EP4641844A1

EP4641844A1 - Symmetrical lever arrangement having variable lever width

Info

Publication number: EP4641844A1
Application number: EP24172739.5A
Authority: EP
Inventors: Nithish Sukumar; Norbert Dobernig
Original assignee: Aptiv Technologies AG
Current assignee: Aptiv Technologies AG
Priority date: 2024-04-26
Filing date: 2024-04-26
Publication date: 2025-10-29

Abstract

The invention relates to a connector assembly that includes a connector housing and a U-shape mate assist device. This device comprises two arms, that can be connected. Each arm has at least three locking elements, designed to form a form-locked connection with matching locking elements on the other arm, creating e.g. a form-locked connection. Additionally, these locking elements are positioned on an interlocking portion of each arm in such a way that they can interlock in at least two different positions, so that the width of the U-shape mate assist device can be adjusted as needed. Further, the connectable arms are symmetrical.

Description

1. Field of the invention

This invention relates to an electrical connector assembly where the connector is provided with a mate assistance device to facilitate coupling with a corresponding counter electrical connector.

2. Background

In the automotive sector, the emergence of hybrid and electric vehicles among other conventional vehicles is increasing the number of electrical connections that need to be done in a vehicle to connect electrical components and protect the connection against accidental disconnection and/or harmful environmental conditions such as water and/or dust. But also, the general mechanical demands in a moving vehicle due to the vibrations form a rigorous regime in which an electrical connection faces difficulties to remain intact.
Often, connectors are coupled by mating the connectors by means of so-called mate assistant devices. These typically involve a lever mechanism whereby one connector housing is drawn towards the other connector housing through the e.g. rotational action of a lever initiating a cam type movement within the connectors, or by a linear sliding movement. The lever usually is formed in a U-shape, although it is recognized that U-shaped levers present installation challenges as they need to be rigid enough to withstand the forces exerted during activation of the mate assist function, yet they need to be flexible enough to be securely attached to the connector which usually involves elastically bending parts.
EP 3 955 395 A1 discloses a connector assembly which comprises a connector housing adapted to engage with a corresponding counter connector housing. A lever comprising a first lever arm and a second lever arm is pivotably and sealingly mounted to the connector housing. Each lever arm comprises interlocking means for connecting the first lever arm to the second lever arm at a first location. The interlocking means of each of the first lever arm and the second lever arm are configured to define complementary symmetrical surfaces that interlock with one another when the lever arms are pivotably mounted to the connector housing. On mounting the lever arms to the connector housing, the lever is configured to move about the connector housing between an open state and a closed state to secure the counter connector housing to the connector housing.
In WO 2010/076592 A1 a connector assembly is disclosed comprising a first connector housing and a complementary second connector housing and a mate assist device. The mate assist device comprises an actuating arm movably mountable to the first connector housing, wherein the actuating arm comprises a cam slot and the second connector housing comprises a corresponding cam peg to engage the cam slot, such that upon actuating of the mate assist device the cam slot can draw the cam peg towards the first connector housing to move the second connector housing towards the first connector housing.
It is disadvantageous here, that the mate assist device is only suitable for a connector housing of a predefined width. Since connector housings can have various widths, there is a demand for differently sized mate assist devices, thus generating high production and logistics costs.
In view of the foregoing, there is a need for an improved connector assembly comprising a mate-assist device, e.g. of the rotary of slider type. It is thus an object of the present invention to overcome at least some of the deficiencies of the prior art. It is in particular an object to provide mate assist devices that can be utilized on connector housings of various widths, where the mate-assist device is formed from symmetrical arms.

3. Summary

The above objects are at least partially achieved by a connector assembly according to independent claim 1. Preferred embodiments are the subject of the dependent claims, and the skilled person will find clues to other suitable aspects of the present invention in the overall disclosure of the present application.
An aspect of the invention relates to a connector assembly that includes a connector housing and a U-shape mate assist device. This device comprises two arms, that can be connected. Each arm has at least three locking elements, designed to form a form-locked connection with matching locking elements on the other arm, creating e.g. a form-locked connection. Additionally, these locking elements are positioned on an interlocking portion of each arm in such a way that they can interlock in at least two different positions, so that the width of the U-shape mate assist device can be adjusted as needed. Further, the connectable arms are symmetrical.
Practically, a preferred embodiment of this invention could be used in various electronic or mechanical systems where connectors are required to connect cables, wires or other components. The adjustable width of the U-shaped device makes it versatile for different sizes and types of connectors, increasing ease of use and flexibility in assembly or maintenance tasks. The form-locking connection ensures a reliable and secure fit between the arms, preventing accidental disconnection and improving the overall stability of the connection. This can be particularly beneficial in environments where connectors are subject to vibration or movement that could otherwise compromise the integrity of the connection. The fact that the arms are symmetrical allows for resourceful manufacturing and assembly, as only one type of arm needs to be manufactured. There is also no need for the assembler to be concerned with the orientation of the arms as there is no left and right orientation. The benefits of having symmetrical interconnectable arms are particularly in applications where precision and reliability is required. For example, symmetry makes the assembly easier and more intuitive for the assembler as there is no need to identify the orientation of a specific arm, thus reducing assembly time and the potential for error. Additionally, this design can also lead to production cost savings and facilitated inventory management as only one type of arm needs to be produced and stocked. Overall, the symmetrical design of the arms improves the ease-of-use, reliability, and efficiency of the connector assembly.
In one preferred embodiment, the mate assist device of the connector assembly can either be a rotary lever or a mate assist slider. This means that the device designed to assist in the mating or connection of the assembly can operate through a rotating action, as seen with a lever, or through a sliding mechanism. Both designs aim to facilitate easier and more reliable connections by providing mechanical leverage or guided sliding to bring the connector components into proper alignment and engagement.
In practical applications, the incorporation of either a rotary lever or a mate assist slider into a preferred embodiment of the connector assembly offers significant advantages in terms of ease of use and efficiency. For example, in automotive electronic connections or industrial machinery where connectors are frequently mated and unmated, a rotary lever could allow users to make secure connections without the need for excessive force or precise manual alignment. Similarly, a mate assist slider could provide a simple, guided means of sliding components together until they lock into place. These mechanisms not only improve the user experience by making the connection process more intuitive, but also help to reduce wear and tear on the connectors themselves, thereby extending their operational life.
In a preferred embodiment of the invention the locking elements comprise snap fit hooks and corresponding snap fit counterparts.
The use of snap fit hooks and counterparts offers significant benefits in terms of assembly speed and simplicity. Not just in the automotive or aerospace realm, but also in consumer electronics or medical devices where components need to be assembled efficiently and securely, snap fit mechanisms can dramatically reduce assembly time and ensure a consistent reliable connection. Snap fit design is particularly beneficial for products that require frequent access for maintenance or upgrades as it allows for a tool-free disassembly and reassembly. This approach not only improves the user experience for the assembler by making the process simpler but also contributes to the overall durability and reliability of the device by ensuring that connections can be made securely without causing wear or damage to the locking elements.
In this embodiment of the invention the locking elements may consist of two or more snap fit hooks and one snap fit counterpart.
In such a configuration, the two or more snap fit hooks might be arranged in a way, that each of the snap fit hooks can form an interlocked configuration with the one snap fit counterpart at two different locking positions of the interlocked arms, thus forming a mate assist device with two adjustable widths.
The invention can also be embodied in a connector assembly where each of the interconnectable arms comprises an interlocking portion and a stem portion, forming an L shape form, wherein the stem portion forms the stem, and the interlocking portion forms the leg of the L-shaped form.
This feature of incorporating an L-shape form allows for a more efficient and ergonomic design in the connector assembly. The L-shaped arms can provide easier access and manipulation during the connection process: the stem section can be designed to function as a handle for the assembler when assembling the device, respectively lever, providing a simple means of engaging or disengaging the connector without direct interaction with the delicate interlocking portion. Meanwhile, the interlocking portion, which forms the leg of the L-shape, provides a robust platform for the locking elements, ensuring a secure and reliable connection once engaged. This mechanical design simplifies the assembly process and enhances the mechanical stability and reliability of the connection and increases performance and durability.
In a preferred embodiment the interlocking portions of the interconnected arms form the bowl of the U-shaped form of the mate assist device when connected to each other, while the stem portions form the stems of the U-shaped form.
The U-shaped form, with its interlocking bowl and supportive stems, allows for a more controlled and guided mating process, reducing the risk of misalignment or damage during connection. In addition, this configuration can increase the mechanical leverage available to the assembler, making the mating process smoother and requiring less force, ensuring a secure, reliable connection.
The invention could also be embodied so that a cross-section of the interlocking portion of each arm comprises a positive shape and a corresponding negative shape, being arranged such that the positive shape of the one arm fits into the negative shape of the other arm.
Such an arrangement, where each arm comprises a positive shape and a corresponding negative shape, being arranged such that the positive shape of the one arm fits into the negative shape of the other arm is advantageous, since it allows for a precise fit between the positive and negative shape, enabling a strong mechanical connection. This also helps maintaining an optimal alignment of the connected parts, which is particularly important since misalignment can lead to potential failure. This design also provides superior vibration resistance, ensuring a secure connection even in harsh environments.
The invention can also be embodied in a way that a cross-section of the interlocking portion of each arm comprises a semi-circular arch and an opposing half circle being arranged such that the half circle of the one arm fits into the semicircular arch of the other arm.
In practical applications, such a geometric design offers several advantages: For instance, the semi-circular arch and half circle configuration ensures a tight and stable connection between the two arms, minimizing the ability of unwanted movement of the arms. This can be particularly beneficial in vibrating environments or in other cases where a connection could loosen over time. Additionally, this design can simplify the alignment process during assembly as these unique shapes guide the arms into the correct orientation. Such a precise fit provided by this configuration contributes to a simpler and less error prone assembly process.
This embodiment can be adapted so that one of the semi-circular arch or the half-circle has at least two locking elements in form of locking teeth, and the respective other at least one locking element in form of a corresponding locking tooth, wherein the at least two locking teeth are adapted to interlock with the one locking tooth, when the arms are joined.
Such an interlocking teeth mechanism can ensure an enhanced connection security and durability, which is particularly beneficial in environments subjected to shocks and/ or vibrations as in automotive settings. Arranging multiple locking teeth allows for an evenly distributed locking force, thus minimizing wear and enhancing connection longevity.
This embodiment can even be adapted further, so that the interlocking portion comprises a first element and a second element, wherein the first element comprises the cross-section with the semi-circular arch and extends from a base portion in connecting direction of the two arms, and wherein the second element comprises the cross-section with the half-circle and extends from the same base portion parallel to the first element.
Such an embodiment can greatly enhance the functionality and reliability of the mate assist device. The parallel arrangement of the semi-circular arch and half-circle elements from the same base portion allows for a compact efficient design, maximizing use of space, yet maintaining mechanical integrity. This specific orientation and shared origin of the interlocking portions ensure a seamless connection process, simplifying assembly and reducing the likelihood of misalignment. Furthermore, this approach creates a robust locking mechanism that can withstand external stresses, making it suitable for applications in environments subject to vibrations, shocks, or frequent handling.
Furtherly improving this embodiment, the second element can further comprise a protruding web extending axially in connection direction of the arms and the first element can comprise a slot extending axially in connection direction of the arms, where the web is received at least partially in the slot when the two arms are connected.
This feature of a protruding web and slot significantly improves the mechanical connection's precision and robustness. The web-and-slot interaction ensures a more secure fit by preventing lateral and vertical and rotational movement of the connected arms, thus maintaining the integrity of the connection even under stress or vibration. Furthermore, this design can facilitate easier assembly and alignment of the components, as the web acts as a guide for inserting into the slot, simplifying the connection process.
This embodiment can be further adapted in a way that the second element further comprises a second protruding web extending axially in connection direction of the arms and being parallel to the first web, and where the first element comprises a second slot extending axially in connection direction of the arms, where the second web is received at least partially in the second slot when the two arms are connected.
The parallel arrangement of the webs and slots provides a more balanced distribution of force across the connection, reducing the risk of misalignment or separation under load. Additionally, this feature could simplify the assembly process, as the parallel webs guide the connection into the correct alignment, ensuring that the components are properly engaged with minimal effort.
Further improvement of the embodiment could be achieved, when the distal end of the second element is provided with a chamfering to ease insertion of the second element of one arm into the first element of the respective other arm, upon connecting the two arms with each other.
The addition of chamfering to the connector assembly significantly improves the assembly's ease of use and efficiency. This feature is especially beneficial in applications requiring frequent assembly and disassembly. The chamfer ensures that the components can be smoothly and quickly connected, reducing the time and effort required for assembly. Moreover, this design consideration can also minimize wear and tear on the components, extending the lifespan of the connector assembly by preventing damage during connection.
Another aspect of the invention is that the connector housing is shaped so that the two arms can be mounted on the connector housing before interlocking them.
Such a design offers benefits in terms of assembly efficiency and flexibility as the arms can be mounted on the connector housing for easy access for the assembler as a sort of a pre-assembly. Additionally, this design allows for easier maintenance as items can be individually removed and replaced if necessary.
In another preferred embodiment, each arm comprises a connection means to connect the arm to the connector housing and preferably the stem portion of each arm tapers between the connection means and the interlocking portion.
In practical terms the inclusion of a dedicated connection means for attaching each arm to the connector housing allows for a robust and reliable assembly process. The tapered stem additionally contributes to a slimmer and more streamlined design which decreases the production cost and spares resources. This can additionally be helpful in tight or confined assembly spaces.

4. Brief description of the figures

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

Fig. 1:: illustrates a connector assembly according to the invention in a perspective view.
Fig. 2:: shows one embodiment of one interconnectable arm.
Fig. 3:: shows the interlocking portion of the arm of Fig. 2 in a cross-sectional perspective view.
Fig. 4A:: shows the interlocked arrangement of two identical arms from Fig. 2 at one locking position in a cross-sectional view.
Fig. 4B:: shows the interlocked arrangement of the same arms at another (second) locking position in a cross-sectional view.
Fig. 5A:: illustrates the U-shaped mate assist device before interlocking in a perspective view.
Figs. 5 B-D:: illustrate the embodiment of Fig. 5A at different locking positions in a perspective view.
Fig. 6:: shows the symmetrical arm of Fig. 2 in a front view.

5. Detailed description of the figures

The subsequent sections provide a detailed description of the invention, referencing the accompanying illustrations for clarity. The descriptions represent examples only and are not intended to limit the invention's scope. Identical reference numerals across the figures and text denote the same components. The illustrations may not reflect actual size or scale; their dimensions, proportions, and depictions of elements might be enhanced for better understanding and visual convenience.
Figure 1 illustrates a connector assembly 1 according to the invention. On a connector housing 2 is mounted a U-shaped mate assist device 10 in form of a rotary lever. Here, the device is built up by two interconnected symmetrical arms 100, which are mounted on the connector housing 2. The arms 100 are connected to the housing 2 by connection means 122.
Advantageously, the arms 100 can be interconnected at various width, so that the width of the mate assist device corresponds to the width of the connector housing. The connection means are configured to connect the symmetrical arms to the housing, e.g. with a snap fit connection.
In Figure 2, one of the two symmetrical arms 100 is depicted in a perspective view. The arm has generally an L-shape, where the interlocking portion 110 forms the leg of the L-shape and the stem portion 120 forms the stem of the L-shape. The interlocking portion 110 comprises locking elements 114, which protrude radially from the axis of the interlocking portion. The locking elements are formed as snap-fit hooks to be connected with corresponding counterparts. The cross-section of the interlocking portion 110 of the symmetrical arm 100 comprises a semicircular arch 116 and an opposing half-circle 118, being arranged such that the half-circle 118 of one symmetrical arm 100 fits into the semicircular arch 116 of another arm 100. The stem portion 120 comprises a connection means 122 in form of a snap-fit hook to connect the arm to the connector housing for an easy mounting onto the housing. Additionally, the stem portion 120 is tapered between the connection means 122 and the interlocking portion 110. Two parallel webs 112 extend on the interlocking portion 110, one on the upper and one on the lower side, as well as two adjacent slots 115. The tip of the interlocking portion comprises a chamfering 117.
Such a chamfering 117 facilitates the insertion of two arms 100 into each other, since that way, the half-circle 118 can be fitted more easily into the circular arch 116. Upon connecting two arms 100, the webs 112 will be guided into the slots 115, thus increasing the structural integrity of the connected arms. The tapering of the stem portion contributes to a slimmer and more streamlined design. With the positive shape of the half-circle fitting into the corresponding negative shape of the semi-circular arch of another arm, a superior fit between two arms can be realized when connecting them.
Figure 3 shows the interlocking portion of the arm depicted in Figure 2 in a perspective and partially cross-sectional view. One can see that the locking elements are formed as teeth 114 and 114'.
The locking elements 114 on the interlocking portion allow for variable interlocking positions with the locking element 114' on the inner surface 111 of the interlocking portion of the other (symmetrical) arm, as can be seen from Figs. 4A and 4B.
In Figure 4A and Figure 4B locking portions of two interlocked symmetrical arms 100 are depicted in a cross-sectional view. They show two different locking positions; resulting in U-shaped devices 10 of different width. As one can take from the figures, the locking elements 114' on the inner surface 111 of one arm 100 engage with one of the locking elements 114 on the interlocking portion of the respective other arm. Since the arms 100 are symmetrical, this leads to a double locking, as the locking elements 114' of each arm interlock with one respective locking element 114 of the other arm. Thus, the mate assist device has two different corresponding widths, depending on which position the locking elements 114, 114' are interconnected: a narrow width in the configuration of Fig. 4A and a wider width in the configuration of Fig. 4B. Further, as the skilled person will understand, the half-circle 118 of each arm 100 is received by the semi-circular arch 116 of the respective other arm 100, leading to a very secure connection, as the locking elements are completely covered and thus protected.
The locking elements 114, 114' are adjusted to form snap-fit connections, as the elements 114' snap into the space between two elements 114. The elements 114, 114' can also be described as snap-fit hooks and corresponding snap-fit counterparts.
In Figure 5A the two interconnectable symmetrical arms 100 are depicted before being assembled into the U-shaped mate assist device 10. For assembly, the two arms 100 need to be aligned such that the half-circle profile 118 of each arm 100 fits into the semi-circular arch profile 116 of the respective other arm 100.
Figures 5B to 5D show the interconnected symmetrical arms 100 at three different interlocking positions. In Fig. 5B, the arms 100 are connected in a first width configuration, by inserting the half-circle profile 118 of each arm 100 into the semi-circular arch profile 116 of the respective other arm 100. The configuration of Fig. 5B corresponds to the configuration of Fig. 4B when the first (distal) locking element 114 of the three locking elements 114 arranged along the axis of outer surface 113, snap-fits with the locking element 114'. This is the widest configuration of the shown embodiment. In Fig. 5C the second of the three locking elements 114 is engaged with element 114' and in Fig. 5D the third of the locking elements 114 is engaged with element 114'. The configuration of Fig. 5D corresponds to the configuration of Fig. 4A and represents the narrowest configuration of the U-shape. The design allows for three different widths. Additional interlocking positions can easily be realized by adding more elements 114 along the axis of surface 113.
As indicated in Fig. 5D, the interlocking portions of the interconnected arms form the bowl 12 of the U-shape mate assist device 10, whereas the stem portions form the stems 14 of the U-shape.
Figure 6 shows the symmetrical arm of Fig. 2 in a front view. The viewer takes that the half circle 118 forms a positive shape corresponding to the negative shape formed by the semi-circular arch 116. The half circle 118 chamfered, thus facilitating the insertion of the half circle 118 of one arm into the semi-circular arch 116 of another arm. The locking elements 114 are arranged on the outer side of the half circle, wherein a corresponding locking element 114' is arranged in the inner part of the semi-circular arch 116. The skilled person understands that such a design is particularly useful to create a symmetrical arm, where two identical arms can form a mate assist device with an adaptable width.

Reference list:

1:: connector assembly
2:: connector housing
10; 10':: mate assist device
12:: bowl of the U-shape
14:: stem of the U-shape
100:: symmetrical arm
110:: interlocking portion
111:: inner surface
112:: web
113:: outer surface
114, 114':: locking elements
115:: slot
116:: semi-circular arch
117:: chamfering
118:: half-circle
120:: stem portion
122:: connection means

Claims

A connector assembly (1) comprising:
a connector housing (2);

a U-shaped mate assist device (10; 10'), comprising two interconnectable arms (100);

each arm (100) comprising:
at least three locking elements (114, 114') to form a form-locked connection with one or more counterpart locking element(s) (114', 114) on the respective other arm (100);

an interlocking portion (110), on which the locking element(s) are arranged on at least two positions, to allow at least two interlocking positions of the arms (100) for adjusting the width of the U-shaped mate assist device (10; 10'); and wherein

the interconnectable arms (100) are symmetrical.
A connector assembly according to claim 1, wherein the mate assist device (10; 10') is a rotary lever or a mate assist slider.
A connector assembly according to one of the preceding claims, where the locking elements (114', 114) comprise snap-fit hooks and corresponding snap-fit counterparts.
A connector assembly according to the preceding claim, wherein the locking elements of each arm consist of two or more snap-fit hooks and one snap-fit counterpart.
A connector assembly according to one of the preceding claims, where each of the interconnectable arms (100) comprises an interlocking portion (110) and a stem portion (120), forming an L-shaped form, wherein the stem portion (120) forms the stem, and the interlocking portion (110) forms the leg of the L-shaped form.
A connector assembly according to one of the preceding claims, where the interlocking portions (110) of the interconnected arms (100) form the bowl of the U-shaped form of the mate assist device (10, 10') when connected to each other, while the stem portions (120) form the stems of the U-shaped form.
A connector assembly according to one of the preceding claims, where a cross-section of the interlocking portion (110) of each arm (100) comprises a positive shape and a corresponding negative shape, being arranged such that the positive shape of the one arm (100) fits into the negative shape of the other arm (100).
A connector assembly according to one of the preceding claims, where a cross-section of the interlocking portion (110) of each arm (100) comprises a semi-circular arch (116) and an opposing half-circle (118), being arranged such that the half-circle (118) of the one arm (100) fits into the semi-circular arch (116) of the other arm (100).
A connector assembly according to the preceding claim, where one of the semi-circular arch or the half-circle has at least two locking elements in form of locking teeth, and the respective other at least one locking element in form of a corresponding locking tooth, wherein the at least two locking teeth are adapted to interlock with the one locking tooth, when the arms are joined.
A connector assembly according to one of the preceding claims 8 or 9, where the interlocking portion comprises a first element and a second element, wherein the first element comprises the cross-section with the semi-circular arch and extends from a base portion in connecting direction of the two arms, and wherein the second element comprises the cross-section with the half-circle and extends from the same base portion parallel to first element.
A connector assembly according to the preceding claim, where the second element further comprises a protruding web extending axially in connection direction of the arms and the first element comprises a slot extending axially in connection direction of the arms, where the web is received at least partially in the slot when the two arms are connected.
A connector assembly according to claim 11, where the second element further comprises a second protruding web extending axially in connection direction of the arms and being parallel to the first web, and where the first element comprises a second slot extending axially in connection direction of the arms, where the second web is received at least partially in the second slot when the two arms are connected.
A connector assembly according to one of the preceding claims 10 to 12, where the distal end of the second element is provided with a chamfering to ease insertion of the second element of one arm into the first element of the respective other arm, upon connecting the two arms with each other.
A connector assembly according to one of the preceding claims, where the connector housing (2) is shaped so that the two arms (100) can be mounted on the connector housing (2) before interlocking them.
A connector assembly according to one of the preceding claims, where each arm (100) comprises a connection means (122) to connect the arm (100) to the connector housing (2), and where preferably the stem portion of each arm tapers between the connection means and the interlocking portion.