WO2002078128A2

WO2002078128A2 - Lever type electrical connector

Info

Publication number: WO2002078128A2
Application number: PCT/US2002/009133
Authority: WO
Inventors: Masahiro Yamamoto; Shinichi Maezono
Original assignee: Molex Incorporated
Priority date: 2001-03-27
Filing date: 2002-03-26
Publication date: 2002-10-03
Also published as: WO2002078128B1; WO2002078128A3; AU2002252495A1; JP2002298982A

Abstract

A lever type electrical connector assembly includes a first connector having a pivotally mounted actuating lever. A cam groove is formed in a portion of the first connector, and a plurality of terminals are mountable at defined positions. A terminal retainer is positionable on the first connector in a preload position and is movable to a retaining position only when the terminals are in their defined positions. A second connector has a cam follower projection to be engaged in the cam groove of the first connector, whereby the connectors are mated and unmated in response to rotation of the actuating lever. The second connector is blocked from mating with the first connector when the terminal retainer is in its preload position.

Description

LEVER TYPE ELECTRICAL CONNECTOR

Background of the Invention:

This invention generally relates to the art of electrical connectors and, particularly, to a low-insertion-force electrical connector having a lever whereby mating and unmating of the connector with a second connector is effected by rotation of the lever. With some electrical connectors, large forces are required to mate and unmate a connector with an associated connector because of the connectors having large numbers of terminals. Consequently, low-insertion-force connectors have been developed which enable mating and unmating with small forces by means of an operating lever. A typical lever type electrical connector assembly includes a first connector which has an actuating lever rotatably or pivotally mounted thereon for connecting and disconnecting the first connector with a complementary mating second connector. The actuating lever and the second connector typically operate through some form of cam groove/cam follower arrangement for drawing the second connector into mating condition with the first connector in response to rotation of the lever. A common structure for a lever-type electrical connector is to provide a generally U-shaped lever structure having a pair of lever amis which are disposed on opposite sides of the first ("actuator") connector.

Japanese Patent Kokai Publication No. Hei. 11-329583 discloses such a connector which includes a connector body to be electrically com ected to the second connector. A slider is slidably mounted on the connector body and is adapted to be driven by the lever to guide the second connector into mated condition. By engaging the lever to a central portion of the slider, it is possible to mate the connectors easily and reliably through the lever operation while preventing rattling caused by vibration, wear and the like. Japanese Utility Model Kokoku Publication No. Hei. 7-45904 shows a connector having technology for reliably fixing the terminals mounted in a terminal module by a retainer inserted through a side surface of the module.

Various problems still are encountered with such prior connectors of the character described. First, there are problems in ensuring that the terminals are fully inserted into their defined positions in the terminal module. In addition, the connectors can be mated even though the connectors, themselves, or the terminals thereof are not fully assembled. Still further, such connectors typically are operated by a cam groove and cam follower arrangement, and this arrangement can be engaged even if the connector and/or tenninals are not fully assembled which could cause considerable damage to the coimectors if attempts are made to actuate the lever structure without the connector assembly being fully mated. The prevent invention is directed to solving these problems and providing improvements in the prior lever-type connectors.

Summary of the Invention:

An object, therefore, of the invention is to provide a new and improved lever type electrical connector assembly. In the exemplary embodiment of the invention, a first connector includes a connector body. A cover is slidably movably mounted on the connector body and includes a cam groove formed therein. An actuating lever is pivotally movably mounted on the cover and is engageable with the connector body, whereby pivotal movement of the actuating lever relative to the cover effects sliding movement of the cover relative to the connector body. A terminal module is positionable in the connector body and mounts a plurality of terminals at defined positions in the module. A terminal retainer is positionable on the terminal module in a preload position and is movable to a retaining position only when the terminals are in their defined positions. A second connector has a cam follower projection to be engaged in the cam groove of the cover, whereby the connectors are mated and unmated in response to rotation of the actuating lever and resulting translation of the cover. The second connector is blocked from mating with the first connector when the terminal retainer on the terminal module is in its preload position.

According to one aspect of the invention, complementary interengaging lock shoulders are provided between the terminal retainer and the terminals to lock the terminals in their defined positions when the terminal retainer is in its retaining position.

According to another aspect of the invention, the cam groove and the cam follower projection are located in the assembly such that the cam follower projection cannot enter the cam groove with the terminal retainer in its preload position.

According to a further aspect of the invention, the first comiector has a mating groove between the connector body and the terminal module for receiving a mating portion of the second connector. The terminal retainer projects into the groove blocking insertion of the mating portion of the second connector into the mating groove when the terminal retainer is in its preload position.

Other objects, features and advantages of the invention will be apparent from the following detailed description taken in connection with the accompanying drawings.

Brief Description of the Accompanying Drawings:

The invention, together with its objects and the advantages thereof, maybe best understood by reference to the following description taken in conjunction with the accompanying drawings, in which like reference numerals identify like elements in the figures and in which:

FIG. 1 is a perspective view of a lever type electrical connector assembly according to the invention, and including first and second connectors;

FIG. 2 is a perspective view of the slider cover and lever of the first connector;

FIG. 3 is a perspective view of the connector body and terminal module of the first connector in conjunction with the second connector;

FIG. 4 is a side elevational view of the comiector assembly in fully mated condition;

FIG. 5 is an end elevational view of the assembly, looking toward the right-hand end of FIG. 4, and showing exploded enlarged sections of the guide rail means between the slider cover and the connector body of the first connector; FIGS. 6a and 6b are sectioned and f agmented views showing the cam grooves inside the slider cover;

FIG. 7 is a cross-section through the connector assemblies showing the terminal retainer in its preload position;

FIG. 8 is a view similar to that of FIG. 7, showing the terminal retainer in its preload position blocking mating of the first and second connectors;

FIG. 9 is a view similar to that of FIG. 7, with the terminal retainer in its retaining position; and

FIGS. 10 and 11 are views similar to that of FIG. 9, but showing the terminal retainer in its retaining position allowing mating of the connectors. Description of the Preferred Embodiments:

Referring to the drawings in greater detail, and first to FIG. 1, the invention is embodied in a lever type electrical connector assembly, generally designated 10, which includes a first or "actuator" connector, generally designated 12, and a second or "mating" connector, generally designated 14. hi the drawings, the cables, terminals and the like of connector assembly 10 are omitted to facilitate the illustrations in the drawings and to avoid unnecessarily cluttering and blocking the major views depicted in the drawings.

With that understanding, and referring to FIGS. 2 and 3 in conjunction with FIG. 1, actuator connector 12 includes a connector body, generally designated 16; a slider cover, generally designated 18; an actuating lever, generally designated 20; and a terminal module, generally designated 21. The lever is a U-shaped lever structure having a pair of actuating arms 20a joined by a cross or bight portion 20b. The actuating arms have actuating bosses 20c (FIG. 2) at the distal ends thereof. Each actuating arm has a pivot hole 20d therethrough and located at a point spaced from the distal end of the respective actuating arm and the respective actuating boss 20c.

Slider cover 18 is positionable over connector body 16 and is slidably mounted thereon, as will be seen hereinafter. The cover includes a top wall 18a and a pair of depending side walls 18b. Each side wall has a pivot pin 18c projecting outwardly therefrom. Referring to FIGS. 6a and 6b in conjunction with FIG. 2, a pair of cam grooves 22 are formed inside each side wall 18b of the cover. Each cam groove includes a mouth 22a, a first inclined portion 22b, a second inclined portion 22c and a closed end portion 22d. The pair of cam grooves inside each side wall 18b of the cover are spaced laterally of a mating direction of connectors 12 and 14, as will be seen hereinafter, and mouths 22a of the cam grooves open downwardly in a vertical direction. Actuating lever 20 is mounted to the outside of cover 18 by spreading actuating arms

20a of the cover slightly outwardly to align pivot pins 18c of the cover with pivot holes 20d in the actuating arms of the lever. On releasing the actuating arms, the arms will spring back inwardly so that pivot pins 18c are inserted into pivot holes 20d, until the lever structure is mounted on the cover as shown in FIG. 2. hi essence, the pivot pins form fulcrums for rotating or pivoting the actuating lever relative to the cover. Connector body 16 of actuator connector 12 of connector assembly 10 includes a pair of side walls 16a as seen best in FIG. 4. A plurality of guide rails 16b project outwardly from each side wall and are elongated in the horizontal direction. The guide rails fonn guide grooves 16c along opposite sides of the comiector body outside side walls 16a thereof. A pair of guide ribs 16d extend along the top of the connector body. An engagement projection 24 extends outwardly from each side wall and fonns a vertical notch 24a (FIG. 4) on the inside thereof which opens in an upward direction. Actuating bosses 20c on lever arms 20a of lever structure 20 engage within vertical notches 24a. A pair of vertical slots 26 (FIG. 3) are fonned in each side wall 16a spaced horizontally or laterally of the mating direction of the connectors. Finally, a pair of end walls 16f define a receptacle 27 in the underside of connector body 16 for receiving terminal module 21 thereinto in the direction of arrow "A" (FIG. 3).

Mating connector 14 of connector assembly 10 includes a connector body 14a having a mating portion 14b which is inserted into a slot "S" surrounding terminal module 21 as best seen in FIG. 1. Slot "S" forms a continuous mating groove about the periphery of terminal module 21. The mating connector is mateable in the direction of arrow "B" (FIG. 1). A pair of laterally spaced cam follower projections 30 project outwardly from each opposite side of mating portion 14b of mating connector 14. Finally, mating connector 14 mounts a plurality of pin terminals 29 which mate with terminals mounted in terminal module 21, as described below.

Before proceeding with the details of the terminal module and the mating operation of the comiector assembly, some assembly considerations should be observed to better understand the operation of the connector assembly. As seen from the above, cover 18 is positionable over the top and sides of connector body 16 of actuator connector 12, with cam grooves 22 being located inside side walls 18b of the cover. When so assembled, engagement projections 24 which extend outwardly from the connector body are located outside the cover, along with vertical notches (FIG. 4) of the engagement projections. Therefore, when actuating lever 20 is mounted to the outside of the cover, actuating bosses 20c are positionable within vertical notches 24a of the connector body. Still further, when mating portion 14b of mating connector 14 is inserted into the bottom of connector body 16 and into mating groove "S", cam follower projections 13 project through slots 26 in side walls 16a of connector body 16 for insertion into cam grooves 22 inside the side walls of cover 18.

Lever structure 20 is used to assist in mating of the connectors. The lever is pivoted from a mating position (FIGS. 1 and 2) to a locked position shown in FIG. 4 where the lever locks behind a latch boss 30 projecting upwardly of cover 18. The lever is pivoted in the direction of arrow "C" (FIG. 4). Assuming mating connector 14 is rigidly mounted to some form of support structure, as lever structure 20 is rotated in the direction of arrow "C", actuating bosses 20c within vertical notches 24b cause cover 18 to slide in the direction of arrow "D" as the actuator connector is mated downwardly in the direction of arrow "E" to the fixed mating connector. This composite relative motion is effected by the interengagement of cam follower projections 30 of the mating connector within cam grooves 22 of slider cover 16 of the actuator connector. hi essence, cover 18 acts as a slider when mounted over connector body 16. This is accomplished by a guide rail means or arrangement as depicted in FIG. 5. It can be seen that the bottom edge of each side wall 18b defines a guide rail or rib 32 which extends into guide groove 16d on the outside of connector body 16. Guide rails 16b of the connector body project into a guide groove 34 on the inside of guide rail 32. At the top of connector body 16, a guide flange 36 on the inside of cover 18 extends downwardly behind guide rib 16e on the connector body as described above and seen in FIG. 1. The invention contemplates provisions to prevent connectors 12 and 14 of connector assembly 10 from mating unless actuator connector 12 and, particularly, tenninal module 21 are fully assembled. More particularly, referring back to FIG. 3, it can be seen that terminal module 21 is sort of a dielectric block which mounts a plurality of female tenninals 40 which mate with pin terminals 29 of mating connector 14. As stated above, the terminal module is inserted into receptacle 27 of connector body 16 in the direction of arrow "A" (FIG. 3). As clearly seen in FIG. 4, the tenninal module mounts an elongated terminal retainer 44 in a recess 56 in the terminal retainer by a press fit. The terminal retainer is movable into and out of the recess in the direction of double-headed arrow "F" (FIG. 3). The terminal retainer is shown in FIG. 3 in a preload position, with ribs 48 on the retainer exposed exteriorly of the terminal module. FIG. 7 shows terminal module 21 mounted within connector body 16 of actuator connector 12, and with tenninal retainer 44 in its preload position as seen above and described in relation to FIG. 3. hi other words, the tenninal retainer projects transversely of the mating direction, outwardly into mating groove or slot "S" when in its preload position. This represents a condition wherein one or more of female terminals 40 may not be inserted fully to their defined final mounted positions. An example can be seen in FIG. 7, where the top terminal is shown still projecting outwardly to the left of the depiction. Until all of the terminals are in their fully defined or inserted positions, terminal retainer 44 cannot be pushed into terminal module 21. Whenever terminal retainer 21 is in its preload position as shown in FIG. 7, certain conditions occur. First, the connectors cannot be mated, and this is seen in FIG. 8. It can be seen that mating portion 14b of mating connector 14 abuts against ribs 48 on the outside of terminal retainer 44 which project into mating groove S. Another important consideration is that cam follower projections 30 cannot enter the mouths of cam grooves 22 so that the actuator lever cannot be pivoted. Otherwise, excessive forces on the actuator lever could easily damage the entire connector assembly if the cam follower projections were allowed to enter the cam grooves. Terminal retainer 44 in its preload position shown in FIG. 8 not only prevents mating of the connectors but also prevents the cam follower projections from entering the cam grooves. FIG. 9 shows a condition wherein all of the female tenninals 40 have been inserted fully into their defined positions within terminal module 21. Terminal retainer 44 now can be pushed inwardly (i.e., downwardly as viewed in the depiction) out of blocking condition within mating groove or slot "S". As seen in FIGS. 10 and 11, mating portion 14b of mating connector 14 now can be fully inserted into mating groove "S", and cam follower projections 30 can be fully inserted into cam grooves 22, whereupon cam lever structure 20 can be pivoted in the direction of arrow "C" (FIG. 4) to mate the connectors.

Finally, FIGS. 9-11 show a feature wherein terminal retainer 44 has a plurality of lock shoulders 44a which engage behind lock shoulders 50 of female tenninals 20 when the terminal retainer is in its inserted position, hi other words, interengagement of locking shoulders 44a on the retainer and 50 on the terminals allows terminal retainer 44 to perform a dual function of locking the terminals when the retainer is in its "retained" position. It will be understood that the invention may be embodied in other specific forms without departing from the spirit or central characteristics thereof. The present examples and embodiments, therefore, are to be considered in all respects as illustrative and not resfrictive, and the invention is not to be limited to the details given herein.

Claims

CLAIMS:

1. A lever type electrical connector assembly, comprising: a first connector including a connector body; a cover slidably movably mounted on the connector body and including a cam groove formed therein; an actuating lever movably mounted on the cover and engageable with said connector body whereby movement of the actuating lever relative to the cover effects sliding movement of the cover relative to said comiector body, a terminal module positionable in said connector body and mounting a plurality of terminals at defined positions in the module, and a terminal retainer positionable on the terminal module in a preload position and movable to a retaining position only when the terminals are in their defined positions; and a second connector including a cam follower projection for engaging in the cam groove of the cover whereby the connectors are mated and unmated in response to rotation of the actuating lever and resulting translation of the cover, the second connector being blocked from mating with the first connector when said terminal retainer on the tenninal module is in its preload position.

2. The lever type electrical comiector assembly of claim 1 , including complementary interengaging lock shoulders between said terminal retainer and the terminals to lock the terminals in their defined positions when said terminal retainer is in its retaining position.

3. The lever type electrical connector assembly of claim 1 , wherein said cam groove and said cam follower projection are located in the assembly such that said cam follower projection cannot enter said cam groove with said tenninal retainer in its preload position.

4. The lever type electrical connector assembly of claim 1, wherein said first connector has a mating groove between said connector body and the terminal module for receiving a mating portion of said second connector, said terminal retainer projecting into the mating groove blocking insertion of the mating portion of the second connector into said mating groove when the terminal retainer is in its preload position.

5. The lever type electrical comiector assembly of claim 1, wherein said actuating lever comprises one actuating ami of a generally U-shaped lever structure having a pair of actuating arms pivotally mounted on opposite sides of said cover.

6. The lever type electrical connector assembly of claim 1, wherein said cover includes a pair of said cam grooves spaced laterally of a mating direction of the connectors and engageable by a pair of said cam follower projections on said second comiector.

7. The lever type electrical comiector assembly of claim 1, wherein said cover is positionable over the connector body and said cam groove is located inside a side wall of said cover.

8. The lever type electrical connector assembly of claim 7, wherein said second comiector is mateable inside said first connector and said cam follower projection extends from said second connector through said connector body of said first connector and into said cam groove inside said cover.

9. The lever type electrical connector assembly of claim 1, including complementary interengaging guide rail means between said cover and said comiector body and extending transversely of a mating direction of said connectors.

10. The lever type electrical connector assembly of claim 1 wherein said second connector is mateable inside said first connector and said cam follower projection extends from said second connector through said connector body of said first connector.

11. A lever type electrical connector assembly, comprising: a first connector including an actuating lever movably mounted thereon, a cam groove fonned therein, and a plurality of terminals mountable at defined positions, a terminal retainer positionable on the first connector in a preload position and movable to a retaining position only when the terminals are in their defined positions; and, a second comiector having a cam follower projection for exchanging the cam groove of said first connector whereby the connectors are mated and unmated in response to movement of the actuating lever, the second comiector being blocked from mating with said first comiector when said terminal retainer is in its preload position.

12. The lever type electrical connector assembly of claim 11, including complementary interengaging lock shoulders disposed between said terminal retainer and said terminals for locking said terminals in their defined positions when said terminal retainer is in its retaining position.

13. The lever type electrical connector assembly of claim 11, wherein said cam groove and said cam follower projection are located in the assembly such that the cam follower projection cannot enter said cam groove with said terminal retainer in its preload position.

14. The lever type electrical connector assembly of claim 11 , wherein said first connector has a mating groove for receiving a mating portion of said second comiector, said terminal retainer projecting into said mating groove blocking insertion of said mating portion of the second connector into said mating groove when said terminal retainer is in its preload position.