Abstract
A sealed electrical connector assembly includes a first and second connector member. The first connector member is arrangeable in open and sealed positions. In the sealed position, the first connector member is mated and sealed to the second connector member. The first and second connector member sealing walls face each other in a sealing region. The first and second connector members includes first and second connector member sealing walls extending essentially the same direction. In the sealed position, a flexible sealing element is configured to be arranged between and contacting the first and second connector member sealing walls in the sealing region. The flexible sealing element is fixed with respect to one of the sealing walls and is releasably engageable with another one of the sealing walls for providing a watertight seal. The sealing wall is slanted with respect to the first direction along an entire sealing region.
Claims
1. A sealed electrical connector assembly, comprising: a first connector member and a second connector member, wherein the first connector member is configured to be arrangeable in an open position and a sealed position, wherein, in the sealed position, the first connector member is fully mated and sealed with the second connector member, wherein the first connector member comprises a first connector member sealing wall extending essentially in a first direction, and wherein the second connector member comprises a second connector member sealing wall extending essentially in the first direction, wherein the first connector member further comprises at least one force feedback element, wherein the second connector member comprises a second connector member housing having at least one force feedback counter element configured to engage the at least one force feedback element when moving the first connector member towards the sealed position, wherein the at least one force feedback element of the first connector member is a rigid member extending in the first direction having a bulge provided at a central portion of the rigid member, wherein the bulge protrudes towards the at least one force feedback counter element, wherein the at least one force feedback counter element is a flexible locking member extending against the first direction and comprising a contact head arranged at a distal end of the flexible locking member and protruding towards the at least one force feedback element, and wherein an engagement between the at least one force feedback element and the at least one force feedback counter element is formed such that a force feedback can be provided to a user when the first connector member is moved to the sealed position; and a flexible sealing element, wherein, in the sealed position, the flexible sealing element is configured to be arranged between and contacting the first connector member sealing wall and the second connector member sealing wall in the sealing region, wherein the first connector sealing wall for releasably engaging the flexible sealing element is slanted with respect to the first direction along an entire sealing region, wherein the flexible sealing element is fixed with respect to the second connector member sealing wall and configured to be releasably engageable with the first connector member sealing wall for providing a watertight seal.
2. The sealed electrical connector assembly according to claim 1, wherein the flexible sealing element comprises at least two compressible lips extending towards the slanted first connector member sealing wall and wherein the at least two compressible lips are configured such that a compression of the at least two compressible lips is essentially the same in the sealed position.
3. The sealed electrical connector assembly according to claim 1, wherein an angle of the slanted first connector member sealing wall is within a range of 1° to 20°.
4. The sealed electrical connector assembly according to claim 1, wherein the flexible sealing element is fixed with respect to the second connector member sealing wall and configured to be releasably engageable with the first connector member sealing wall.
5. The sealed electrical connector assembly according to claim 1, wherein the contact between the flexible sealing element and the slanted first connector member sealing wall is formed such that a compressive sealing reaction force against the first direction is essentially constantly increasing when first connector member is moved from the open to the sealed position.
6. The sealed electrical connector assembly according to claim 1, wherein the first connector member is configured to be moveable about a first connector member closing path distance from the open position to the sealed position and wherein the at least one force feedback element and the at least one force feedback counter element are formed to allow that, in the last 10% of a first connector member closing path distance of the first connector member, a resulting reaction force acting on the first connector member becomes minimum.
7. The sealed electrical connector assembly according to claim 6, wherein the first connector member closing path distance of the first connector member from the open position towards the sealed position is up to 20 mm.
8. The sealed electrical connector assembly according to claim 1, wherein when the first connector member is moved from the open to the sealed position in the first direction, the flexible locking member is configured to: a. initially engage the bulge of the rigid member with the contact head at a contact portion, b. deflect due to the engagement with the bulge while the movement continues, and c. flexibly return to an initial position of the flexible locking member after the contact portion has passed a maximum protruding width of the bulge, wherein the deflected contact head urges the bulge in the first direction towards the sealed position.
9. The sealed electrical connector assembly according to claim 8, wherein the electrical connector assembly is configured to provide a haptic feedback to a user pushing the first connector member towards the sealed position when the first connector member has reached the sealed position.
10. The sealed electrical connector assembly according to claim 8, wherein one of the connector members is a plug connector.
11. The sealed electrical connector assembly according to claim 8, wherein an engagement between the first connector member, the flexible sealing element and the second connector member housing is formed such that a resulting reaction force acting on the first connector member, when the first connector member is moved from the open position to the sealed position along a first direction: a. assumes positive values in a beginning of the first connector member movement such that the resulting reaction force acts in a direction against the first direction, b. continuously increases until the resulting reaction force reaches a single maximum value, and then c. continuously decreases until the resulting reaction force assumes a minimum value in the sealed position.
12. The sealed electrical connector assembly according to claim 1, wherein the first connector member sealing wall for releasably engaging the flexible sealing element is slanted with respect to the first direction along the entire sealing region such that width of the first connector member sealing wall for releasably engaging the flexible sealing element continuously decreases along the first direction.
13. The sealed electrical connector assembly according to claim 1, wherein the first connector member is a connector position assurance (CPA) member and wherein the second connector member is a plug connector and wherein the first direction is a CPA member closing direction.
14. The sealed electrical connector assembly according to claim 1, wherein the first connector member is a counter-connector and wherein the second connector member is a corresponding plug connector and wherein the first direction is a connector assembly mating direction.
15. A method for coupling an electrical connector assembly, comprising: providing a sealed electrical connector assembly having a first connector member and a second connector member, wherein the first connector member is configured to be arrangeable in an open position and a sealed position, wherein, in the sealed position, the first connector member is fully mated and sealed with the second connector member, wherein the first connector member comprises a first connector member sealing wall extending essentially in a first direction, and wherein the second connector member comprises a second connector member sealing wall extending essentially in the first direction, wherein the first connector member further comprises at least one force feedback element, wherein the second connector member comprises a second connector member housing having at least one force feedback counter element configured to engage the at least one force feedback element when moving the first connector member towards the sealed position, wherein the at least one force feedback element of the first connector member is a rigid member extending in the first direction having a bulge provided at a central portion of the rigid member, wherein the bulge protrudes towards the at least one force feedback counter element, wherein the at least one force feedback counter element is a flexible locking member extending against the first direction and comprising a contact head arranged at a distal end of the flexible locking member and protruding towards the at least one force feedback element, and wherein an engagement between the at least one force feedback element and the at least one force feedback counter element is formed such that a force feedback can be provided to a user when the first connector member is moved to the sealed position, wherein the sealed electrical connector assembly also has a flexible sealing element, wherein, in the sealed position, the flexible sealing element is configured to be arranged between and contacting the first connector member sealing wall and the second connector member sealing wall in the sealing region, wherein the first connector sealing wall for releasably engaging the flexible sealing element is slanted with respect to the first direction along an entire sealing region, wherein the flexible sealing element is fixed with respect to the second connector member sealing wall and configured to be releasably engageable with the first connector member sealing wall for providing a watertight seal; and moving the first connector member from the open to the sealed position for providing an electrical connection and a watertight seal.
16. A sealed electrical connector assembly, comprising: a first connector member and a second connector member, wherein the first connector member is configured to be arrangeable in an open position and a sealed position, wherein, in the sealed position, the first connector member is fully mated and sealed with the second connector member, wherein the first connector member comprises a first connector member sealing wall extending essentially in a first direction, wherein the second connector member comprises a second connector member sealing wall extending essentially in the first direction, wherein the first connector member further comprises at least one force feedback element, wherein the second connector member comprises a second connector member housing having at least one force feedback counter element configured to engage the at least one force feedback element when moving the first connector member towards the sealed position, wherein the at least one force feedback element of the first connector member is a rigid member extending in the first direction having a bulge provided at a central portion of the rigid member, wherein the bulge protrudes towards the at least one force feedback counter element, wherein the at least one force feedback counter element is a flexible locking member extending against the first direction and comprising a contact head arranged at a distal end of the flexible locking member and protruding towards the at least one force feedback element, and wherein an engagement between the at least one force feedback element and the at least one force feedback counter element is formed such that a force feedback can be provided to a user when the first connector member is moved to the sealed position; and a means for providing a watertight seal between the first connector member to the second connector member, wherein the means is arranged between the sealing walls of the first connector member and the second connector member in the sealing region, wherein the means is fixed with respect to one of the sealing walls and is releasably engageable with another one of the sealing walls.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The present invention will now be described, by way of example with reference to the accompanying drawings, in which:
(2) FIG. 1 schematically shows a cross sectional view of an electrical connector assembly according to the present invention, wherein the first connector member is a CPA member in an open position;
(3) FIG. 2 schematically shows a cross sectional view of an electrical connector assembly according to the present invention wherein the first connector member is a CPA member in a sealed position;
(4) FIGS. 3A-3D schematically shows a flexible sealing element during a displacement of a connector position assurance (CPA) member of an electrical connector assembly according to the present invention;
(5) FIG. 3E schematically shows a reaction force originating from a flexible sealing element during a displacement of a CPA member in an electrical connector assembly according to the present invention;
(6) FIG. 4 schematically shows a cross sectional close-up view of a force feedback element and a force feedback counter element of an electrical connector assembly according to the present invention wherein a CPA member is in an open position;
(7) FIG. 5 schematically shows a reaction force and corresponding engagement positions of a force feedback element and a force feedback counter element of an electrical connector assembly according to the present invention;
(8) FIG. 6 schematically shows reaction forces originating from a flexible sealing element and a CPA member and a resulting total reaction force during a displacement of a CPA member in an electrical connector assembly according to the present invention;
(9) FIG. 7 schematically shows a cross sectional close-up view of a force feedback element and two force feedback counter elements of an electrical connector assembly according to the present invention wherein a CPA member is in an open position.
(10) FIG. 8 schematically shows a cross sectional view of an electrical connector assembly according to another embodiment of the present invention, wherein the first connector member is a plug connector in an open position;
(11) FIG. 9 schematically shows a cross sectional view of an electrical connector assembly according to another embodiment of the present invention wherein the first connector member is a plug connector in a sealed position; and
(12) FIGS. 10A-10C schematically show a flexible sealing element during a displacement of a plug connector of another embodiment of an electrical connector assembly according to the present invention.
DETAILED DESCRIPTION
(13) FIG. 1 shows a cross sectional view of an electrical connector assembly according to the present invention when the first connector member, which is shown as a connector position assurance (CPA) member 20 in an open position. A second connector member is shown as a plug connector 10, which is configured to mate with a corresponding counter-connector 60, which together form a sealed electrical connector assembly 1. The counter-connector 60 is shown in a disconnected state, whereas it should be understood that it may of course be provided being mated with the plug connector 10. The plug connector 10 includes a second connector member housing 30, which is shown as a connector housing 30, which encloses any further parts of the plug connector 10, such as electrical components. An electrical cable 12 is connected to the plug connector 10 and provides an electrical connection to further components which are connected to the sealed electrical connector assembly 1. The plug connector 10 further includes the CPA member 20, which is arranged to be received by the connector housing 30. In this embodiment, the CPA member 20 and the connector housing 30 are formed in a circular manner. The CPA member 20 is able to move along a first or closing direction 100 into a sealed position, whereas the connector housing 30 and its respective parts remain in a fixed position. The CPA member 20 includes a first connector member sealing wall 22, which is shown as a CPA member sealing wall 22 at its top side, which extends essentially along the closing direction 100. The CPA member sealing wall 22 is slightly slanted along the closing direction 100, such that it has a cone-shaped appearance. On the top side of the CPA member a pushing surface is provided, which allows a user to push the CPA member 20 in the closing direction 100 about a first connector member closing path distance 28, which is shown as a CPA member closing path distance 28 from an open to a sealed position. The slanted CPA member sealing wall 22 is received by a respective aperture on the top side of the connector housing 30, which has, in this embodiment, a circular appearance. The inner wall of the circular receiving aperture, which forms a second connector member sealing wall 32, which is shown as a connector housing sealing wall 32 is provided with a flexible sealing element 50 which includes two compressible lips 52, which are configured such that the slanted CPA member sealing wall 22 can slide along said compressible lips 52 when the CPA member 20 is pushed into the sealed position.
(14) The CPA member 20 further includes inner parts which facilitate the mating and alignment of mechanical and electrical parts of the plug connector 10 and the counter-connector 60, such as a force feedback element 24. This force feedback element 24 extends from the top of the CPA member in the closing direction 100 towards the counter-connector 60 and has a bulge 26, which is configured to engage a respective contact head 36 of a force feedback counter element 34 of the connector housing 30. The connector housing 30 forms a respective chamber, in which the force feedback element 24 can move downwards in the closing direction 100, when the CPA member 20 is accordingly pushed.
(15) FIG. 2 schematically shows a cross sectional view of the electrical connector assembly of FIG. 1 according to the present invention when the CPA member 20 is in a sealed position. Again, the counter-connector 60 is shown being connected to the plug connector 10 to establish an electrical connection. After the plug connector 10 and the counter-connector 60 have been mated, the CPA member 20 is brought into the sealed position, which allows the CPA member 20 to align any mechanical and electrical parts in the sealed electrical connector assembly 1 and thus allows to ensure a safe connection. As can be seen the CPA member 20 has been pushed towards the closing direction 100. The CPA member sealing wall 22 has been moved along the compressible lips 52, which are arranged and compressed in the sealing region 40, which is the region wherein the watertight seal between the CPA member sealing wall 22 and the connector housing sealing wall 32 is formed. The contact head 36 is latched behind the recess of the bulge 26.
(16) FIGS. 3A-3D shows compressible lips 52 of the flexible sealing element 50 during a displacement of a CPA member 20 of a sealed electrical connector assembly 1 according to the present invention. The progress of movement is depicted in FIGS. 3A-3D, such that the CPA member 20 moves along the closing direction 100 and travels across the CPA member closing path distance 28 from FIGS. 3A-3D. The flexible sealing element 50 is fixed to the connector housing 30. FIG. 3E shows a corresponding force-path-diagram depicting the reaction force occurring during progression of the CPA member movement in the closing direction 100. The slanted CPA member sealing wall 22 decreases in width W2 along the closing direction 100, which is illustrated by an angle α in FIG. 3D, with respect to the closing direction 100, which is the vertical direction. The slanted CPA member sealing wall 22 includes a lead-in chamfer 23, which is slanted to facilitate a lead-in of the flexible sealing element 50. FIG. 3A shows the situation when the upper compressible lip of the compressible lips 52 is already in contact with the slanted CPA member sealing wall 22. However, the upper one of the compressible lips 52 was not engaged by the lead-in chamfer 23 but directly contacted the slanted CPA member sealing wall 22 when the CPA member 20 was pushed towards the closing direction 100. This is reflected by the corresponding reaction force diagram of FIG. 3B, wherein the compressive sealing reaction force F1 constantly rises as the upper lip is constantly further compressed. In FIG. 3B, the lower one of the compressible lips 52 only slightly contacts the CPA member sealing wall 22. FIG. 3D shows the CPA member 20 in a final and fully sealed position, wherein the flexible sealing element 50 is compressed in the sealing region 40 between the CPA member sealing wall 22 and connector housing sealing wall 32. The corresponding compressive sealing reaction force F1 is maximum in this position. As can be seen from FIG. 3E, no significant force peaks are provided by the engagement between the flexible sealing element 50 and the CPA member sealing wall 22 when the CPA member 20 is moved into the sealed position. The overall force level is relatively low, since the compressible lips 52 are accordingly formed to fit the slanted CPA member sealing wall 22. As shown, the compressible lips are not compressed to the maximum in the beginning of the movement. The main contact pressure is applied at the last third of the CPA member movement.
(17) FIG. 4 shows a cross sectional close-up view of a force feedback element 24 and a force feedback counter element 34, when the CPA member 20 is in an open position. As shown, the contact head 36 of a force feedback counter element 34 is formed by a connector housing 30. The contact head 36 is arranged between a latching protrusion 27 and a bulge 26 of a force feedback element 24, wherein the bulge 26 has a maximum protrusion width W1.
(18) As is further shown in FIG. 5, the contact head is configured to slide flexibly along the outer surface of the force feedback element 24 when the CPA member 20 is moved from an open to a sealed position along the closing direction 100. Respective positions of the bulge 26 of the force feedback element 24 and the contact head 36 of the force feedback counter element 34 during a closing movement are shown in the FIG. 5. The contact portion 38 is shown as the region where contact between the bulge 26 and the contact head 36 occurs. In the beginning of the movement, the contact head 36 is flexibly deflected by the rigid bulge 26. The reaction force from the force feedback element F2 of said engagement, which is shown in FIG. 5 accordingly increases and reaches a maximum value at around 0.8 mm displacement. At the end of the first ramp angle, when the radius to maximum width W1 starts, as shown in the leftmost portion of FIG. 5, the force starts decreasing. To avoid a further force increase when movement continues, the contact head 36 is provided with a backward angle on its front face which is non-vertical when relaxed and vertical when bent. After passing the maximum width W1 of the bulge 26, the force F2 further decreases until it gets negative, which means that the CPA member 20 no longer needs to be pushed in the closing direction 100 but the contact head 36 flexibly returns to its initial position such that it urges the bulge 26 in closing direction 100 until the CPA member 20 has reached its sealed position.
(19) FIG. 6 shows reaction forces F1 and F2 originating from the compression of a flexible sealing element 50 and from the engagement of a CPA member 20 with the connector housing 30, respectively, and a resulting total reaction force F3 along a displacement of a CPA member 20 in a sealed electrical connector assembly 1 according to the present invention. As can be seen, the resulting reaction force F3 is a sum of the compressive sealing reaction force F1 and the CPA member closing reaction force F2. As is apparent from the graph of the force F2, which originates from the engagement of the CPA member 20 with the connector housing 30, said force F2 partly compensates in the constantly increasing compressive sealing reaction force F1 originating from the compression and friction of the flexible sealing element 50 in the last half millimeter of displacement of the CPA member 20. Hence the resulting reaction force F3 becomes negative although force F1 increases. This allows that the CPA member 20 is urged towards its sealed position and no further pushing force must be applied by a user. As is apparent from graph F3, the interplay of the single components of the plug connector 10, namely the CPA member 20, the connector housing 30 and the flexible sealing element 50 allows to obtain a resulting force F3 with one maximum value around 0.8 mm of displacement and no further force peaks and negative force values at the end of the displacement. This accordingly allows a proper haptic feedback for a user, wherein he or she is able to unambiguously determine the state of the CPA member 20 movement and its state during closing movement.
(20) FIG. 7 shows a cross sectional close-up view of another embodiment of a force feedback configuration with a rigid force feedback element 24 and two flexible force feedback counter elements 34, when the CPA member 20 is in an open position. As shown, respective contact heads 36 of the two force feedback counter elements 34 are formed by a connector housing 30. The contact heads 36 are each arranged between the latching protrusions 27 and a respective side of the bulge 26 of the force feedback element 24, wherein the bulge 26 has a maximum protrusion width W1. The two symmetrical flexible force feedback counter elements 34 thus work symmetrically against the central rigid force feedback element 24 such that the rigid force feedback element 24 is loaded symmetrically.
(21) In particular, FIG. 8 shows a cross sectional view of another embodiment of the electrical connector assembly according to the present invention when the first connector member 20, which is shown as a counter-connector 20 is in an open or unmated position. A second connector member is shown as a plug connector 10, which is configured to mate with the corresponding counter-connector 20, which together form a sealed electrical connector assembly 1. The counter-connector 20 is shown in a disconnected state, whereas it should be understood that it may of course be provided being mated with the plug connector 10. The plug connector 10 includes a second connector member housing 30, which is shown as a connector housing 30, which encloses any further parts of the plug connector 10, such as electrical components. An electrical cable 12 is connected to the plug connector 10 and provides an electrical connection to further components which are connected to the sealed electrical connector assembly 1. The plug connector 10 further includes a CPA member. Both, the counter-connector 20 and the CPA member are arranged to be received by the connector housing 30. In this embodiment, the CPA member, the counter-connector 20 and the connector housing 30 are formed in a circular manner. The counter-connector 20 is able to move along a first or mating direction 100 into a sealed position, whereas the connector housing 30 and its respective parts remain in a fixed position. The counter-connector 20 includes a first connector member sealing wall 22, which is shown as a counter-connector sealing wall 22 at its top side, which extends essentially along the mating direction 100. The counter-connector sealing wall 22 is slightly slanted along the mating direction 100, such that it has a cone-shaped appearance. The slanted counter-connector sealing wall 22 is received by a respective aperture on the bottom side of the connector housing 30, which has, in this embodiment, a circular appearance. The inner wall of the circular receiving aperture, which forms a second connector member sealing wall 32, which is shown as a connector housing sealing wall 32 is provided with a flexible sealing element 50 which includes two compressible lips 52, which are configured such that the slanted counter-connector sealing wall 22 can slide along said compressible lips 52 when the counter-connector 20 is pushed into the sealed position.
(22) FIG. 9 schematically shows a cross sectional view of the electrical connector assembly of FIG. 8 according to the present invention when the counter-connector 20 is in a sealed position. Again, the counter-connector is shown being connected to the plug connector 10 to establish an electrical connection. After the plug connector 10 and the counter-connector have been mated, the counter-connector 20 is brought into the sealed position, which allows the counter-connector 20 to allow a safe electrical connection. As can be seen, the counter-connector 20 has been pushed towards the mating direction 100. The counter-connector sealing wall 22 has been moved along the compressible lips 52, which are arranged and compressed in the sealing region 40, which is the region wherein the watertight seal between the counter-connector sealing wall 22 and the connector housing sealing wall 32 is formed.
(23) FIG. 10 shows compressible lips 52 of the flexible sealing element 50 during a displacement of a counter-connector 20 of an embodiment of a sealed electrical connector assembly 1 according to the present invention as shown in FIGS. 8 and 9. The progress of movement is depicted in FIG. 10A-10C, such that the counter-connector 20 moves along the mating direction 100 and travels across the counter-connector mating path distance 28 from FIG. 10A-10C. The flexible sealing element 50 is fixed to the connector housing 30. The slanted counter-connector sealing wall 22 decreases in width W2 along the mating direction 100, which is illustrated by an angle α in FIG. 10C, with respect to the mating direction 100, which is the vertical direction. The slanted counter-connector sealing wall 22 includes a lead-in chamfer 23, which is slanted to facilitate a lead-in of the flexible sealing element 50. FIG. 10A shows the situation before the counter-connector 20 contacts the flexible sealing element 50. FIG. 10B shows the situation when the lower compressible lip of the compressible lips 52 is in slight contact with the slanted counter-connector sealing wall 22. FIG. 10C shows the counter-connector 20 in a final and fully sealed position, wherein the flexible sealing element 50 is compressed in the sealing region 40 between the counter-connector sealing wall 22 and connector housing sealing wall 32. A respective compressive sealing reaction force is maximum in this position. The configuration essentially corresponds to the configuration of the first embodiment of the present invention depicted for instance in FIGS. 3A-3E and similar reaction force behavior can be obtained such that no significant force peaks are provided by the engagement between the flexible sealing element 50 and the counter-connector sealing wall 22 when the counter-connector 20 is moved into the sealed position. The overall force level is relatively low, since the compressible lips 52 are accordingly formed to fit the slanted counter-connector sealing wall 22. The compressible lips are not compressed to the maximum in the beginning of the movement. The main contact pressure is applied at the last third of the counter-connector movement.
LISTING OF REFERENCE NUMBERS
(24) 1 sealed electrical connector assembly 10 second connector member 12 cable 20 first connector member 22 first connector member sealing wall 23 lead-in chamfer 24 force feedback element 26 bulge 27 latching protrusion 28 first connector member closing path distance 30 second connector member housing 32 second connector member sealing wall 34 force feedback counter-element 36 contact head 38 contact portion 40 sealing region 50 flexible sealing element 52 compressible lips 60 counter-connector 100 first direction α angle of the slanted sealing wall W1 maximum protruding width of the bulge W2 width of the sealing wall F1 compressive sealing reaction force F2 CPA member closing reaction force F3 resulting reaction force
