EP4614736A1

EP4614736A1 - Method of assembling connector modules using secondary lock

Info

Publication number: EP4614736A1
Application number: EP24162322.2A
Authority: EP
Inventors: Anna ARASIMOWICZ; Przemyslaw SLABAS
Original assignee: Aptiv Technologies AG
Current assignee: Aptiv Technologies AG
Priority date: 2024-03-08
Filing date: 2024-03-08
Publication date: 2025-09-10

Abstract

The present disclosure relates to an electrical connector system. An electrical connector system (200) is provided. The electrical connector system (200) comprises a housing (202) and at least one connector module (204A, 204B, 204C, 204D) adapted for holding a plurality of terminals. Each terminal comprises a primary lock adapted for primary locking the terminal in the connector module (204A, 204B, 204C, 204D). The connector module (204A, 204B, 204C, 204D) is associated with a secondary lock. The secondary lock is adapted for secondary locking the terminals in the connector module. The secondary lock is integrated with the housing (202) and comprises an elongate locking beam (214A, 214B, 214C, 214D) having a snap-fit profile adapted for snapping into a corresponding groove (216A, 216B, 216C, 216D) of the connector module (204A, 204B, 204C, 204D) for fastening the connector module to the housing (202).

Description

1. Field of the invention

The present disclosure generally relates to an electrical connector system.

2. Prior art

Electrical connector systems are generally used to provide a removable electrical connection for terminals arranged therein. Modular electrical connector systems typically comprise one or more modules arranged in a housing of the electrical connector system. A modular electrical connector system may offer flexibility in the quantity and types of terminals arranged in the electrical connector system (i.e., within a single housing) while maintaining standardized dimensions of the modules for ease of assembling, for example, automated assembling. More specifically, instead of constructing cables with a mix of terminals having different sizes and shapes, connector modules having a unified size and shape (typically box-shape) may be used. For example, one connector module may be constructed to accommodate a smaller number of terminals, each having a greater effective contact area, while another connector module may be constructed to accommodate a greater number of miniaturized terminals, each having a smaller effective contact area. In addition, a housing may be provided to accommodate a number of such connector modules. In general, each terminal comprises a primary lock (e.g., a tab, a hook, or the like) adapted to engage with a corresponding recess/counterpart in the connector module for primary locking the terminal in the connector module. In addition, each connector module is often associated with a secondary lock (e.g., a beam) for an additional locking of terminals.
In some modular electrical connector systems, the secondary locking function is provided by an element integrated with the housing of the modular electrical connector system. In other modular electrical connector systems, the secondary locking function is provided by the connector module itself or by a separate part. In such modular electrical connector systems, often additional parts/elements are provided to block the connector modules against accidental removal from the housing (i.e., to fasten the connector modules in the housing). Furthermore, other deficiencies may also be attributed to prior art modular electrical connector systems. This is explained below in conjunction with Figs. 1A and 1B.
The object of the disclosed subject matter is to at least partially overcome deficiencies of prior art electrical connector systems, particularly, to provide an electrical connector system having a simplified design, enabling the use of different sizes of terminals in one row and providing reduced installation space while meeting the same requirements relative to the prior art electrical connector systems.

3. Summary of the invention

The above-mentioned objects are at least partially realized by an electrical connector according to claim 1.
Particularly, the above-mentioned object is realized by an electrical connector system comprising a housing and at least one connector module. The connector module holds (is adapted for holding) a plurality of terminals. Each terminal comprises a primary lock (e.g., a tab, a hook, or the like) adapted for primary locking the terminal in the connector module (e.g., adapted to engage with a corresponding recess/counterpart in the connector module). The connector module is associated with a secondary lock. The secondary lock is adapted for secondary locking the terminals in the connector module, for example, as a safeguard in the case of a failure of the primary locking. In some aspects, the secondary lock may also be referred to as a terminal position assurance (TPA) member or may provide the functionality of a TPA member. The secondary lock is integrated with the housing and comprises an elongate beam having a snap-fit profile adapted for snapping into a corresponding groove in the connector module. As a result, the connector module is advantageously fastened (fixed) with the housing (i.e., is blocked from being accidentally removed from the housing) and hence no additional parts/elements need to be provided to fasten (fix/block) the connector module in the housing.
In an aspect of the present disclosure, the elongate beam is integrated with and projecting from a wall of the housing. This provides a robust design and allows advantageously the production of housing and beam in a single injection molding process.
In a further aspect of the present disclosure, the housing comprises a middle wall and a plurality of parallel sidewalls arranged perpendicular to the middle wall. In addition, the beam is arranged between two adjacent sidewalls. As a result, the middle wall and the sidewalls are arranged to form a grid which is advantageously adapted to receive (enable insertion) a plurality of connector modules in openings of the grid. This may, in turn, advantageously enable the use of terminals having different sizes in one row of connector modules (each of which may be defined in accordance with any one of the aspects of the present disclosure) because the elongate locking beams do not interfere with connector modules in the assembly direction. This will be explained in more detail with reference to the figures.
In a further aspect of the present disclosure, when the connector module is fastened, the groove and the beam extend parallel to a normal of two adjacent sidewalls. As a result, substantially uniform stress may be advantageously exerted on the groove and on the beam along their respective lengths.
In a further aspect of the present disclosure, the beam is spaced from at least one (and preferably from both) of the two adjacent sidewalls of the housing, between which it is arranged. In other words, the beam extends e.g. between two adjacent sidewalls but does not contact one (or both) sidewalls. The gap may be rather small, in the range of a few millimeters. As a result, the beam may advantageously exhibit enhanced flexibility along its partial (or entire) length which facilitates fastening the connector module to the housing.
In a further aspect of the present disclosure, the connector module is substantially box-shaped (i.e., has substantially a form of a rectangular prism) having through-holes for receiving terminals. Further, the groove is arranged in a sidewall of the connector module and is arranged perpendicular to an insertion direction of the terminals. As a result, a connector module of a uniform shape may be advantageously provided which may facilitate flexibility of the use of the connector module.
In a further aspect of the present disclosure, when the connector module is fastened, the beam prevents movement of the connector module relative to the housing in at least two directions. As a result, movement of the connector module may be advantageously blocked, for example, except for the dimension parallel to the beam.
In a further aspect of the present disclosure, the profile of the beam comprises a hook shape and the profile of the groove comprises a corresponding undercut for engaging with the hook. As a result, movement of the connector module relative to the housing may be advantageously prevented at least in dimensions located in the cross-section of the profiles.
In a further aspect of the present disclosure, the groove is closed by a wall on at least one end and, when the connector module is fastened, the wall provides a contact to the beam to limit the movement of the connector module along an extension of the beam. As a result, movement of the connector module relative to the housing may be advantageously prevented in the dimension parallel to the beam in at least one direction.
In a further aspect of the present disclosure, the groove is closed by a corresponding wall (i.e., two individual walls) on both ends and, when the connector module is fastened, the walls limit movement of the connector module along both extension directions of the beam. As a result, movement of the connector module relative to the housing may be advantageously prevented in the dimension parallel to the beam.
In a further aspect of the present disclosure, when the module is fastened, a sidewall of the housing provides a contact to an outside wall of the connector module to limit movement of the connector module along an extension direction of the beam. As a result, movement of the connector module relative to the housing may be advantageously prevented in the dimension parallel to the beam in at least one direction, for example, the direction opposite to the direction prevented by the sidewall.
In a further aspect of the present disclosure, the electrical connector system comprises at least two elongate locking beams (each of which may be defined in accordance with any one of the aspects of the present disclosure). The elongate locking beams are parallel to each other and preferably perpendicular to sidewalls of the housing, i.e. they extend parallel to the normal of the sidewalls. In addition, the elongate locking beams are arranged at different heights relative to an edge of a mating face of the housing. As a result, flexibility may be advantageously enhanced since more than one connector module, each of which being adapted for holding terminals of a different size (height), may be used within a single housing.
In a further aspect of the present disclosure, the electrical connector system comprises at least two connector modules (each of which may be defined in accordance with any one of the aspects of the present disclosure). The at least two connector modules may have different sizes and preferably different heights and/or different widths. Further preferably, the at least two connector modules are aligned at a plane being parallel to a mating face of the housing. As a result, flexibility may be advantageously enhanced since connector modules of different sizes may be used within the (single) housing.
In a further aspect of the present disclosure, the at least two connector modules are adapted for holding terminals having different sizes. As a result, flexibility may be advantageously enhanced since connector modules each of which being adapted for holding terminals of a different size (e.g., having a different effective contact area) may be used within the (single) housing.
In a further aspect of the present disclosure, the housing and/or the connector module is made of a moldable material, preferably of a thermoplastic material and further preferably of polyamide or polyethylene terephthalate. As a result, the housing and/or the connector module may advantageously exhibit stiffness which is required for stability of the electrical connector system and flexibility which is required for fastening the connector module to the housing (i.e., inserting the beam into the groove).

4. Brief description of the drawings

In the following, various aspects of the disclosed subject matter are described in detail with reference to the accompanying figures, in which:

Fig. 1A: shows a three-dimensional view of a modular electrical connector system according to the prior art;
Fig. 1B: shows a three-dimensional side view of a single connector module of the prior art modular electrical connector system;
Fig. 2A: shows a three-dimensional view of an embodiment of an electrical connector system according to the invention;
Fig. 2B: shows a three-dimensional view of the inventive embodiment of an electrical connector system with fastened connector modules;
Fig. 2C: shows a sideview of the embodiment before fastening the connector modules;
Fig. 2D: shows a sideview of the embodiment with fastened connector modules;
Fig. 2E: shows a three-dimensional view of the housing of the embodiment;
Fig. 2F: shows a three-dimensional view of a connector module of the embodiment.

5. Detailed description

Fig. 1A shows - in a three-dimensional view - a modular electrical connector system 100 in accordance with the prior art. The modular electrical connector system 100 comprises a housing 102 and a plurality of connector modules 104A, 104B, 104C and 104D, each adapted for holding a plurality of terminals (not shown). The direction of assembly into the housing 102 is indicated by an arrow 108. The direction indicated by the arrow 108 may be, in the context of the modular electrical connector system 100, referred to as assembling from the top. Each of the connector modules 104A, 104B, 104C and 104D comprises integrated locking beams which act as respective secondary locking means for locking the terminals inside the modules. Beams 110A and 110B of the respective modules 104A and 104B are shown in Fig. 1A, whereas the remaining beams are not visible in the figures. The beams of the modular electrical connector system 100 are arranged at ends of L-shape carrier elements which are explained below in conjunction with Fig. 1B.
The beams of the modular electrical connector system 100 (e.g., the beams 110A and 110B) do not fasten the connector modules 104A, 104B, 104C and 104D to the housing 102 but prevent (only) an accidental removal of the terminals. Therefore, the connector modules 104A, 104B, 104C and 104D comprise separate locking means in the form of latches, to latch the modules inside housing 102. Recess portions 112A and 112B of the latches of the connector modules 104A and 104B are indicated in Fig. 1A. The latches of the modular electrical connector system are adapted for fixing the connector modules 104A, 104B, 104C and 104D to the housing 102 and hence block against accidental removal from the housing 102. To this end, the housing 102 comprises corresponding counterparts at the bottom thereof, that are adapted to latch with the corresponding portions of the modules. Such latch elements are well known to the skilled person, so that it is refrained from giving a detailed explanation thereof.
Fig. 1B shows - in a three-dimensional view - a single connector module 104A of the prior art modular electrical connector system in more detail. The connector module 104A comprises two L-shaped flexible carrier elements 114 at the ends of which locking beams 110A are formed. For installation of terminals inside the module 104A, the carrier elements 114 are bend outwardly, so that the locking beams 110A do not block the installation space of the terminals. Once the terminals are correctly inserted into module 104A, the carrier elements 114 are placed in the position shown in Fig. 1B and the locking beams 110A interact with the inserted terminals, blocking them in their position. In other words, Fig. 1B shows the closed or locked position of the carrier elements 114, where a removal of the terminals is not possible.
Fig. 2A shows - in a three-dimensional exploded view - an electrical connector system 200 according to an embodiment of the present invention. The electrical connector system comprises a housing 202 and four connector modules 204A, 204B, 204C and 204D that are adapted to be mounted to or in housing 202. Each of the connector modules 204A, 204B, 204C and 204D is substantially box-shaped and comprises a plurality of through holes 206A, 206B, 206C and 206D. Each of the through holes is adapted for receiving a terminal and comprises a primary locking feature (not visible in the figures) for holding the inserted terminal.
The housing 202 comprises a middle wall 208 and a plurality of sidewalls 210 extending therefrom at right angles. The middle wall 208 and the plurality of sidewalls 210 are arranged to form a grid having openings arranged between the respective sidewalls 210 and parallel to the middle wall 208 adapted to receive the modules. The directions of assembly of the electrical connector system 200 are indicated by arrows 212. One can see that the modules are not assembled or inserted from the top of the housing, but rather from the side. One could also say that the assembly direction is perpendicular to the middle wall 208 (i.e., parallel to the normal of the middle wall 208). The housing 202 comprises four elongate locking beams 214A, 214B, 214C and 214D to lock with a respective one of the modules. Due to the perspective, in Fig. 2A only elongate locking beams 214A and 214C are visible. The elongate locking beams are integrated with and are projecting from the middle wall 208, extending each between two adjacent sidewalls 210, in a direction parallel to the plane of middle wall 208.
The connector modules 204A, 204B, 204C and 204D are provided with grooves 216A, 216B, 216C and 216D designed to be engaged by a respective elongate locking beam. The beam and groove do not only fasten the modules to the housing but also act as secondary locking means for the respective connector module. Once the terminals are inserted and arranged in their correct position inside the module, the elongate locking beams in the shown embodiment will not only latch the module to the housing but it will also prevent an accidental removal of the inserted terminals. Thus, the elongate locking beams may also serve as TPA (Terminal Position Assurance) member, if e.g., the modules are shaped such that the elongate locking beams may only be arranged in the groove when the terminals are in their correct position.
Each groove is arranged perpendicular to the insertion direction of the terminals, i.e., perpendicular to the through-holes 206A, 206B, 206C and 206D of the connector modules 204A, 204B, 204C and 204D. Each beam is formed to have a snap-fit profile adapted for snapping into a corresponding groove of the respective connector module (e.g., the connector modules 204A, 204B, 204C and 204D) to fasten the connector module to the housing (e.g., the housing 202) as explained below in conjunction with Fig. 2D. In Fig. 2A, connector module 204B is fastened to housing 202, whereas the connector modules 204A, 204C and 204D are shown before assembly.
As one can take from the figures, the connector modules 204A and 204C differ in terms of width. In particular, the connector module 204A is narrower than the connector module 204C. Further, the through-holes 206A for receiving terminals are much smaller than the through-holes 206C of connector module 204C. Thus, module 204A is adapted for relatively small terminals, whereas module 204C is adapted for relatively larger terminals. Nevertheless, both can be mounted side by side without obstructing each other and the same fastening principle of elongate locking beam and groove can be used for both modules. In addition, the connector modules 204C and 204D differ in terms of height. In particular, the connector module 204C is higher than the connector module 204D.
Fig. 2B shows - in a three-dimensional view - the electrical connector system 200 with connector modules 204A, 204B, 204C and 204D fastened to housing 202. Although the modules differ in height and width, all can readily be installed to housing 202.
Fig. 2C shows the electrical connector system 200 in a sideview. The connector modules 204C and 204D are not fastened yet to housing 202. The elongate locking beams 214C and 214D are arranged at different heights 218C and 218D relative to an edge of a mating face 201 of housing 202. As a result, the elongate locking beams 214C and 214D in conjunction with the grooves 216C and 216D may also serve as a secondary locking means for terminals (not shown) having different heights.
Fig. 2D shows the same viewpoint as Fig. 2C with the modules fastened to housing 202. The connector modules 204C and 204D are fastened to the housing 202 after having been assembled in the directions indicated by the arrows 212. Each profile of the elongate locking beams 214C and 214D comprises a hook shape and each profile of the grooves 216C and 216D comprises a corresponding undercut for engaging with the respective hook of the elongate locking beams 214C and 214D and hence for fastening the connector modules 204C and 204D to the housing 202 by a snap-fit type engagement. The snap-fit prevents movement of each of the connector modules 204C and 204D in any direction perpendicular to an extension direction of the elongate locking beams 214C and 214D. In other words, the snap-fit prevents movement in at least two dimensions. In addition, movement of the connector modules 204C and 204D in the extension direction of the elongate locking beams 214C and 214D is among others prevented by the two adjacent sidewalls 210 between which the respective module is arranged (as the skilled person will understand from considering Fig. 2A).
Fig. 2E shows - in a three-dimensional view - the housing 202 of the electrical connector system 200. The elongate locking beams 214A and 214C are integrated with and are projecting from the middle wall 208. The sidewalls 210 are arranged parallel to each other and perpendicular to the middle wall 208. The elongate locking beams 214A and 214C are arranged between adjacent sidewalls 210 and are spaced from both of the adjacent sidewalls 210. Alternatively, the elongate locking beams 214A and 214C may be spaced from only one of the adjacent sidewalls 210 and integrated with the other one of the adjacent sidewalls 210.
Fig. 2F shows the connector module 204A in a three-dimensional perspective view. Groove 216A is closed by a wall 222 on one end. When connector module 204A is fastened to elongate locking beam 214A, the wall 222 provides a stop for one edge of the elongate locking beam 214A to limit movement of the connector module 204A along an extension direction of the beam 214A. In addition, or as alternative, when the connector module 204A is fastened to elongate locking beams 214C, a sidewall 210 of the housing 202 may serve as stop element for an outside wall 224 of connector module 204A. In addition, or as further alternative, groove 216A may be closed by a corresponding wall on both ends. When the connector module 204A is fastened, the corresponding walls may limit movement of the connector module 204A along both extension directions of the beam 214A.

List of reference signs:

100: prior art connector system
102: prior art connector housing
104A/B/C/D: prior art connector module
108: installation/insertion direction
110A/B/C/D: locking beam
112A/B: recess portions
114: carrier element

200: electrical connector system
201: mating face
202: connector housing
204A/B/C/D: connector module
206A/B/C/D: through-holes (for receiving terminals)
208: middle wall
210: sidewall
212: installation/insertion direction
214A/B/C/D: elongate locking beams
216A/B/C/D: grooves
218C/D: height of beam on connector module
222: groove wall
224: outside wall of module

Claims

An electrical connector system (200) comprising:
a. a housing (202); and

b. at least one connector module (204A, 204B, 204C, 204D) adapted for holding a plurality of terminals, each terminal comprising a primary lock adapted for primary locking the terminal in the connector module (204A, 204B, 204C, 204D),

c. the connector module (204A, 204B, 204C, 204D) being associated with a secondary lock, the secondary lock adapted for secondary locking the terminals in the connector module,
characterized in that

d. the secondary lock is integrated with the housing (202) and comprises an elongate locking beam (214A, 214B, 214C, 214D) having a snap-fit profile adapted for snapping into a corresponding groove (216A, 216B, 216C, 216D) of the connector module (204A, 204B, 204C, 204D) for fastening the connector module to the housing (202).
The electrical connector system (200) of claim 1, wherein the elongate locking beam (214A, 214B, 214C, 214D) is integrated with and projecting from a wall (208) of the housing (202).
The electrical connector system (200) of claim 1 or 2, wherein the housing (202) comprises a middle wall (208) and a plurality of parallel sidewalls (210) arranged perpendicular to the middle wall (208), and wherein the elongate locking beam (214A, 214B, 214C, 214D) is arranged between two adjacent sidewalls (210).
The electrical connector system (200) of claim 3, wherein, when the connector module (204A, 204B, 204C, 204D) is fastened, the groove (216A, 216B, 216C, 216D) and the elongate locking beam (214A, 214B, 214C, 214D) extend parallel to a normal of two adjacent sidewalls (210).
The electrical connector system (200) of claim 3 or 4, wherein the elongate locking beam (214A, 214B, 214C, 214D) is spaced from at least one, preferably from both, of the two adjacent sidewalls (210) of the housing (202).
The electrical connector system (200) of any one of the preceding claims, wherein the connector module (204A, 204B, 204C, 204D) is substantially box-shaped having terminal receiving through-holes (206A, 206B, 206C, 206D) and the groove (216A, 216B, 216C, 216D) is arranged in a sidewall of the connector module, and wherein the groove is arranged perpendicular to an insertion direction of the terminals.
The electrical connector system (200) of any one of the preceding claims, wherein, when the connector module (204A, 204B, 204C, 204D) is fastened, the elongate locking beam (214A, 214B, 214C, 214D) prevents movement of the connector module relative to the housing (202) in at least two dimensions.
The electrical connector system (200) of any one of the preceding claims, wherein the profile of the elongate locking beam (214A, 214B, 214C, 214D) comprises a hook shape and the profile of the groove (216A, 216B, 216C, 216D) comprises a corresponding undercut for engaging with the hook.
The electrical connector system (200) of any one of the preceding claims, wherein the groove (216A, 216B, 216C, 216D) is closed by a wall (222) on at least one end, and wherein, when the connector module is fastened, the wall (222) provides a contact to the elongate locking beam (214A, 214B, 214C, 214D) to limit movement of the connector module along an extension direction of the elongate locking beam (214A, 214B, 214C, 214D).
The electrical connector system (200) of claim 9, wherein the groove is closed by a corresponding wall on both ends, and wherein, when the connector module is fastened, the walls limit movement of the connector module along both extension directions of the beam.
The electrical connector system (200) of any one of the preceding claims, wherein, when the module (204A, 204B, 204C, 204D) is fastened, a sidewall (210) of the housing (202) provides a contact to an outside wall (224) of the connector module to limit movement of the connector module along an extension direction of the elongate locking beam (214A, 214B, 214C, 214D).
The electrical connector system (200) of any one of the preceding claims, wherein the electrical connector system comprises at least two elongate locking beams (214A, 214B, 214C, 214D), the elongate locking beams being parallel to each other and preferably being perpendicular to sidewalls (210) of the housing (202), the elongate locking beams being arranged at different heights relative to an edge of a mating face of the housing.
The electrical connector system (200) of any one of the preceding claims, wherein the electrical connector system comprises at least two connector modules (204A, 204B, 204C, 204D), wherein the at least two connector modules have different sizes and preferably different heights and/or different widths, and further preferably, wherein the at least two connector modules are aligned at a plane being parallel to a mating face (201) of the housing (202).
The electrical connector system (200) of claim 12 or 13, wherein the at least two connector modules (204A, 204B, 204C, 204D) are adapted for holding terminals having different sizes.
The electrical connector system (200) of any one of the preceding claims, wherein the housing (202) and/or the connector module (204A, 204B, 204C, 204D) is made of a moldable material, preferably of a thermoplastic material and further preferably of polyamide or polyethylene terephthalate.