EP3975346A1

EP3975346A1 - Electrical connector assembly with mating lever, system comprising such assembly and method for mating such system

Info

Publication number: EP3975346A1
Application number: EP20198430.9A
Authority: EP
Inventors: Klaus Mueller; Rainer Schmidt; Bruno Barth
Original assignee: Aptiv Technologies Ltd
Current assignee: Aptiv Technologies AG
Priority date: 2020-09-25
Filing date: 2020-09-25
Publication date: 2022-03-30

Abstract

The present disclosure relates to an electrical connector assembly, a system and a method. The assembly comprises a housing 100, that houses at least one electrical contact a mating lever 200 that is arranged pivotable relative to the housing 100 between an alignment position and a mating position. The mating lever is configured to be engageable with the electrical counter connector assembly 2, in order to move the electrical counter connector assembly 2 along a mating direction A relative to the housing into a mated configuration, when being pivoted from the alignment position to the mating position. The mating lever 200 includes at least one first slide track 220 that is engageable with a corresponding first slide member 20 of the electrical counter connector assembly. The first slide track is shaped so that the pivoting movement of the mating lever 200 is transferred into an axial movement of the electrical counter connector assembly via the first slide member 20, if the first slide member is engaged with the first slide track. The first slide track 220 has a curved shape that is composed of at least two radius segments, wherein a center of a first radius segment is different from a center of a second segment, wherein each of the radius segments defines a transmission ratio between the pivoting movement of the mating lever 200 and the movement of the electrical counter connector assembly along the mating direction A.

Description

Field of the invention

The present disclosure relates to an electrical connector assembly, having a mating lever, to a connector system, comprising said electrical connector assembly and to a method for mating the connector system.

Background art

Electrical connectors having a mating lever are known in the art. Those connectors are for example used in automotive vehicles for interconnecting power- and/or data lines.
From WO 2010/035 247 A2 a connector is known, that has a housing and a mating lever coupled thereto. When the mating lever is at an open position, the connector is ready to be mated with a corresponding counter connector. When the mating lever is in the process of being closed (pivoted), the pivoting movement of the mating lever leads to an axial movement of counter connector relative to the connector. Thereby, the connectors are mated via the mating lever.
In known connectors and connector systems, mating levers are designed so that they provide a substantially constant transmission ratio between the pivoting movement of the lever and the resulting axial mating movement of the connector/counter connector. This may be achieved by a guiding means, such as a slide track, in form of an Archimedean spiral. However, Archimedean spirals are difficult to define in technical drawings and difficult to prove during quality control. Further, the moment for actuating the lever varies, as the mating resistance for mating the connector with a corresponding counter connector varies, too. This is, as at the beginning of a mating procedure, e.g. the housings of the connector and the corresponding counter connector are mated, resulting in a relatively low mating resistance. Subsequently, the electrical contacts are mated, resulting in a higher mating resistance. This rise of mating resistance has to be overcome, and thus leads to a rise of the actuating moment. Thus, a substantially constant transmission ratio is often times not appropriate.
Further, connectors are known, which have a guiding means in form of a radius bow. These known radius-bow-shaped guiding means/slide tracks lead to an under-average transmission ratio in the middle of the track, where usually a high transmission ratio would be required. This is, as the middle of the track is assigned to a mating phase, where a high direct mating force occurs. Thus, the transmission ratio is not ideally adapted to the occurring direct mating force.
To compensate for the non-ideal transmission ratio provided by the guiding means, known mating levers are typically designed relatively long, i.e. having a long lever arm. This long lever arm may compensate for the non-ideal transmission ratio and allows for easily mating of the connectors. However, a long lever arm requires free space in the surrounding of the connectors operating position, which is often not available.
Thus, it is an object of the present disclosure to provide an electrical connector assembly, a connector system and a mating method for said system that overcomes the aforementioned drawbacks at least partially.

Summary

These objects are achieved, at least partly, by an electrical connector assembly, by a connector system and by a method, as defined in the independent claims. Further aspects of the present disclosure are defined in the dependent claims.
In particular, the object is achieved by an electrical connector assembly according to claim 1. The electrical connector assembly comprises a housing, that houses at least one electrical contact. Said contact may be adapted for signal and/or power transmission. Particularly, the electrical connector assembly may comprise multiple electrical contacts, wherein some of the contacts may be adapted for power transmission and others for signal transmission. Those contacts may be shielded.
The housing may be a female housing that is adapted to, at least partially, receive a housing of a corresponding (male) counter connector. Alternatively, the housing is a male housing that is adapted to, at least partially, be received in a housing of a corresponding (female) counter connector.
The electrical connector assembly comprises a mating lever that is arranged pivotable relative to the housing between an alignment position and a mating position. Particularly, the mating lever may be adapted to be pivotable and translationally slidable relative to the housing. In the alignment position, the mating lever is opened. Thus, the mating lever allows an electrical counter connector assembly to be aligned with the housing of the connector assembly. Further, in the alignment position, the electrical counter connector assembly may be partially inserted into the housing, but not mated yet. Thus, in the alignment position, there is typically no electrical connection between the electrical connector assembly and the counter connector assembly.
In the mating position the mating lever is closed and thus couples the housing of the connector assembly with the electrical counter connector assembly in a mated configuration. In the mated configuration, there is an electrical connection between the electrical connector assembly and the counter connector assembly.
The mating lever is configured to be engageable with the electrical counter connector assembly, in order to move the electrical counter connector assembly along a mating direction "A" relative to the housing of the connector assembly into the mated configuration, when being pivoted from the alignment position to the mating position. Thus, when the mating lever is closed, the electrical connector assembly and the counter connector assembly are forced into the mated configuration and an electrical connection is established.
The connector assembly includes at least one first slide track that is engageable with a corresponding first slide member of the electrical counter connector assembly. The first slide track may be formed as a groove, as an elongated through opening and/or the like within the mating lever. In an alternative embodiment, the first slide track may be provided in the housing of the counter connector assembly. When being engaged with a corresponding first slide member, the first slide track guides the first slide member along the first slide track, when the mating lever is pivoted (i.e. opened and/or closed).
Particularly, the first slide track is shaped so that the pivoting movement of the mating lever is transferred into an axial movement of the electrical counter connector assembly via the first slide member, if the first slide member is engaged with the first slide track.
The first slide track has a curved shape and that is composed of at least two radius segments, wherein a center of a first radius segment is different from a center of a second radius segment. Optionally, the radius of the first radius segment is different from the radius of the second radius segment. Each of the radius segments defines a course of a transmission ratio as a function of the angular position of the mating lever. Wherein the transmission ratio is defined as a ratio between the pivoting movement of the mating lever and the movement of the electrical counter connector assembly along a mating direction "A" (i.e. when closing the mating lever).
With providing at least two radius segments, each having a different center and optionally a different curvature radius, the course of the transmission ratio between the pivoting movement of the mating lever and the axial movement of the counter connector assembly relative to the housing of the connector assembly can be adapted to the mating resistance. Thus, it is possible to compensate for peaks in the direct mating force (i.e. when mating the connector assembly with a counter connector without using the lever). Accordingly, an actuating moment (pivoting moment) can be provided that is closer to an ideal constant actuating moment that has to be applied when closing the mating lever. Further, the length of the mating lever can be reduced, compared to known mating levers.
For example, a first segment of the first slide track may have a first center and a first curvature radius and a second segment may have second center that is different from the first center. The second curvature radius may be different from the first curvature radius. The curvature radius and center of the first segment may be chosen so as to provide a pre-defined course of the transmission ratio and the second radius segment (center and curvature radius) may be chosen so as to provide a different course of the transmission ratio. In an exemplary first case, the course of the transmission ratio of each radius segment may be substantially constant. The first radius segment may define a transmission ratio that is lower than the transmission ratio defined by the second radius segment.
In an exemplary second case, the first radius segment may provide an increasing course of the transmission ratio and the second radius segment may provide a decreasing course of the transmission ratio. It is to be understood, that all or only some of the segments described with respect to the first and second case can be combined in other embodiments. As the radius segments are different (in center and optionally in curvature radius) a desired transmission ratio can be provided dependent on the angular position of the mating lever. With defining the transmission ratio dependent on the angular position of the mating lever, a difference in mating resistance can be compensated, while applying substantially the same actuating moment on the mating lever. A difference in mating resistance may result from different parts that are mated. For example, upon mating the connector assembly with the counter connector assembly in a first mating phase, the housings are mated, resulting in a relatively low mating resistance. In a second phase, the electrical contacts are mated, resulting in a higher mating resistance.
In the first case, the first radius segment (low transmission ratio) may be associated with the mating of the housings and the second radius segment (high transmission ratio) may be associated with the mating of the electrical contacts. In the second case (increasing/decreasing course of the transmission ratio) the radius segments can be combined so as to provide a peak in the course of the transmission ratio. This peak may be associated with the mating of the electrical contacts.
Accordingly, with choosing and combining different radius segments, the course of the transmission ratio can be adapted to the occurring direct mating force.
Further, the electrical connector assembly may include at least one second slide track that is engaged with a corresponding second slide member of the electrical connector assembly, particularly of the housing of the electrical connector assembly. In this configuration, the mating lever is arranged pivotable around a pivot pin that is supported slidably in a third slide track of the electrical connector assembly. The third slide track may be substantially parallel to the mating direction.
The second slide track may be provided at the mating lever or at the housing. In the first case, the second slide member may be provided at the housing and in the second case, the second slide member may be provided at the mating lever. The second slide track may be shaped so that the pivoting movement of the mating lever is transferred into an axial movement of the mating lever relative to the housing in the mating direction A via the second slide member. Said axial movement of the mating lever is transferred into an axial movement of the counter connector assembly, when the mating lever is engaged with the counter connector assembly.
The second slide track may be formed as a groove, as an elongated through opening and/or the like. When being engaged with a corresponding second slide member, the second slide track guides the second slide member along the second slide track, when the mating lever is pivoted (i.e. opened and/or closed).
The second slide track may have a curved shape and may be composed of at least two radius segments, wherein a center of a first radius segment of the second slide track is different from a center of a second segment of the second slide track. Optionally, the radii of the first radius segment of the second slide track and the second segment of the second slide track may be different. Each of the radius segments defines a course of the transmission ratio between the pivoting movement of the mating lever and the axial movement of the mating lever.
With providing a second slide track, the mating may be speeded up, as both, the first and second slide tracks provide an axial movement of the counter connector assembly relative to the connector assembly. Further, the forced axial movement of the counter connector assembly relative to the connector assembly can be split up. A first portion of the movement can be achieved by the first slide track and a second portion of the movement can be achieved by the second slide track. This allows for a smaller build size of the slide tracks and therefore of the lever.
Further, with providing at least two radius segments, each having a different center (and optionally a different curvature radius), the course of the transmission ratio between the pivoting movement of the mating lever and the axial movement of the mating lever (which corresponds to an axial movement of the counter connector assembly) relative to the housing of the connector assembly can be adapted to the direct mating force.
Further, in alternative embodiments the first slide track and/or the second slide track may be part of the housing of the connector assembly, or the counter connector assembly, respectively. In these alternative embodiments, the mating lever may include first and/or second slide members, that are engageable with the respective slide tracks.
The at least one first slide track and the at least one second slide track may comprise substantially identical radius segments, wherein the at least one second slide track is rotatively offset with respect to a pivoting axis of the mating lever relative to the first slide track. The rotational offset may be in a range between 150° and 210°, preferably in a range between 170° to 190° and most preferably about 180 °. With providing identical or substantially identical radius segments for the first and second slide tracks, the transmission ratios associated with the first and second slide track (respectively the radius segments thereof) are also (substantially) identical. Thus, the proportions of the axial movement of the counter connector assembly resulting from the first and second slide tracks are similar. In this configuration, the counter connector assembly will move twice as fast into the mating direction than the mating lever.
The first slide track and/or the second slide track may define a course of the transmission ratio, so that the force that has to be applied for pivoting the mating lever from the alignment position to the mating position does not exceed 90 N (actuating force), preferably does not exceed 75 N, more preferably does not exceed 50 N and most preferably does not exceed 40 N. The actuating force times the length of the mating lever gives the actuating moment. With providing an actuating force that does not exceed 90 N, a convenient manual actuation of the mating lever can be provided. In addition, small mating levers can be used with these actuating forces so that not much installation space is required.
The first radius segment of the first slide track and/or the second slide track may define an increasing course of the transmission ratio. The second radius segment of the first slide track and/or the second slide track may define a decreasing course of the transmission ratio, wherein upon pivoting the mating lever from the alignment position to the mating position, the first radius segment engages with the corresponding first/second slide member prior to engagement occurring between the second radius segment and the corresponding first/second slide member. Particularly, the first and second radius segments may be arranged directly adjacent to each other.
Further, the first radius segment of the first slide track and/or the second slide track may define an average transmission ratio that is lower than an average transmission ratio defined by the second radius segment of the first slide track and/or the second slide track, wherein upon pivoting the mating lever from the alignment position to the mating position, the first radius segment engages with the corresponding first/second slide member prior to engagement occurring between the second radius segment and the corresponding first/second slide member. The average transmission ratio is a transmission ratio that is averaged over the course of the transmission ratio, defined by the respective radius segment.
For example, the average transmission ratio of the first radius segment maybe chosen so that a ratio of direct mating force : actuating force is in a range between 3 to 6, preferably in a range of 3.5 to 4 and the transmission ratio of the second radius segment may be chosen so that a ratio direct mating force : actuating force direct mating force : actuating force is in a range of 5 to 8, preferably in arrange of 6 to 8. Accordingly, when the transmission ratio is chosen so that a ratio of direct mating force : actuating force is e.g. 3 (first radius segment), an actuating force of 50 N will result in a mating force of 150 N (minus frictional losses). When the second radius segment comes into engagement, the ratio of direct mating force : actuating force may be about 6. Thus, the same actuating force of 50 N will result in a mating force of 300 N (minus a frictional losses). This allows for compensating peaks in the direct mating force, that may result for example from mating of electrical terminals.
The first slide track and/or the second slide track may comprise a third radius segment. Said third radius segment is arranged so that upon pivoting the mating lever from the alignment position to the mating position, the third radius segment engages with the corresponding first/second slide member after the corresponding first/second slide member was engaged with the second radius segment. The third radius segment may define an average transmission ratio that is lower than the average transmission ratio defined by the second radius segment and optionally higher than the average transmission ratio defined by the first radius segment.
The center and curvature radius of the third radius segment may be chosen so as to provide a pre-defined course of the transmission ratio. The course of the transmission ratio of the third radius segment may be substantially constant. Particularly, the third radius segment may be associated with a third mating phase. In said third mating phase, e.g. a friction of a seal member of the connector assembly must be overcome. The resulting rise of mating resistance can be compensated by choosing the center and curvature radius of the third radius segment respectively. For example, the average transmission ratio of the third radius segment may be chosen so that a ratio of direct mating force : actuating force is a range between 3.5 to 5.5, preferably in a range between 4 to 5.
Further, the first slide track and/or the second slide track may comprise a first set of radius segments that defines transmission ratios between the pivoting movement of the mating lever from the alignment position into the mating position and the movement of the electrical counter connector assembly and/or the mating lever in the mating direction "A". Accordingly, this first set defines a course of the transmission ratio for mating the counter connector assembly with the connector assembly. Particularly, each segment of the set first set of radius segments may provide a course of the transmission ratio, wherein this course may either be increasing, decreasing or essentially constant. By combining different radius segments in the first set of radius segments, the course of the transmission ratio for closing the lever may be adapted to the direct mating force.
Additionally, the first slide track and/or the second slide track may comprise a second set of radius segments that defines transmission ratios between the pivoting movement of the mating lever from the mating position into the alignment position and the movement of the electrical counter connector assembly and/or the mating lever in a direction opposite to the mating direction "A". Accordingly, this second set defines a course of the transmission ratio for un-mating (separating) the counter connector assembly and the connector assembly.
The first set may comprise concave radius segments and the second set convex radius segments, wherein the first set of radius segments and the second set of radius segments are provided on opposing sides of the respective slide track. In other words, the first set of radius segments is provided on radially outer curve and the second set on a radially inner curve of the respective slide track.
The second set of radius segments may comprise a fourth radius segment and a fifth radius segment, wherein the fourth radius defines an average transmission ratio that is higher than an average transmission ratio defined by the fifth radius segment, wherein upon pivoting the mating lever from the mating position to the alignment position, the fourth radius segment engages with the corresponding first/second slide member prior to engagement occurring between the fifth radius segment and the corresponding first/second slide member. Particularly, the fourth and/or fifth radius segments may be chosen to have a substantially constant transmission ratio.
The fourth radius segment may be associated with a first un-mating phase for separating the connector assembly and the counter connector assembly. In said first un-mating phase, e.g. the electrical terminals are separated. The fifth radius segment maybe associated with a second un-mating phase, wherein the housings of the connector assembly and the counter connector assembly are separated. For example, the transmission ratio of the fourth radius segment may be chosen, so that a ratio of direct unmating force : actuating force is in a range of 4.5 to 6.5, preferably in a range of 4 to 6 and the transmission ratio of the fifth radius segment may be chosen, so that a ratio of ratio of direct unmating force : actuating force is in a range of 2.5 to 4, preferably in a range of 3 to 4.
Particularly, each segment of the second set of radius segments may provide a course of the transmission ratio, wherein this course may either be increasing, decreasing or essentially constant. By combining different radius segments in the second set of radius segments, the course of the transmission ratio for opening the lever may be adapted to the un-mating force.
At least two of the radius segments of the first slide track and/or the second slide track may be connected in a non-tangential or a tangential way.
A tangential connection of two adjacent radius segments allows to avoid a sudden change of the transmission ratio in a transition area from e.g. the first radius segment to the second radius segment. Particularly, in case the first radius segment provides an increasing course of the transmission ratio and the second radius segment provides a decreasing course of the transmission ratio, a tangential connection may be desired. Thus, a peak in the course of the transmission ratio, without sudden changes, can be provided. If adjacent radius segments are non-tangentially connected, the transmission ratio will vary step-wise. This may be desirable, if adjacent radius segments provide a substantially constant course of the transmission ratio and different average transmission ratios.
Further, the radius segments typically have a center that is different from the pivoting axis of the mating lever. The first and/or second slide track may comprise at least one additional radius segment, wherein the center of the additional radius segment is same as the center of the pivoting axis of the mating lever. This additional radius segment(s) may serve as a parking position for the mating lever, e.g. in the mating position. Thus, the mating lever can rest in the mating position with a minimum of residual stress in the mating lever. Further, the mating lever may comprise a lever-locking element that is adapted to engage with a corresponding lever-locking element, so as to secure the lever in the mating position. This allows securing the mating lever in the mating position. The lever-locking element may be formed as a locking hook that engages with a corresponding locking shoulder of the counter connector assembly and/or the connector assembly.
Further, the lever-locking element may include a ramp portion provided in the first slide track and/or the second slide track, that allows the first slide member and/or the second slide member to rest, when the mating lever is in the mating position. Accordingly, the lever-locking element may be integrally formed within the first slide track and/or the second slide track.
The electrical connector assembly may further comprise a connector position assurance (CPA) member that is arranged moveable relative to the housing so as to be moveable into a locked position. Particularly, the connector position assurance member may be supported by the housing so as to be axially slidable. The electrical connector assembly may further comprise an elastic element. Said elastic element may be integrally formed with the connector position assurance member or may be a separate element, such as a compression spring, particularly a spiral spring. The elastic element may be associated with the connector position assurance member and may be configured to urge the connector position assurance member into the locked position when the mating lever is in the mating position. In the locked position, the connector position assurance member locks the mating lever in the mating position. As the connector position assurance member locks the mating lever in the mating position, unintentionally opening the mating lever can be prevented. Thus, the mated configuration of the electrical connector assembly and the counter connector assembly is secured by the connector position assurance member.
Further, the object is at least partially achieved by an electrical connector system, comprising an electrical connector assembly as described above, and an electrical counter connector assembly. The electrical counter connector assembly of the system comprises a mating means, that may be a corresponding first slide member. In this system, the mating lever of the electrical connector assembly is configured to engage with the mating means of the electrical counter connector assembly, in order to move the electrical counter connector assembly along a mating direction A relative to the housing of the connector assembly into a mated configuration, when being pivoted from the alignment position to the mating position.
Further, the object is at least partially achieved by a method for mating the electrical connector system, wherein the method comprises the following steps:

providing an electrical connector assembly as described above,
providing an electrical counter connector assembly;
aligning the electrical counter connector assembly with the electrical connector assembly, and engaging the mating lever of the electrical connector assembly with the electrical counter connector assembly;
pivoting the mating lever from the alignment position to the mating position (i.e. closing the mating lever), thereby moving the electrical counter connector assembly along a mating direction "A" relative to the housing of the connector assembly into the mated configuration.

The method may further comprise the steps of

pivoting the mating lever into the alignment position (i.e. opening the mating lever) to allow un-mating the electrical connector assembly and the electrical counter connector assembly, wherein the pivoting movement of the mating lever into the alignment position is transferred into an axial movement of the electrical counter connector assembly in a direction opposite to the mating direction "A" by the first slide track and/or the second slide track.

Brief description of the figures

In the following, the accompanying figures are briefly described:

Fig. 1A: is a schematic view of an electrical connector assembly according to an embodiment of the present disclosure;
Fig. 1B: is a schematic side view of the connector assembly of Fig. 1A;
Fig. 2A: is a schematic view of a connector system in an alignment position, according to an embodiment of the present disclosure;
Fig. 2B: is a schematic view of the connector system in an intermediate position;
Fig. 2C: is a schematic view of the connector system in a mating position;
Fig. 3: is an exemplary graph of a mating force;
Fig. 4A: is a schematic side view of a mating lever, according to an embodiment of the present disclosure;
Fig. 4B: is a schematic graph of a transmission ratio for the mating lever of Fig. 4A (mating curve);
Fig. 5A: is a schematic side view of a further mating lever, according to an embodiment of the present disclosure;
Fig. 5B: is a schematic graph of a transmission ratio for the mating lever of Fig. 5A (mating curve);
Fig. 5C: is a schematic graph of a transmission ratio for the mating lever of Fig. 5A (un-mating curve), and
Fig. 5D: is an exemplary graph of an un-mating force.

Detailed description of the figures

Fig. 1A is a schematic view of a connector system, comprising an electrical connector assembly 1 and a counter connector assembly 2, according to an embodiment of the present disclosure. Fig. 1B shows the connector system of Fig 1A is a cut side view. The electrical connector assembly 1 comprises a housing 100, that houses at least one electrical contact (not shown). The housing 100 is a female housing that is adapted to, at least partially, receive a housing of a corresponding (male) counter connector 2. In the configuration shown in Figs. 1A and 1B, the connector assembly 1 and the corresponding counter connector 2 are not entirely mated yet.
Further, the electrical connector assembly 1 comprises a mating lever 200 that is arranged pivotable relative to the housing between an alignment position (as shown in Fig. 2A) and a mating position (as shown in Fig. 2C).
The electrical connector assembly 1 further comprises a connector position assurance member 300 that is arranged moveable relative to the housing 100 so as to be moveable into a locked position. Particularly, the connector position assurance member 300 is supported by the housing 100 so as to be axially slidable. In the locked position, the connector position assurance member 300 secures the mating lever 200 in the mated position.
The alignment position of the mating lever 200 is shown in Fig. 2A. Here, the mating lever 200 is fully opened (alignment position). In the alignment position, the electrical counter connector assembly 2 can be aligned with the housing 100 of the connector assembly 1. Further, in the alignment position, the electrical counter connector assembly may be partially inserted into the housing, but not mated yet.
The mating position of the mating lever 200 is shown in Fig. 2C. Here, the mating lever 200 is fully closed (mating position). In the mating position the mating lever 200 couples the housing 100 of the connector assembly with the electrical counter connector assembly 2 in a mated configuration. In the mated configuration, there is an electrical connection between the electrical connector assembly and the counter connector assembly.
Figs. 2A to 2C show a pivoting sequence of the mating lever 200 and a respective mating sequence of the connector system, including the connector assembly 1 and the counter connector assembly 2, according to an embodiment of the present disclosure. The mating lever 200 is configured to be engageable with the electrical counter connector assembly 2, in order to move the electrical counter connector assembly 2 along a mating direction "A" relative to the housing 100 of the connector assembly 1 into the mated configuration, when being pivoted from the alignment position to the mating position. Thus, when the mating lever 200 is getting closed, the electrical connector assembly 1 and the counter connector assembly 2 are forced into the mated configuration and an electrical connection is established. In Fig. 2A, the mating lever 200 is in the alignment position, i.e. opened. In Fig. 2B, the system is shown, wherein the mating lever 200 is in an intermediate position (cf. also Fig. 1A and Fig. 1B). In Fig. 2C, the system is shown, wherein the mating lever 200 is in the mating position, i.e. closed.
In the embodiments shown in Figs. 1A, 1B and Figs. 2A to 2C the mating lever 200 includes a first slide track 220 that is engaged with a corresponding first slide member 20 of the electrical counter connector assembly 2. The first slide member 20 is formed as a pin, laterally protruding from the electrical counter connector assembly 2 and being received within the first slide track 220. The first slide track 220 is formed as an elongated through opening and guides the first slide member 20, when the mating lever 200 is pivoted (i.e. opened and/or closed).
Particularly, the first slide track 220 is shaped so that the pivoting movement of the mating lever 200 is transferred into an axial movement of the electrical counter connector assembly 2 via the first slide member 20. The first slide track 220 has a curved shape that defines a course of the transmission ratio between the pivoting movement of the mating lever 200 and the axial movement of the counter connector assembly 2 relative to the housing 100 of the connector assembly 1. By choosing the center and curvature radius (respectively centers and curvature radii of different curvature segments, as will be described in greater detail with regard to Figs. 4A and 5A), it is possible to provide a desired course of the transmission ratio. This course may either be increasing, decreasing or essentially constant. Thus, the course of the transmission ratio can be adapted to the direct mating force of the electrical connector assembly/counter connector. Particularly, peaks or sudden changes in the direct mating force can be compensated. The mating lever 200 may comprises multiple first slide tracks 220 that are arranged laterally on opposing sides of the mating lever.
Further, the mating lever 200 includes at least one second slide track 222 that is engaged with a corresponding second slide member 122 of the electrical connector assembly 1, particularly of the housing 100 of the electrical connector assembly 1. In this configuration, the mating lever 200 is arranged pivotable around a pivot pin 225 (cf. Fig. 1A) that is supported slidably in a third slide track 125 of the electrical connector assembly 1. The pivot pin 225 may be integrally formed with the mating lever 200. The third slide track 125 is substantially parallel to the mating direction A.
The second slide track 222 is shaped so that the pivoting movement of the mating lever 200 is transferred into an axial movement of the mating lever 200 relative to the housing 100 via the second slide member 122. Said axial movement of the mating lever 200 is transferred into an axial movement of the counter connector assembly 2, as the mating lever 200 is engaged with the counter connector assembly 2.
The second slide track 222 is formed as an elongated through opening and guides the second slide member 122 when the mating lever 200 is pivoted (i.e. opened and/or closed). The second slide track 222 has a curved shape that defines a course of the transmission ratio between the pivoting movement of the mating lever 200 and the axial movement of the mating lever 200 relative to the housing 100 of the connector assembly 1. By choosing the center and the curvature radius (respectively centers and curvature radii of different curvature segments, as will be described in greater detail with regard to Figs. 4A and 5A), it is possible to provide a desired course of the transmission ratio. This course may either be increasing, decreasing or essentially constant. Thus, the course of the transmission ratio can be adapted to the direct mating force of the electrical connector assembly/counter connector. Particularly, peaks or sudden changes in the direct mating force can be compensated. The mating lever 200 may comprises multiple second slide tracks 222 that are arranged laterally on opposing sides of the mating lever.
Thus, when pivoting the mating lever 200 from the alignment position (cf. Fig. 2A) to the mating position (cf. Fig. 2C), the aligned counter connector assembly 2 is forced into the connector assembly 1 and mated to establish an electrical connection. In the mating position, the connector position assurance member 300 is urged into the locked position and locks the mating lever 200 in the mating position.
Fig. 3 is an exemplary graph of a mating force F_m along a mating distance X_m that may occur during mating the counter connector assembly 2 with the connector assembly 1. In an alignment phase Po, the counter connector assembly 2 is aligned with the housing 100 of the connector assembly 1. In this phase Po, the mating force is low. At the beginning of mating phase P1, the counter connector assembly 2 is guided into the housing 100 of the connector assembly 1. During phase P1, friction resulting from a first connector sealing must be overcome. Further friction may occur between the housing 100 and the counter connector assembly 2. Thus, the mating resistance and accordingly the mating force slightly increase. During phase P2, electrical contacts/terminals of the connector assembly 1 and the counter connector assembly 2 are mated. Here, a peak in the mating force occurs. In phase P3, friction resulting from a further engagement with a connector sealing must be overcome. Thus, the mating resistance and accordingly the mating force may be higher than in phase P1. Despite the difference in mating forces, the electrical connector assembly and the respective system provide a substantially constant actuating moment (pivoting moment) that has to be applied when closing the mating lever, i.e. when mating the connector assembly 1 with the counter connector assembly 2. This is achieved by providing slide tracks with different radius segments, as shown in Figs. 4A and 5A.
Fig. 4A is a schematic side view of a mating lever, according to an embodiment of the present disclosure, that may be mating lever 200 of the connector assembly 1, shown in Figs. 1A to 2C. The mating lever 200 comprises a first slide track 220 that may be formed as a groove, as an elongated through opening and/or the like. When being engaged with a corresponding first slide member 20 (cf. Fig. 1A), the first slide track 220 guides the first slide member 20 along the first slide track (cf. dashed arrow), when the mating lever is closed.
The first slide track 220 has a curved shape and that is composed of at least two radius segments S11, S12, wherein a center and a radius of a first radius segment S11 is different from a center and a radius of a second segment S12. Each of the radius segments defines a course of the transmission ratio R between the pivoting movement of the mating lever and the movement of the electrical counter connector assembly along a mating direction "A" (i.e. when closing the mating lever). The course of the transmission ratio R is shown in Fig. 4B, dependent on the angular position α of the mating lever 200.
With these two radius segments S11 and S12, the transmission ratio between the pivoting movement of the mating lever 200 and the axial movement of the counter connector assembly 2 relative to the housing 100 of the connector assembly 1 can be adapted to the mating resistance. Thus, it is possible to provide an essentially constant actuating moment (pivoting moment) that has to be applied when closing the mating lever 200.
For example, the center and the curvature radius of the first segment S11 may be chosen so as to provide an increasing course of the transmission ratio and the center and the curvature radius of the second segment S12 maybe chosen so as to provide an decreasing course of the transmission ratio. As the first and second radius segments are provided adjacent to each other, a peak in the mating resistance, as demonstrated in Fig. 3, can be compensated by a corresponding peak in the course of the transmission ratio as shown in Fig 4B.
Further, the mating lever 200 includes a second slide track 222 that is engaged with a corresponding second slide member 122 of the electrical connector assembly 1. The mating lever 200 is arranged pivotable around a pivot pin 225 that is supported slidably in a third slide track 125 of the electrical connector assembly 1 (cf. Fig. 1A).
The second slide track 222 is shaped so that the pivoting movement of the mating lever 200 is transferred into an axial movement of the mating lever 200 relative to the housing 100 in the mating direction A via the second slide member 122. Said axial movement of the mating lever 200 is transferred into an axial movement of the counter connector assembly 2, when the mating lever 200 is engaged with the counter connector assembly 2.
The second slide track 222 may be formed as a groove, as an elongated through opening and/or the like. When being engaged with a corresponding second slide member 122, the second slide track 222 guides the second slide member 122 along the second slide track 222 (cf. dashed arrow), when the mating lever is closed.
The second slide track has a curved shape that is composed of at least two radius segments S21, S22, wherein a radius of a first radius segment S21 of the second slide track 222 is different from a radius of a second segment S22 of the second slide track 222. Each of the radius segments defines a course of a transmission ratio R between the pivoting movement of the mating lever and the axial movement of the mating lever (cf. Fig. 4B).
Segments S11, S12 and S21, S22 constitute a first set of radius segments that define a course of the transmission ratio between the pivoting movement of the mating lever 200 from the alignment position into the mating position and the movement of the electrical counter connector assembly 2 and/or the mating lever 200 in the mating direction "A". Accordingly, this first set defines transmission ratios for mating the counter connector assembly with the connector assembly (mating curve).
The resulting course of the transmission ratio for closing the mating lever 200 is shown in Fig. 4B, dependent on the angular position of the mating lever 200. At an angular position of 0°, the lever is open (alignment position) and at an angular position of about 90°, the lever is closed (mating position). The centers and radii of segments S11 and S21 are defined so that the transmission ratio increases with increasing angular position (increasing course). The centers and radii of segments S12 and S22 are defined so that the transmission ratio decreases with increasing angular position (decreasing course). Segments S11 and S12 as well as segments S21 and S22 maybe connected in a tangential way. As segments S12 and S22, having an increasing course, and segments S12 and S22, having a decreasing course, are arranged adjacent to each other, a local peak of the transmission ratio can be achieved. This local peak may be associated with mating phase P2 (cf. Fig. 3). Segments S11 and S21 may be associated with mating phase P1 and segments S12 and S22 with mating phase P3. Thus, the transmission ratio is adapted to the occurring mating resistance, so as to provide a substantially constant actuating moment for closing the mating lever 200.
Further, the mating lever 200 may comprise a lever-locking element 260 that is adapted to engage with a corresponding lever-locking element, so as to secure the lever in the mating position. In the embodiment shown in Fig. 4A, the lever-locking element 260 includes a ramp portion provided in the second slide track 222, that allows the second slide member 122 to rest, when the mating lever 200 is in the mating position. In other words, the second slide member 122 is prevented from sliding back, when having passed the lever-locking element 260.
Fig. 5A is a schematic side view of a mating lever, according to an embodiment of the present disclosure, that may be mating lever 200 of the connector assembly 1, shown in Figs. 1A to 2C. The mating lever 200 comprises a first slide track 220 and a second slide track 222. As described with respect to Fig. 4A the first/ second slide track 220, 222 may be formed as a groove, as an elongated through opening and/or the like. When being engaged with a corresponding first/ second slide member 20, 122, the first slide track 220 guides the first slide member 20 along the first slide track (cf. dashed arrow), when the mating lever is closed and the second slide track guides the second slide member 122 along the second slide track (cf. dashed arrow).
Further, the first slide track 220 comprises a first set of radius segments S11, S12, S13 that define transmission ratios between the pivoting movement of the mating lever 200 from the alignment position into the mating position and the movement of the electrical counter connector assembly 2 in the mating direction A. Accordingly, this first set defines a course of the transmission ratio for mating the counter connector assembly with the connector assembly (mating curve). This first set of radius segments may include at least two segments, preferably at least three segments and most preferably at least five segments
Likewise, the second slide track 222 comprises a first set of radius segments S21, S22, S23 that define transmission ratios between the pivoting movement of the mating lever 200 from the alignment position into the mating position and the movement of the mating lever 200 in the mating direction A. Accordingly, this first set defines transmission ratios for mating the counter connector assembly with the connector assembly (mating curve). This first set of radius segments may include at least two segments, preferably at least three segments and most preferably at least five segments.
Additionally, the first slide track 220 and/or the second slide track 222 may comprise a second set of radius segments S14, S15 and S24, S25, respectively, that define a course of the transmission ratio between the pivoting movement of the mating lever from the mating position into the alignment position and the movement of the electrical counter connector assembly and/or the mating lever in a direction opposite to the mating direction A. Accordingly, this second set defines transmission ratios for un-mating (separating) the counter connector assembly 2 and the connector assembly 1. This second set of radius segments may include at least two segments, preferably at least three segments and most preferably at least five segments.
The first set of segments S11, S12, S13 and S21, S22, S23 comprises concave radius segments and the second set convex radius segments S14, S15 and S24, S25, wherein the first set of radius segments and the second set of radius segments are provided on opposing sides of the respective slide track 220, 222.
The resulting course of the transmission ratio for closing the mating lever 200 of Fig. 5A is shown in Fig. 5B, dependent on the angular position of the mating lever 200. At an angular position of 0°, the lever is open (alignment position) and at an angular position of about 90°, the lever is closed (mating position). The centers and radii of segments S11, S21 are defined so that a low average transmission ratio is provided. These segments may be associated with mating phase P1 (cf. Fig. 3). The centers and radii of segments S12, S22 are defined so that a high average transmission ratio is provided. These segments may be associated with mating phase P2. The center and radii of segments S13, S23 are defined so that a mid-average transmission ratio is provided. These segments may be associated with mating phase P3. Thus, the transmission ratio is adapted to the occurring mating resistance, so as to provide a substantially constant actuating moment for closing the mating lever 200.
Segments S11, S12, S13 and S21, S22, S23 may each be interconnected in a non-tangential way. Thus, it is possible to vary the transmission ratio step-wise. Alternatively, adjacent segments of the first set of segments S11, S12, S13 and S21, S22, S23 may be interconnected via small rounding portions, so as to smoothen the sudden change of the average transmission ratio provided by said adjacent segments. The rounding portions may be connected tangentially with adjacent segments.
The course of the transmission ratio defined by the second set of radius segments S14, S15 and S24, S25 for opening the mating lever 200 of Fig. 5A is shown in Fig. 5C, dependent on the angular position of the mating lever 200. At an angular position of o°, the lever is open (alignment position) and at an angular position of about 90°, the lever is closed (mating position). The centers and radii of segments S14, S24 (fourth radius segments) are defined so that a high average transmission ratio is provided. These segments may be associated with an un-mating phase (phase P4 in Fig. 5D), where the electrical contacts/terminals are separated. After having separated the electrical contacts/terminals a lower un-mating force is sufficient. Thus, the average transmission ratio of radius segments S15, S25 (fifth radius segments) can be lower, as those segments are associated with an un-mating phase (phase P5 in Fig. 5D), where the electrical contacts/terminals are already separated.
Fig. 5D is an exemplary graph of an un-mating force that may occur during un-mating the counter connector assembly 2 and the connector assembly 1. During un-mating, the counter connector assembly 2 is moved in a direction opposite to the mating direction A, relative to the connector assembly 1. In phase P4, the electrical contacts/terminals are separated, resulting in a high un-mating force. In phase P5, the electrical contacts/terminals are already separated and only the housings and optionally seals have to be separated. Thus, the un-mating force in phase P5 is lower than in phase P4.

List of reference signs

1: electrical connector assembly

2: electrical counter connector assembly
20: first slide member

100: housing
122: second slide member
125: third slide track

200: mating lever
220: first slide track
222: second slide track
225: pivot pin

S11, S12, S13: radius segments of the first slide track (mating curve)
S14, S15: radius segments of the first slide track (un-mating curve)
S21, S22, S23: radius segments of the second slide track (mating curve)
S24, S25: radius segments of the second slide track (un-mating curve)

300: connector position assurance member (CPA)

A: mating direction
R: transmission ratio
Fm: mating force
xm: mating distance
P0, P1, P2, P3: mating phases
P4, P5: un-mating phases
α: angular position (mating lever)

Claims

An electrical connector assembly (1) comprising:
a housing (100), that houses at least one electrical contact;

a mating lever (200) that is arranged pivotable relative to the housing (100) between an alignment position and a mating position, wherein

in the alignment position, the mating lever (200) allows an electrical counter connector assembly (2) to be aligned with the housing (100) of the connector assembly (1), and

in the mating position the mating lever (200) couples the housing (100) of the connector assembly (1) with the electrical counter connector assembly (2) in a mated configuration, wherein

the mating lever (200) is configured to be engageable with the electrical counter connector assembly (2), in order to move the electrical counter connector assembly (2) along a mating direction (A) relative to the housing (100) of the connector assembly (1) into the mated configuration, when being pivoted from the alignment position to the mating position, wherein

the connector assembly (1) includes at least one first slide track (220) that is engageable with a corresponding first slide member (20) of the electrical counter connector assembly (2), wherein

the first slide track (220) is shaped so that the pivoting movement of the mating lever (200) is transferred into an axial movement of the electrical counter connector assembly (2) via the first slide member (20), if the first slide member (20) is engaged with the first slide track (220), wherein

the first slide track (220) has a curved shape that is composed of at least two radius segments, wherein a center of a first radius segment (S11) is different from a center of a second segment (S12),

wherein each of the radius segments (S11, S12) defines a transmission ratio between the pivoting movement of the mating lever (200) and the movement of the electrical counter connector assembly (2) along a mating direction (A).
The electrical connector assembly (1) according to claim 1, wherein the connector assembly (1) includes at least one second slide track (222) that is engaged with a corresponding second slide member (122) of the connector assembly (1), wherein
the mating lever (200) is arranged pivotable around a pivot pin (225) that is supported slidably in a third slide track (125) of the electrical connector assembly (1), wherein
the second slide track (222) is shaped so that the pivoting movement of the mating lever (200) is transferred into an axial movement of the mating lever (200) relative to the housing (100) in mating direction A via the second slide member (122), wherein
the second slide track (222) has a curved shape that is composed of at least two radius segments (S21, S22), wherein a center of a first radius segment (S21) of the second slide track is different from a center of a second segment (S22) of the second slide track,
wherein each of the radius segments (S21, S22) defines a transmission ratio between the pivoting movement of the mating lever (200) and the axial movement of the mating lever (200).
The electrical connector assembly (1) according to any preceding claim, wherein the at least one first slide track (220) and the at least one second slide track (222) comprise substantially identical radius segments, and wherein the at least one second slide track is rotatively offset with respect to a pivoting axis of the mating lever (200) relative to the first slide track (220).
The electrical connector assembly (1) according to any one of claims 1 to 3, wherein the first radius segment (S11, S21) of the first slide track (220) and/or the second slide track (222) defines an increasing course of the transmission ratio, and wherein the second radius segment (S21, S22) of the first slide track (220) and/or the second slide track (222) defines a decreasing course of the transmission ratio, wherein
upon pivoting the mating lever (200) from the alignment position to the mating position, the first radius segment (S11, S21) engages with the corresponding first/second slide member (20, 122) prior to engagement occurring between the second radius segment (S12, S22) and the corresponding first/second slide member (20, 122).
The electrical connector assembly (1) according to any one of claims 1 to 3, wherein the first radius segment (S11, S21) of the first slide track (220) and/or the second slide track (222) defines an average transmission ratio that is lower than an average transmission ratio defined by the second radius segment (S12, S22) of the first slide track (220) and/or the second slide track, wherein
upon pivoting the mating lever (200) from the alignment position to the mating position, the first radius segment (S11, S21) engages with the corresponding first/second slide member (20, 122) prior to engagement occurring between the second radius segment (S12, S22) and the corresponding first/second slide member (20, 122).
The electrical connector assembly (1) according to any preceding claim, wherein the first slide track (220) and/or the second slide track (222) comprises a third radius segment (S13, S23), wherein the third radius segment (S13, S23) is arranged so that upon pivoting the mating lever (200) from the alignment position to the mating position, the third radius segment (S13, S23) engages with the corresponding first/second slide member (20, 122) after the corresponding first/second slide member (20, 122) was engaged with the second radius segment (S12, S22), and wherein the third radius segment (S13, S23) defines an average transmission ratio that is lower than the average transmission ratio defined by the second radius segment (S12, S22) and optionally higher than the average transmission ratio defined by the first radius segment (S11, S21).
The electrical connector assembly (1) according to any preceding claim wherein the first slide track (220) and/or the second slide track (222) comprises
a first set of radius segments (S11, S12, S13, S21, S22, S23) that defines transmission ratios between the pivoting movement of the mating lever (200) from the alignment position into the mating position and the movement of the electrical counter connector assembly (2) and/or the mating lever in the mating direction (A) and
a second set of radius segments (S14, S15, S24, S25) that defines transmission ratios between the pivoting movement of the mating lever (200) from the mating position into the alignment position and the movement of the electrical counter connector assembly (2) and/or the mating lever in a direction opposite to the mating direction (A), and wherein the second set of radius segments (S14, S15, S24, S25) comprises a
fourth radius segment (S14, S24) and a fifth radius segment (S15, S25), wherein
the fourth radius defines an average transmission ratio that is higher than an average transmission ratio defined by the fifth radius segment, wherein
upon pivoting the mating lever (200) from the mating position to the alignment position, the fourth radius segment (S14, S24) engages with the corresponding first/second slide member (20, 122) prior to engagement occurring between the fifth radius segment (S15, S25) and the corresponding first/second slide member (20, 122).
The electrical connector assembly (1) according to any preceding claim, wherein at least two of the radius segments (S11, S12, S13, S21, S22, S23) of the first slide track (220) and/or the second slide track (222) are connected in a non-tangential or a tangential way.
The electrical connector assembly (1) according to any preceding claim, wherein at least two of the radius segments (S11, S12, S13, S21, S22, S23) of the first slide track (220) and/or the second slide track (222) have different curvature radii.
The electrical connector assembly (1) according to any preceding claim, wherein the mating lever (200) comprises a lever-locking element (260) that is adapted to engage with a corresponding lever-locking element, so as to secure the mating lever in the mating position.
The electrical connector assembly (1) according the preceding claim, wherein the lever-locking element (260) includes a ramp portion provided in the first slide track and/or the second slide track, that allows the first slide member and/or the second slide member to rest, when the mating lever (200) is in the mating position.
The electrical connector assembly (1) according to any preceding claim, wherein the electrical connector assembly (1) further comprises:
a connector position assurance, CPA, member (300) that is arranged moveable relative to the housing (100) so as to be moveable into a locked position, and

an elastic element (400), wherein the elastic element is associated with the connector position assurance member (300) and configured to urge the connector position assurance member (300) into the locked position when the mating lever (200) is in the mating position, so that the connector position assurance member (300)

locks the mating lever (200) in the mating position.
An electrical connector system, comprising
an electrical connector assembly (1) according to any one of claims 1 to 12 and
an electrical counter connector assembly (2), wherein the electrical counter connector assembly (2) comprises a mating means, optionally being a corresponding first slide member (20), wherein the mating lever (200) of the electrical connector assembly (1) is configured to engage with the mating means of the electrical counter connector assembly (2), in order to move the electrical counter connector assembly (2) along a mating direction (A) relative to the housing (100) of the connector assembly (1) into a mated configuration, when being pivoted from the alignment position to the mating position.
A method for mating an electrical connector system according to claim 13, wherein the method comprises the following steps:
providing an electrical connector assembly (1) according to any one of claims 1 to 12,

providing an electrical counter connector assembly (2);

aligning the electrical counter connector assembly (2) with the electrical connector assembly (1), and engaging the mating lever (200) of the electrical connector assembly (1) with the electrical counter connector assembly (2);

pivoting the mating lever (200) from the alignment position to the mating position, thereby moving the electrical counter connector assembly (2) along a mating direction (A) relative to the housing (100) of the connector assembly (1) into the mated configuration.
The method according to claim 14, further comprising
pivoting the mating lever (200) into the alignment position to allow un-mating of the electrical connector assembly (1) and the electrical counter connector assembly (2), wherein
the pivoting movement of the mating lever into the alignment position is transferred into an axial movement of the electrical counter connector assembly (2) in a direction opposite to the mating direction by the first slide track (220) and/or the second slide track (222).