EP4629446A1

EP4629446A1 - Position assurance member

Info

Publication number: EP4629446A1
Application number: EP24168057.8A
Authority: EP
Inventors: Norbert Dobernig; Nithish Sukumar
Original assignee: Aptiv Technologies AG
Current assignee: Aptiv Technologies AG
Priority date: 2024-04-02
Filing date: 2024-04-02
Publication date: 2025-10-08

Abstract

A position assurance member 1, such as a terminal position assurance (TPA) member or a connector position assurance (CPA) member, for an electrical connector assembly 100, wherein the position assurance member 1 is a rigid unitary element.

Description

1. Field of the invention

The present invention relates to a position assurance (PA) member, in particular a terminal position assurance (TPA) member or a connector position assurance (CPA), which is securely held at a connector housing. The present invention further relates to an electrical connector assembly comprising such a PA member.

2. Technical background

Electrical connectors and electrical connector assemblies are commonly used to connect various cables, such as for example telecommunication cables, common networking cables, signaling cables or in general any electrical wiring. In this context electrical connectors are particularly used for joining electrical circuits, wherein a male ended plug of an electrical connector may be adapted to be connected to a respective female ended jack of a corresponding counter connector.
Many electrical connector assemblies are provided with a so-called terminal position assurance (TPA) member, which allows for assuring that a terminal or contact is securely held in a fully inserted position within an electrical connector housing to form the electrical connector. An electrical connector typically comprises one or more electrical terminals connected to electrical wires. Usually, the terminal or contact is inserted into the connector housing from the back side of the connector housing and then the TPA member is moved to a locking position to fix the terminal within the connector housing. After the TPA is brought into its locking position, the electrical terminal is fixed within the housing of the electrical connector such that the electrical connector can be used. To such an electrical connector, a corresponding connector may be mated from an end opposite to and end at which the terminal is inserted.
A TPA member is further utilized to detect incomplete insertion of contact terminals into a connector housing. They also assist in assuring that the contact terminals are properly positioned in the respective housing. A TPA member may thereby be mounted movably to the connector housing and may secure the terminal within the connector housing when being fully inserted.
Similarly, connector position assurance (CPA) members are often employed in electrical and electronic connectors, especially in the automotive industry and other applications where secure and reliable electrical connections is important. A CPA member is a feature or mechanism designed to ensure that a connector is properly and securely mated or fully engaged with the respective counter connector, preventing it from unintentional disconnection or loosening due to vibration, shock, or other external forces. CPA members can take various forms, but their primary purpose is to provide mechanical locking or latching of the female and male electrical connectors to maintain the connection's integrity.
Conventional TPA members and CPA members have various different ways of locking with the connector housing. Many TPA and CPA members comprise flexible latching hooks for securing the TPA members and CPA members to the connector housing. In some cases, conventional TPA members and CPA members are manufactured from a stiff and brittle plastic material for improving the stability thereof, particularly if such TPA and CPA members have small dimensions. Thus, the flexibility of the latching hooks may be affected such they are hard to deflect and may lead to failure or even break. Further, many TPA and CPA members tend to unintentionally disconnect from the connector housing during transport prior to assembly or even after assembly. In addition, in many conventional electrical connectors, it poses difficulties to remove a position assurance member from the final-locking position to the pre-locking position and from the pre-locking position to an unmounted position. Oftentimes, special tools must be used by users in order to remove a TPA/CPA member. However, this could lead to damages to the TPA/CPA member, which makes reusability of the TPA/CPA member during its lifetime more difficult.
It is thus an object of the present invention to provide a position assurance member, particularly a TPA member and/or a CPA member, for an electrical connector assembly which overcomes the above outlined disadvantages at least partially. It is, particularly, an object of the present invention to provide a position assurance member for an electrical connector assembly, which has an improved reliability both in use and during assembly.

3. Summary of the invention

The above-mentioned objects are at least partially achieved by the subject-matter of the independent claim 1. Preferred embodiments are subject of the dependent claims, and the skilled person finds hints for other suitable aspects of the present invention through the overall disclosure of the present application.
Preferably, the above-mentioned problem is solved by a position assurance member, such as a terminal position assurance (TPA) member or a connector position assurance (CPA) member, for an electrical connector assembly, wherein the position assurance member is a rigid unitary element. Thus, as the position assurance member is a rigid unitary element it has an improved reliability as it has no parts that are to be intentionally bend. Thus, preferably the position assurance member can be made of stiff plastic material. Preferably, the position assurance member is made of a glass-fiber-reinforced plastic material, for improved stability and rigidity. Preferably, the position assurance member has no flexible elements like arms with latching hooks as prior art position assurance members. Thus, as such flexible elements are missing, there is no danger of breaking any flexible elements of the position assurance member. All the flexible elements for holding the position assurance member in its different positions are preferably part of the connector housing. This further provides various design options, preferably for saving space of the connector assembly.
Preferably, the position assurance member is adapted to be mounted to a connector housing of the electrical connector assembly and being movable relative to the connector housing between a pre-locking position and a final-locking position along a position assurance movement direction. Thus, the position assurance member can be pre-mounted to the electrical connector assembly and is switchable between a pre-locking position, where e.g. terminals can be inserted or connectors can be mated, and a final-locking position, where e.g. terminals are locked within a connector housing or wherein the connectors are locked in the fully mated position. Further, by pre-mounting a manufacturing step can be done already by the connector manufacturer and must not be done be the wiring manufacturer. Further, by pre-mounting the position assurance member cannot be lost during transport.
Preferably, the position assurance member further comprises a body portion and at least one terminal or connector locking element extending in a position assurance movement direction. A terminal locking element prevents un-locking of an electrical terminal and a connector locking element prevents disconnection of two mated connectors.
Preferably, the position assurance member further comprises at least one pre-locking notch arranged at the body portion. The pre-locking notch defines the pre-position of the position assurance member. Preferably, the pre-locking notch is engaged by a pre-position locking arm of the connector housing when the position assurance member is in the pre-position.
Preferably, the position assurance member further comprises a final-locking notch arranged at the body portion. The final-locking notch defines the final-locking position of the position assurance member. Preferably, the final-locking notch is engaged by a final-locking locking arm of the connector housing when the position assurance member is in the final-locking position.
Preferably, the final-locking notch is arranged between two pre-locking notches. This enables a symmetric holding-force introduction to the position assurance member both in the pre-locking position and in the final-locking position. Further, as two pre-locking notches are used, the retention force against unintended separation of the position assurance member from the connector assembly is improved.
Preferably, the position assurance member further comprises an opening wedge arranged at the body portion, wherein the opening wedge is arranged for moving the position assurance member from the final-locking position to the pre-locking position. The wedge easily translates a release force of an external tool into a force along the position assurance movement direction (MD). Thus, for example a simple flat screwdriver or a special release tool that applies a pushing force can be used to generate a perpendicular movement force to switch the position assurance member from the final-locking position to the pre-locking position. Preferably, the special release tool can be a needle shaped tool with rounded tip in order to prevent damage of the terminal during release sequence.
Preferably, the above-mentioned problem is also solved by an electrical connector assembly, comprising the position assurance member as mentioned above and a connector housing, wherein the connector housing comprises a flexible final-locking arm that engages in the final-locking position the final position locking notch. Thus, the position assurance member is temporarily held in the final-locking position by a final-locking arm of the connector housing. As the flexible final-locking arm is part of the connector housing it can be designed as needed without affecting the small size of the position assurance member. Thus, the electrically connector assembly can be provided very space efficient.
Preferably, the final-locking arm is straight and comprises a rounded edge at an end thereof. The rounded edge allows switching of the position assurance member from the final-locking position to the pre-locking position and vice versa multiple times without damage of the final locking arm or the final-locking notch.
Preferably, the connector housing further comprises at least one flexible pre-position locking arm that engages in the pre-locking position the pre-position locking notch. Thus, the position assurance member is temporarily held in the pre-locking position by a pre-position locking arm of the connector housing. As the flexible pre-position locking arm is also part of the connector housing it can be designed as needed without affecting the small size of the position assurance member. Thus, also for this reason the electrically connector assembly can be provided very space efficient.
Preferably, the pre-position locking arm is L-shaped and comprises a snapping hook at an end thereof. The L-shape of the pre-position locking arm increases its effective length by optimizing the occupied space at the connector housing. The snapping hook prevents disengagement of the position assurance member from the connector housing.
Preferably, the connector housing further comprises an elastic terminal primary locking that secures an electrical terminal within the connector housing, wherein the position assurance member engages the terminal primary locking in the final-locking position to prevent opening the terminal primary lock. Thus, the position assurance member acts as a TPA and effectively secures the electrical terminal within the connector housing.
Preferably, the electrical connector assembly further comprises a removal tool that can engage the opening wedge of the position assurance member for moving the position assurance member from the final-locking position to the pre-lock-position, wherein the removal tool can also engage the terminal primary locking for opening a terminal primary locking to release an electrical terminal. Thus, the same removal tool can be used to switch the position assurance member and to open the terminal primary locking for removing the electrical terminal out of the connector housing. The removal tool may preferably be a common flat screwdriver.
Preferably, the terminal primary locking comprises an end notch at an end thereof for receiving a tip of the removal tool for opening the terminal primary lock. The end notch can easily be engaged by a tip of a removal tool, for example the tip of a flat screwdriver or the rounded tip of a needle shaped release tool.

4. Brief description of preferred embodiments

In the following, preferred embodiments of the disclosure are disclosed by reference to the accompanying figures.

Fig. 1:: shows a three-dimensional view of a position assurance member according to an embodiment of the present invention;
Fig. 2:: shows a three-dimensional view of the position assurance member of Fig. 1 from the underside;
Fig. 3A:: shows a three-dimensional partial view of an electrical connector assembly with the position assurance member of Fig. 1 in a pre-locking position;
Fig. 3B:: shows a three-dimensional partial view of the electrical connector assembly of Fig. 3A with the position assurance member in a final-locking position;
Fig. 4:: shows a three-dimensional partial view of the electrical connector assembly of Fig. 3A without the position assurance member;
Fig. 5A:: shows a three-dimensional partial sectional view of the electrical connector assembly of Fig. 3A with the position assurance member in the pre-locking position;
Fig. 5B:: shows a three-dimensional partial sectional view of the electrical connector assembly of Fig. 5A with the position assurance member in the final-locking position;
Fig. 6A:: shows a three-dimensional partial sectional view of the electrical connector assembly of Fig. 3A with the position assurance member in the pre-locking position;
Fig. 6B:: shows a three-dimensional partial sectional view of the electrical connector assembly of Fig. 6A with the position assurance member in the final-locking position;
Fig. 7:: shows a partial sectional view of the electrical connector assembly of Fig. 3B during moving the position assurance member from the final-locking position to the pre-locking position by a removal tool;
Fig. 8:: shows a three-dimensional partial view of the electrical connector assembly of Fig. 3B from the connection side, with an opening for the insertion of a removal tool;
Fig. 9A:: shows a partial sectional view of the electrical connector assembly of Fig. 3A during opening of a terminal primary locking by a removal tool;
Fig. 9B:: shows a partial sectional view of the electrical connector assembly of Fig. 9A with the terminal primary locking in an open state; and
Fig. 10:: shows a partial view of the electrical connector assembly of Fig. 3A from the connection side, with the opening for the insertion of a removal tool.

5. Detailed description of preferred embodiments

In the subsequent passages, a preferred embodiment of the invention is described with reference to the accompanying figures in more detail. It is noted that further embodiments are certainly possible, and the below explanations are provided by way of example only, without limitation. Throughout the present figures and specification, the same reference numerals refer to the same elements. The figures may not be to scale, and the relative size, proportions, and depiction of elements in the figures may be exaggerated for clarity, illustration, and convenience.
It is noted that when features, aspects, and/or embodiments are described herein by the term "substantially", manufacturing tolerances must be taken into consideration. In this manner, minor deviations during any kind of manufacturing, assembling or the like may pertain. Further, manufacturing tolerances, aging effects, or other minor defects or the like may pertain. These are all encompassed by the term "substantially". Although not always explicitly expressed by using the term "substantially", it is understood that the elements, parts, units, shapes, and/or the like described herein may nevertheless comprise such manufacturing tolerances.
Figs. 1 and 2 show a position assurance member 1 according to an embodiment of the invention. The position assurance member 1 can be a terminal position assurance (TPA) member or a connector position assurance (CPA) member for an electrical connector assembly 100. In the shown example the position assurance member 1 is a terminal position assurance member (TPA).
The position assurance member 1 is a rigid unitary element. Thus, it has no parts that are intentionally flexible, like flexible snapping hooks or flexible lugs, levers or the like. The position assurance member 1 is preferably made by injection molding of plastic material, for example PE or PP. Preferably, a glass-fiber-reinforced plastic material is used for the position assurance member 1 to increase the mechanical strength or rigidity thereof.
The position assurance member 1 comprises a body portion 10, a first terminal or connector locking element 20 and a second terminal or connector locking element 22. In the shown embodiment the locking elements 20 and 22 have a "fork" design and are for locking the same terminal or connector. In other embodiments (not shown), each of the two locking elements 20, 22 can be for locking one corresponding terminal or connector. Thus, the two locking elements 20, 22 can generally be for the locking of two terminals or connectors as well. The body portion 10 has a substantially cuboid shape and comprises two cavities 14 on the rear side to decrease material usage. Further, the cavities 14 provide support for a mounting tool during assembly. The cavities 14 can also facilitate gripping the position assurance member 1 by a robotic gripper. Thus, the position assurance member 1 allows automatic assembly by automatic assembly machines or robots.
The locking elements 20, 22 extend substantially perpendicularly from the body portion 10 in mounting direction MD. The locking elements 20, 22 have a substantially cuboid shape with tapered tips. The locking elements 20, 22 are intended to mechanically lock one electrical terminal 150 or multiple electrical terminals 150 in the same plane within a connector housing 110 (TPA case) or locking two mated connector housings 110 with each other to prevent disassembly (CPA case). The first and second locking elements 20, 22 extend through first and second openings 112, 114 (see Fig. 4) within the connector housing 110 to engage the preferably one electrical connector 150 from two opposite sides.
In another embodiment (not shown) the position assurance member 1 only comprises one locking element 20 that extends substantially perpendicularly from the body portion 10 in mounting direction MD. The single locking element 20 can lock a single terminal 150 or multiple terminals 150 in the same plane.
In further embodiments (not shown) the position assurance member 1 can comprise more than two, particularly three, four, five or six locking elements 20 that each extend substantially perpendicularly from the body portion 10 in mounting direction MD. Such locking elements can also lock three, four, five or six terminals 150 or even more terminals 150 in the same plane.
The position assurance member 1 further comprises a first pre-locking notch 30 and a second pre-locking notch 32. The pre-locking notches 30, 32 are preferably arranged on the upper side of the body portion 10. Preferably, they are arranged at the rear edge of the upper side of the body portion 10. The pre-locking notches 30, 32 are intended to prevent that the position assurance member 1 leaves the pre-locking position 102 and disassembles from the connector housing 110 (see Fig. 5A). To this end the pre-locking notches 30, 32 cooperates with corresponding first and second pre-position locking arms 130, 132 of the connector housing 110.
The position assurance member 1 further comprises a final-locking notch 40. The final-locking notch 40 is preferably arranged on the upper side of the body portion 10. Preferably, it is arranged at the rear edge of the upper side of the body portion 10. Preferably, the final-locking notch 40 is arranged in-between the pre-locking notches 30, 32. The final-locking notch 40 is intended to hold the position assurance member 1 in the final-locking position 104 (see Fig. 6B). To this end the final-locking notch 40 cooperates with a corresponding final-locking arm 120 of the connector housing 110.
The position assurance member 1 further comprises an opening wedge 50 at the front side of the body portion 10. The opening wedge 50 is tapered from a small thickness at the lower edge 52 to a larger thickness at an upper edge 54 of the opening wedge 50. The opening wedge 50 enables the position assurance member 1 to be moved or opened from the final-locking position 104 to the pre-locking position 102.
The position assurance member 1 further comprises two cuboid wings 12 that extend the upper surface of the body portion 10. The wings 12 support the position assurance member 1 when assembled in the pre-locking position 102 at the connector housing 110 (see Fig. 3A). Further, the wings 12 act as poka-yoke feature for a correct insertion of the position assurance member 1 into the body portion 10.
As shown in Figs. 3A and 3B the position assurance member 1 is usually movably mounted to a connector housing 110 of an electrical connector assembly 100 for securing an electrical terminal 150 within the connector assembly 100 or for securing mated electrical connectors. Therefore, the position assurance member 1 movable relative to the connector housing 110 between a pre-locking position 102 as shown in Fig. 3A and a final-locking position 104 as shown in Fig. 3B along a position assurance movement direction MD. The position assurance movement direction MD is preferably substantially perpendicular to the connection direction CD.
The Figs. 3A and 5A show that in pre-locking position 102 the position assurance member 1 is prevented from disassembly by substantially L-shaped pre-locking arms 130, 132. The pre-locking arms 10, 132 are attached at an upper end at the connector housing 110 and comprise at a lower end snapping hooks 134 that engage the corresponding pre-locking notches 30, 32. The L-shaped pre-locking arms 130, 132 are flexible to allow insertion of the position assurance member 1 into the connector housing 110. Fig. 4 shows the first and second flexible pre-locking arms 130, 132 in more detail.
Fig. 6A shows that the position assurance member 1 is additionally held in the pre-locking position 102 by the final-locking lever 120 that engages a front edge 18 of the upper side 16 of the body portion 10. Thus, the position assurance member 1 does not unintentionally move from the pre-locking position 102 to the final-locking position 104.
The Figs. 3B, 5B and 6B show the position assurance member 1 in the final-locking position 104 in which the position assurance member 1 was pushed further into the connector housing 110 to lock the terminal 150. In the final-locking position 104 the rounded tip 122 of the final-locking lever 120 engages the final locking notch 40. Thus, the position assurance member 1 does not unintentionally move from the final-locking position 104 to the pre-locking position 102. Fig. 4 shows the flexible final-locking arm 120 in more detail.
As shown in Fig. 5B in detail, in the final-locking position 104 the tip 24 of the terminal locking element 20 is inserted into a circumferential terminal notch 152 of the terminal 150 to secure the electrical terminal 150within the connector housing 110.
Further, as shown in Fig. 6A and 6B, the terminal 150 is further locked within the connector housing 110 by a flexible terminal primary lock 140. The terminal primary lock 140 comprises a locking edge 144 that engages the terminal notch 152 after insertion of the electrical terminal 150 into the connector housing 110.
In addition, as shown in Fig. 6B a front side 17 of the body portion 10 in the final-lock position 104 blocks an opening movement of the flexible terminal primary lock 140.
Figs. 7 to 10 show how an electrical terminal 150 can be disassembled from the connector housing 110 after being fully locked by the position assurance member 1 and the terminal primary lock 140.
As shown in Fig. 7 in a first step a removal tool 160 can be inserted into an opening window 116 (see Figs. 8 and 10) at the connection side of the connector housing 110. The removal tool 160 then engages the opening wedge 50 and can be moved to the right as shown by arrow 162 in order to move the position assurance member 1 from the final-locking position 104 to the pre-locking position 102. When the position assurance member 1 is moved from the final-locking position 104 to the pre-locking position 102 the flexible final locking arm 120 is bent open as indicated by the reference number 120' and dashed lines. Thereby, the edge 122 of the final locking arm 120 disengages from the final-locking notch 40.
When the position assurance member 1 is in the pre-mounting position 102, the opening window 116 allows access to an end notch 142 of the terminal primary lock 140 by the removal tool 160 as shown in Fig. 10.
As shown by Figs. 9A and 9B, the same or a different removal tool 160 is inserted or remains inserted into the opening window 116 and is moved to the right as indicated by arrow 160 to bend the terminal primary lock 140 to its open state 140' (shown in dashed lines). Then, the terminal primary lock 140 disengages from the terminal notch 152 and the terminal 150 is free to be retracted out of the connector housing 110 as indicated by arrow 166.

List of reference signs

1: position assurance member
10: body portion
12: wings
14: cavities
16: upper side
18: front edge
20: first terminal or connector locking element
22: second terminal or connector locking element
24: tapered tips
30: first pre-locking notch
32: second pre-locking notch
40: final-locking notch
50: opening wedge
52: lower edge
54: upper edge
100: connector assembly
102: pre-locking position
104: final-locking position
110: connector housing
112: first opening
114: second opening
116: opening window
120: final-locking arm
122: rounded edge
130: first pre-locking arm
132: second pre-locking arm
134: snapping hook
140: terminal primary lock
142: end notch
150: electrical terminal
152: terminal notch
160: removal tool
162, 164, 166: arrows

Claims

A position assurance member (1), such as a terminal position assurance (TPA) member or a connector position assurance (CPA) member, for an electrical connector assembly (100), wherein the position assurance member (1) is a rigid unitary element.
The position assurance member according to claim 1, being made of a glass-fiber-reinforced plastic material.
The position assurance member according to one of the claims 1 or 2, wherein the position assurance member (1) is adapted to be mounted to a connector housing (110) of the electrical connector assembly (100) and being movable relative to the connector housing (110) between a pre-locking position (102) and a final-locking position (104) along a position assurance movement direction (MD).
The position assurance member according to one of the claims 1 to 3, further comprising a body portion (10) and at least one terminal or connector locking element (20, 22) extending in a position assurance movement direction (MD).
The position assurance member according to one of the claims 1 to 4, further comprising at least one pre-locking notch (30, 32) arranged at the body portion (10).
The position assurance member according to one of the claims 1 to 5, further comprising a final-locking notch (40) arranged at the body portion (10).
The position assurance member according to claim 6, wherein the final-locking notch (40) is arranged in-between two pre-locking notches (30, 32).
The position assurance member according to one of the claims 1 to 7, further comprising an opening wedge (50) arranged at the body portion (10), wherein the opening wedge (50) is arranged for moving the position assurance member (1) from the final-locking position (104) to the pre-locking position (102).
An electrical connector assembly (100), comprising the position assurance member according to one of the claims 1 to 8 and a connector housing (110), wherein the connector housing (110) comprises a flexible final-locking arm (120) that engages in the final-locking position (104) the final-locking notch (40).
The electrical connector assembly according to claim 9, wherein the final-locking arm (120) is straight and comprises a rounded edge (122) at an end thereof.
The electrical connector assembly according to one of the claims 9 or 10,
wherein the connector housing (110) further comprises at least one flexible pre-locking arm (130, 132) that engages in the pre-locking position (110) the pre-locking notch (30, 32).
The electrical connector assembly according to claim 11, wherein the pre-locking arm (130, 132) is L-shaped and comprises a snapping hook (134) at an end thereof.
The electrical connector assembly according to one of the claims 9 to 12,
wherein the connector housing (110) further comprises an elastic terminal primary lock (140) that secures an electrical terminal (150) within the connector housing (110), wherein the position assurance member (1) engages the terminal primary lock (140) in the final-locking position (104) to prevent opening the terminal primary lock (140).
The electrical connector assembly according to one of the claims 9 to 13, further comprising a removal tool (160) that can engage the opening wedge (50) of the position assurance member (1) for moving the position assurance member (1) from the final-locking position (104) to the pre-locking position (102), wherein the removal tool (160) can also engage the terminal primary lock (140) for opening a terminal primary lock (140) to release an electrical terminal (150).
The electrical connector assembly according to claim 14, wherein the terminal primary lock (140) comprises an end notch (142) at an end thereof for receiving a tip of the removal tool (160) for opening the terminal primary lock (140).