EP4641846A1

EP4641846A1 - Low cost lever arrangement reusable for different connector width

Info

Publication number: EP4641846A1
Application number: EP24172762.7A
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 housing and a U-shaped mate assist device. This device comprises two arms that can be connected. Each arm has one or more locking elements designed to engage 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. This feature allows the width of the U-shaped mate assist device to be adjusted as needed.

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.

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 housing and a U-shaped mate assist device. This device comprises two arms that can be connected. Each arm has one or more locking elements designed to engage 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. This feature allows the width of the U-shaped mate assist device to be adjusted as needed.
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.
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 another aspect of the invention the locking elements of the connector assembly as previously described comprise one or more protrusions.
In a practical context a preferred embodiment with protrusions as locking elements can be particularly beneficial in applications where a robust and reliable connection is required. For example, in the field of electrical connectors used in automotive or even aerospace applications these protrusions can provide tactile feedback to the assembler indicating that a secure connection has been made. The protrusions of one arm can interlock with the protrusions of another arm, thus forming a stable form fit. This design choice enhances safety and reliability in critical applications were loose or incomplete connection could lead to system failure. The ability to adjust the widths of the U-shaped mate assistant device combined with the secure locking provided by the protrusions makes this connector assembly versatile and suitable for a wide range of applications.
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 another preferred embodiment of the invention the interconnectable arms are symmetrical.
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.
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 can also be embodied such that the interlocking portion on one arm is provided in form of a shaft and the interlocking portion on the other arm is provided in form of a corresponding receptacle.
A design with a shaft and a receptacle has significant advantages particularly in applications where high precision and reliability are required, as this design ensures a foolproof connection process, as the unique fit of the shaft into its receptacle prevents incorrect assembly. This might also include a self-aligning mechanism that reduces the need for manual adjustment, speeding up the assembly process and minimizing the risk of damage due to incorrect connection of components. The shaft and receptacle design is also well suited for applications where resistance to vibrations is critical as the tight fit can help prevent loosening over time.
Such an embodiment can even be improved further when the shaft is provided with at least two snapping teeth and interior walls of the receptacle are provided with at least one counterpart that allow connection of teeth and counterparts for realizing the at least two interlocking positions of the arms for adjusting the width of the U-shape mate assist device.
Such a feature greatly enhances the versatility and adaptability of the connector assembly, since space constraints or component sizes of connectors may vary. The snapping teeth mechanism ensures that adjustments can be made quickly and securely, without the need for tools or excessive force. This not only improves the assembly process but also ensures that the connection can withstand the operational stresses it may encounter in form of e.g. vibrations. Furthermore, the secure locking at multiple positions ensures a robust mechanical connection for various connector housing size demands.
This embodiment can even be improved further when the teeth are arranged circumferentially around the shaft in at least two axially offset locations.
Such an embodiment yields the advantage, that the teeth which are arranged circumferentially can be positioned at various axially offset locations, defining the width of the total lever configuration as each tooth defines a locking position of the interlocked arms. By the axial offset of the teeth, a robust and secure connection is provided at multiple locking points which helps to maintain the integrity of the connection over time for different width demands.
In a further preferred embodiment, the shaft is at least partially covered by a cap that is adapted to at least partially receive the interlocking portion of the other arm when the arms are connected with each other.
Adding a cap over the shaft provides numerous benefits: it can serve as a protective barrier against environmental demands such as dust or moisture and it can also safeguard the interlocking portions. It can also aid the aligning of the interlocking portions and it furthermore reduces the wear of the interlocking portions by protecting it mechanically from external damage. Additionally, it can serve as an ergonomic feature to facilitate the assembly of the lever by the assembler.
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.
In a further preferred embodiment an inner and/or outer surface of the interlocking portion comprises at least one locking element.
An advantage of incorporating the looking elements on an inner and/or outer surface is, that the locking elements can be arranged such that they are protected against harsh environment.
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 and economical 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 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 the arms at one locking position in a cross-sectional view.
Fig. 4B:: shows the interlocked arrangement of the 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. 6A:: shows another embodiment of an interlocking portion of a male arm in a perspective view.
Fig. 6B:: shows a detail of the embodiment of Fig. 6A in a cross-sec-tional view.
Fig. 7:: shows the interlocking portion of the arm of Figs. 6A and 6B in a schematic view.
Fig. 8A:: illustrates one embodiment of a female arm adapted to interact with the arm of Figs. 6A and 6B in a perspective view from one direction.
Fig. 8B:: shows the embodiment of Fig. 8A in a cross-sectional view.
Fig. 9A:: illustrates the embodiments of Figs. 6 to 8 before interlocking in a perspective view.
Fig. 9B-E:: illustrate the embodiment of Fig. 9A at different locking positions in perspective views.

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. 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.
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 semi-circular arch 116 and an opposing half-circle 118, being arranged such that the half-circle 118 of one symmetrical arm 100 fits into the semi-circular 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 to contribute to a slimmer and more streamlined design.
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 fin-like protrusions 114, 114'. The locking elements 114 on the outer surface 113 of 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 outer surface 113 of 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 6A shows another embodiment of an interconnectable arm 600. In this second embodiment, the arms are not symmetrical but have different but matching configurations. The arm 600 may be denoted as a male arm and the corresponding second arm as a female arm (shown in Figs. 8A and 8B). The interlocking portion 610 comprises a shaft 602, on which locking elements 614 in form of snapping teeth are arranged. Here, the shaft 602 is partially covered by a cap 604, which guards the shaft and serves as an ergonomic feature for the assembler. Further, the arm 600 is provided with connection means 622 to connect the arm to a connector housing.
Figure 6B shows the male arm of Figure 6A in a cross-sectional view for visual convenience. One can see that the shaft 602 comprises several locking elements 614 axially offset with respect to each other along the axis of shaft 602.
Figure 7 shows a schematic view of the shaft 602 of male arm 600. The locking elements 614 in form of snapping teeth are arranged circumferentially around the shaft 602, in four axially offset locations, to allow for four different interlocking positions when the snapping teeth 614 engage with corresponding counterparts, when connected to the corresponding female arm 800.
Figure 8A shows the interlocking portion 810 of a female arm 800, adapted to connect with the male arm 600. The interlocking portion 810 comprises a receptacle 802 to receive the corresponding shaft 602 of male arm 600. Locking elements 814 are arranged on the inner surface at the entrance of receptacle 802 of the interlocking portion 810 adapted to interact with the locking elements 614, when the shaft 602 is inserted. Figure 8B depicts a cross-sectional view of the interlocking portion 810 of Figure 8A. Upon insertion of the shaft 602 into the receptacle 802, the teeth of the locking elements 614 snap-fit onto one of the locking elements 814. As the shaft 602 in the shown embodiment comprises four axially offset locking elements 614, the embodiment provides four different interlocking positions and thus four differently wide configurations of the U-shaped mate assist device.
Figure 9A shows the two arms 600 and 800 before assembly. The arms are aligned such that the shaft 602 of the male arm 600 fits into the receptacle 802 of the female arm 800. The cap 604 provides guidance for the alignment and insertion process and protects the locking elements 614.
Figs. 9 B to 9E show various connection status of male arm 600 with female arm 800. When connected, the two arms form a U-shaped mate assist device 10' in form of a rotary lever. Figures 9B to 9E show the assembled mate assist device in various locking positions, enabling four different widths. Here, the locking elements 614 arranged on the shaft 602 form a form fit connection with the locking elements 614 arranged on the inner walls of the receptacle 802. The four possible widths of the mate assist device are defined by the four different axial positions of the four locking elements 614 arranged on the shaft 602 which are engaging with one of the counterparts 814 on the inner wall of the receptacle. The shaft 602 of the male arm is at least partially covered by a cap 604, which serves as an assembly guide and a mechanical protection of the interlocking portion.
The skilled person will understand that the U-shaped mate assist device 10' may be used with the connector housing 2 shown in Fig. 1 in the same way as U-shaped mate assist device 10.

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
113:: outer surface
114, 114'; 614, 814:: locking elements
116:: semi-circular arch
118:: half-circle
120:: stem portion
122; 622, 822:: connection means
600:: male arm
602:: shaft
604:: cap
800:: female arm
802:: receptacle

Claims

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

a U-shaped mate assist device (10; 10'), comprising two interconnectable arms (100; 600, 800);

each arm (100; 600, 800) comprising:
one or more locking element(s) (114, 114'; 614, 814) to form a form-locked connection with one or more counterpart locking element(s) (114', 114; 614, 814) on the respective other arm (100; 600, 800); and

an interlocking portion (110; 610, 810), on which the locking element(s) are arranged on at least two positions, to allow at least two interlocking positions of the arms (100; 600, 800) for adjusting the width of the U-shaped mate assist device (10; 10').
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; 614, 814) comprise one or more protrusions.
A connector assembly according to one of the preceding claims, where the locking elements (114', 114; 614, 814) comprise snap-fit hooks and corresponding snap-fit counterparts.
A connector assembly according to one of the preceding claims, where each of the interconnectable arms (100; 600, 800) comprises an interlocking portion (110; 610, 810) and a stem portion (120; 620, 820), forming an L-shaped form, wherein the stem portion (120; 620, 820) forms the stem, and the interlocking portion (110; 610, 810) forms the leg of the L-shaped form.
A connector assembly according to one of the preceding claims, where the interlocking portions (110; 610, 810) of the interconnected arms (100; 600, 800) 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; 620, 820) form the stems of the U-shaped form.
A connector assembly according to one of the preceding claims, where the interlocking portion (610) on one arm (600) is provided in form of a shaft (602) and the interlocking portion (810) on the other arm (800) is provided in form of a corresponding receptacle (802).
A connector assembly according to claim 7, where the shaft (602) is provided with at least two snaping teeth (614) and interior walls of the receptacle (802) are provided with at least one counterpart (814) that allow a connection of teeth (614) and counterparts (812), for realizing the at least two interlocking positions of the arms (600, 800) for adjusting the width of the U-shaped mate assist device (10').
A connector assembly according to claim 8, where the teeth (614) are arranged circumferentially around the shaft (602), in at least two axially offset locations.
A connector assembly according to one of the preceding claims 7 to 9, wherein the shaft (602) is at least partially covered by a cap (604) that is adapted to at least partially receive the interlocking portion (810) of the other arm (800) when the arms (600, 800) are connected with each other.
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 one of the preceding claims, where an inner and/or outer surface of the interlocking portion (110; 610, 810) comprises at least one locking element (114, 114'; 614, 814).
A connector assembly according to one of the preceding claims, where the connector housing (2) is shaped so that the two arms (100; 600, 800) 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; 600, 800) comprises a connection means (122; 622, 822) to connect the arm (100; 600, 800) to the connector housing (2), and where preferably the stem portion of each arm tapers between the connection means and the interlocking portion.