at least one stop element and the follower projection in sliding contact slides under the first connector locking protrusion and the cross-bar locking element and the tongue part returns to the normal relaxed position after losing sliding contact with the cross-bar locking element such that the at least one stop element is disposed within one of the opened-ended stop-receiving channels thereby rendering the connector position assurance device in a final locked stage.

[0012] The present invention will be better appreciated in view of the detailed description of the exemplary embodiments of the present invention with reference to the accompanying drawings, in which:

[0031] Exemplary embodiments of the present invention are hereinafter described. It is emphasized that any terms used herein relating to the orientation of the invention components or the direction of movement of the components including but not limited to “upper”, “lower”, “upward”, “downward”, “below” and the like have been selected for the purpose of simplifying the description of the invention, particularly in view of the drawing figures, for ease of understanding the invention and should not be construed as limiting the scope of the invention. It is believed that using non-descriptive terms unassociated with the orientation of the invention components or direction of movement such as “first”, “second” or the like would render the reading and comprehension of the detailed description of the exemplary embodiments of the present invention difficult.

[0032] The exemplary embodiments of the present invention are generally introduced in FIGS. 1-4. A connector position assurance device 10 of the present invention is used as a component of a connector assembly 110 of the present invention. The connector assembly 110 as discussed in more detail below includes the connector position assurance device 10, a first connector housing 12 and a second connector housing 14.

[0033] With reference to FIGS. 5-8, the connector position assurance device 10 includes a base panel member 16 and a latch assembly 18. The latch assembly 18 is connected to and extends generally perpendicularly from the base panel member 16. Also, the latch assembly 18 has a tongue part 20 and a pair of rigid rails 22a and 22b. The pair of rails 22a and 22b is disposed apart from and extends parallel to one another. The tongue part 20 is positioned between and yet is disposed apart from the pair of rails 22a and 22b to define a pair of open-ended stop-receiving channels 24a and 24b that are positioned between the tongue part 20 and respective ones of the pair of rails 22a and 22b as best shown in FIGS. 5 and 6. One of ordinary skill in the art would appreciate that each one of the pair of rigid rails 22a and 22b is intended to be disposed in a fixed position and is not intended to be movable for purposes of the present invention although either one of the pair of rails might move somewhat if a sufficient force is applied thereto.

[0034] In FIGS. 5 and 6, the latch assembly 18 includes an anchor panel part 26. The anchor panel part 26 is connected to and between the base panel member 16 and the tongue part 20. In FIG. 6, the tongue part 20 has a tongue fixed end 20a and an opposing tongue free end 20b. The tongue part 20 is connected to the anchor panel part 26 at the tongue fixed end 20a in a cantilever fashion such that the tongue part 20 is movable in an upward direction as shown by the broken lines in FIG. 9 and in a downward direction as shown by the broken lines in FIG. 10. In the upward direction in FIG. 9, the tongue part 20 moves to and between a relaxed normal position as shown by the solid lines and an upward flexed position as shown by the broken lines. In the downward direction in FIG. 10, the tongue part 20 moves to and between the relaxed normal position as shown by the solid lines and a downward flexed position as shown by the broken lines. By comparing FIGS. 9 and 10, a skilled artisan would comprehend that the downward flexed position is opposite the upward flexed position. Further, when the tongue part 20 is in either the upward flexed position or the downward flexed position, the tongue part 20 is resiliently biased to the relaxed normal position as reflected by the solid lines in both FIGS. 9 and 10.

[0035] Additionally, the latch assembly 18 as shown in FIGS. 5-8 includes a follower projection 28 connected to the tongue part 20 adjacent the tongue free end 20b thereof. The follower projection 28 projects from the tongue part 20 in the upward direction. Also, although not by way of limitation, the follower projection 28 is positioned centrally between to the pair of rails 22a and 22b as best shown in FIGS. 6 and 7. In FIGS. 5 and 6, the tongue part 20 has a pair of tongue part legs 20c that defines a slot 30 therebetween that is formed though the tongue part 20. The slot 30 is disposed centrally of the tongue part 20 and extends from the tongue fixed end 20a and towards the follower projection 28.

[0036] Again with reference to FIGS. 5-8, connector position assurance device 10 further includes a hollow box element 32 having a box-shaped cavity 32a formed therein (FIGS. 6 and 7) and a box-shaped opening 32b (FIGS. 6 and 7) into the box-shaped cavity 32a facing the follower projection 28. The box element 32 is integrally connected to the anchor panel part 26 and the base panel member 16. Further, the box element 32 extends from the base panel member 16 and terminates to cover a rear end portion 30a (FIG. 6) of the slot 30 with the rear end portion 30a of the slot 30 being in communication with the box-shaped cavity 32a.

[0037] As best shown in FIGS. 5-8, the follower projection 28 has a rear surface 28a, a front surface 28b, a top surface 28c and an inclined surface 28d. As best shown in FIGS. 5, 6 and 8, the rear surface 28a faces the box-shaped opening 32b. The front surface 28b is opposed to the rear surface 28a and faces away from the box-shaped opening 32b. The inclined surface 28d is inclined relative to and interconnects the top surface 28c and the front surface 28b. The top surface 28c interconnects the inclined surface 28d and the rear surface 28a. Although not by way of limitation, the top surface 28c and the inclined surface 28d are interconnected in an arcuate manner as best shown in FIGS. 5 and 8.

[0038] As best shown in FIG. 11, the anchor panel part 26 is integrally connected perpendicularly to the base panel member as represented by angle a. Note that a top surface 26a of the anchor panel part 26 is disposed in a first plane Pf represented by the alternating long and short dashed lines and a top surface 20d of at least a forward portion 20e of the tongue part is disposed in a second plane Ps that extends parallel to the first plane Pf in a space-apart manner at a distance d. By way of example only and not by way of limitation, the first plane Pf is disposed below the second plane Ps. This construction is achieved by a pair of angled leg portions 20c1 with each one of the pair of angled leg portions 20c1 being a component of a respective one of the pair of tongue part legs 20c.

[0039] Furthermore, as best shown in FIGS. 6 and 7, the latch assembly 18 includes a pair of block elements 34a and 34b that are integrally connected at the tongue free end 20b of the tongue part 20. Each one of the pair of block elements 34a and 34b is laterally disposed apart from one another on opposing sides of the follower projection 28 and project forwardly of the tongue free end 20b. In FIGS. 5 and 6, the tongue part 20 includes a pair of ramps 20f. Each ramp 20f is disposed at an outer lateral edge 20g of the tongue part 20 and inclines upwardly relative to the tongue fixed end 20a and towards the tongue free end 20b.

[0040] With reference to FIGS. 6 and 7, although not by way of limitation, each one of the pair of rails 22a and 22b is angled as viewed in cross-section. Specifically, rail 22a is configured in cross-section generally as an L-shape while rail 22b is configured in cross-section generally as a mirrored-image of the L-shape. Each rail 22a and 22b has a bottom rail surface 22a1 and 22b1 respectively and a side rail surface 22a2 and 22b2 respectively with the bottom rail surfaces and the side rail surfaces being perpendicular to one another.

[0041] Another exemplary embodiment of the connector assembly 110 of the present invention as mentioned above is generally introduced in FIGS. 1-4 and 11-15B. The connector assembly 110 includes the first connector housing 12, the second connector housing 14 and the connector position assurance device 10. The first connector housing 12 has a first connector opened end 36 and a first connector inner cavity 38 as best shown in FIG. 1 and a first connector locking protrusion 40 as shown in FIGS. 14A, 15 and 16A. The first connector locking protrusion 40 extends from a first connector upper wall 42 into the first connector inner cavity 38 (FIG. 1).

[0042] With reference to FIGS. 1-4 and 14A, 15 and 16A, the second connector housing 14 is sized and adapted to be received by the first connector inner cavity 38 through the first connector opened end 36. The second connector housing 14 has a second connector opened end 44, a second connector inner cavity 46, a second connector latch assembly 48 with a cross-bar locking element 58 and a second connector latch hole 60 defined in part by the cross-bar locking element 58, a second connector bottom wall 50 facing the second connector latch assembly 48, a pair of facially opposing second connector side walls 52, a pair of stop elements 54 disposed between the second connector latch assembly 48 and the second connector bottom wall 50, a second connector upwardly projecting locking protrusion 56 projecting upwardly from the second connector bottom wall 50. As best shown in FIG. 1, the second connector housing 14 includes a joist structure 62 disposed within the second connector inner cavity 46. The joist structure 62 has a pair of joists 64a and 64b disposed apart from one another and extends in the insertion direction X. A respective one of the pair of joists 64a and 64b is disposed apart from a respective one of the second connector side walls 52 and the second connector bottom wall 50 to form a rail-receiving channel 66 therebetween.

[0043] As best shown in FIG. 1. the second connector latch assembly 48 includes a pair of parallel bars 48a disposed apart from one another to define a channel 48b therebetween. Respective distal ends of the pair of parallel bars are integrally connected at a rear portion of the second connector housing 14 in a cantilevered manner. The cross-bar locking element 58 spans the pair of parallel bars forwardly of the second connector housing 14.

[0044] The second connector latch assembly 48 is operative to move to and between a normal, relaxed condition (as shown in FIGS. 12, 13, 14A and 16A) and a downward flexed condition (as shown only in FIG. 15) for reasons discussed below. The second connector latch assembly 48 is resiliently biased to the normal relaxed condition.

[0045] In FIGS. 1-4, the connector position assurance device 10 sized and adapted to be received by the second connector inner cavity 46. In FIGS. 1 and 12, respective ones of the pair of rails 22a and 22b of the connector position assurance device 10 is aligned with respective ones the rail-receiving channels 64a and 64bb of the second connector housing 14 in order to slidably receive the pair of rails 22a and 22b in a close-fitting relationship. As best shown in FIG. 13, the connector position assurance device 10 is inserted into the second connector inner cavity 46 in the insertion direction at a first insertion force Ff sufficient to cause the tongue part 20 to slide over the second connector upwardly projecting locking protrusion 56 thereby moving the tongue part 20 from the relaxed normal position shown in FIG. 12 to the upward flexed position shown in FIG. 13 while the tongue part 20 is in sliding contact with and slides over the second connector upwardly projecting locking protrusion 56 as best shown in FIG. 13. Then the tongue part 20 moves from the upward flexed position as shown in FIG. 13 to the relaxed normal position as shown in FIGS. 14A and 14B when a forward portion 20e of the tongue part 20 loses sliding contact with the second connector upwardly projecting locking protrusion 56 and the follower projection 28 confronts the cross-bar locking element 58 and the slot 30 receives the second connector upwardly projecting locking protrusion 56 at a forward end portion 30b (FIG. 6) of the slot 30 to render the connector position assurance device 10 in a pre-set stage partially within the second connector inner cavity 46. This configuration is also shown in FIGS. 2 and 3 as perspective views.

[0046] Thereafter the second connector housing 14 with the connector position assurance device 10 in the pre-set stage is inserted into the first connector inner cavity 38 as shown in FIGS. 2 and 3 and in sequence in FIGS. 14A through 16B in the insertion direction X at a second insertion force Fs by being received in the first connector inner cavity 38 such that the first connector locking protrusion 40 in sliding contact with the cross-bar locking element 58 pushes downwardly on the cross-bar locking element 58 (see FIG. 15) thereby moving the second connector latch assembly 48 from the normal relaxed condition (for example in FIG. 14A) to the downward flexed condition as shown in FIG. 15. The second connector latch assembly 48 returns to the normal relaxed condition as shown in FIGS. 16A and 16B as the first connector locking protrusion 40 loses sliding contact with the cross-bar locking element 58 (FIG. 16A) and the first connector locking protrusion 40 in sliding contact with the follower projection 28 pushes downwardly on the follower projection (FIG. 15) thereby moving the tongue part 20 from the relaxed normal position (for example, in FIG. 15) to the downward flexed position (FIG. 15) so that the forward portion 20e of the tongue part 20 in sliding contact with the pair of stop elements 54 slides underneath the pair of stop elements 54 and the follower projection 28 in sliding contact slides under the first connector locking protrusion 40 and the cross-bar locking element 58 (FIG. 15) and the tongue part 20 returns to the normal relaxed position (FIGS. 16A and 16B) after losing sliding contact with the cross-bar locking element 58 such that the pair of stop elements 54 is disposed within respective ones of the opened-ended stop-receiving channels 24a and 24b thereby rendering the connector position assurance device 10 in a final locked stage.

[0047] Although not by way of limitation, the second insertion force Fs is larger than the first insertion force Ff. Further, although not by way of limitation, this exemplary embodiment of the connector assembly 110 of the present invention describes a pair of stop elements 54 but one of ordinary skill in the art would appreciate that only one stop element can be used. Thus, there is at least one stop element employed for the present invention.

[0048] As best shown in FIG. 16B, a respective one of the pair of stop elements 54 is connected to a respective one of the pair of joists 64a and 64b. Each one of the pair of stop elements 64 extends from the respective one of the pair of joists 64a and 64b towards a center of the second connector inner cavity 46.

[0049] Additionally, as shown in FIG. 16B, the tongue part 20 has a pair of ramps 20f. Each ramp 20f is disposed at an outer lateral edge 20g of the tongue part 20 and inclines upwardly relative to the tongue fixed end 20a and towards the tongue free end 20b. Respective ones of the pair of ramps 20f are disposed at least adjacent to or abutting respective ones of the pair of stop elements 54 in a generally facially opposing manner. Respective ones of the pair of stop elements 54 are disposed in respective ones of the open-ended stop-receiving channels 24a and 24b when the connector position assurance device 10 is in the final locked stage.

[0050] With reference to FIG. 6, the latch assembly 18 includes an anchor panel part 26 and a pair of block elements 34a and 34b. The anchor panel part 26 is connected to and between the base panel member 16 and the tongue part 20. The tongue part 20 has the tongue fixed end 20a and the tongue free end 20b opposing the tongue fixed end 20a. The tongue part 20 is connected to the anchor panel part 26 at the tongue fixed end 20a. The pair of block elements 34a and 34b are integrally connected at the tongue free end 20b of the tongue part 20. Each one of the pair of block elements 34a and 34b is laterally disposed apart from one another on opposing sides of the follower projection 28 and projects forwardly of the tongue free end 20b. Respective ones of the pair of the block elements 34a and 34b are disposed at least adjacent to or abut respective ones of the pair of stop elements 54 in a generally facially opposing manner when the connector position assurance device 10 is in the pre-set stage.

[0051] It is appreciated that the connector position assurance device 10 of the present invention is not stressed when it is engaged either in its pre-set stage or in its final locked stage because the connector position assurance device is in its relaxed normal position. The connector position assurance device is only stressed when the tongue part moves from its relaxed normal position to either the upward flexed position or the downward flexed position. Furthermore, because the connector position assurance device includes a pair of rails that are received in a close-fitting relationship by the rail-receiving channels formed by the joist structure, the connector position assurance device is stably positioned within the second connector housing when connector position assurance device is engaged therewith.

[0052] The present invention, may, however, be embodied in various different forms and should not be construed as limited to the exemplary embodiments set forth herein; rather, these exemplary embodiments are provided so that this disclosure will be thorough and complete and will fully convey the scope of the present invention to those skilled in the art.