阅读说明：本技术 密封的电连接器 (Sealed electrical connector ) 是由 M·贡尔本 B·巴特 于 2021-03-25 设计创作，主要内容包括：本发明涉及密封的电连接器。密封的电连接器组件包括：第一连接器构件和第二连接器构件,其中第一连接器构件适于可布置在打开位置和密封位置,其中,在所述密封位置中,第一连接器构件与第二连接器构件完全配合并密封,其中,第一连接器构件包括基本上沿第一方向延伸的第一连接器构件密封壁,并且其中第二连接器构件包括基本上沿所述第一方向延伸的第二连接器构件密封壁,其中在所述密封位置中,所述第一连接器构件密封壁和所述第二连接器构件密封壁在密封区域中面向彼此；柔性密封元件,其中,在所述密封位置中,所述柔性密封元件适于布置在所述密封区域中的所述第一连接器构件和所述第二连接器构件的所述密封壁之间并与所述密封壁接触。(The present invention relates to sealed electrical connectors. A sealed electrical connector assembly comprising: a first connector member and a second connector member, wherein the first connector member is adapted 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 substantially along a first direction, and wherein the second connector member comprises a second connector member sealing wall extending substantially along the first direction, wherein in the sealed position the first connector member sealing wall and the second connector member sealing wall face each other in a sealing area; a flexible sealing element, wherein in the sealing position the flexible sealing element is adapted to be arranged between and in contact with the sealing walls of the first and second connector members in the sealing area.)

1. A sealed electrical connector assembly (1) comprising:

a first connector member (20) and a second connector member (10), wherein the first connector member (20) is adapted to be arrangeable in an open position and a sealed position, wherein in the sealed position the first connector member (20) is fully mated and sealed with the second connector member (10),

wherein the first connector member (20) comprises a first connector member sealing wall (22) extending substantially in a first direction (100),

and wherein the second connector member (10) comprises a second connector member sealing wall (32) extending substantially along the first direction (100),

wherein in the sealing position the first connector member sealing wall (22) and the second connector member sealing wall (32) face each other in a sealing area (40);

a flexible sealing element (50), wherein in the sealing position the flexible sealing element (50) is adapted to be arranged between and in contact with the sealing walls of the first and second connector members (20, 10) in the sealing region (40), wherein the flexible sealing element (50) is fixed relative to one of the sealing walls of the first and second connector members and is adapted to releasably engage with the respective other of the sealing walls of the first and second connector members to provide a water-tight seal,

wherein the sealing wall for releasably engaging the flexible sealing element (50) is inclined with respect to the first direction (100) along the entire sealing area (40).

2. Electrical connector assembly (1) according to claim 1,

wherein the flexible sealing element (50) comprises at least two compressible lips (52) extending towards the inclined sealing wall (22, 32), wherein the at least two compressible lips (52) are adapted such that the compression of the at least two compressible lips (52) in the sealing position is substantially the same.

3. Electrical connector assembly (1) according to any of the preceding claims, wherein the angle (a) of the inclined sealing wall is 1 ° to 20 °, preferably 3 ° to 15 °, most preferably 5 ° to 10 °.

4. The electrical connector assembly (1) according to any one of the preceding claims, wherein the flexible sealing element (50) is fixed relative to the second connector member sealing wall (32) and is adapted to be releasably engaged with the first connector member sealing wall (22).

5. Electrical connector assembly (1) according to any of the preceding claims, wherein the contact between the flexible sealing element (50) and the inclined sealing wall is formed such that a compressive sealing reaction force (F1) against the first direction (100) increases substantially continuously when the first connector member (20) is moved from the open position to the sealing position.

6. Electrical connector assembly (1) according to any of the preceding claims, wherein the first connector member (20) further comprises at least one force feedback element (24),

and wherein the second connector member (10) comprises a second connector member housing (30), wherein the second connector member housing (30) comprises at least one force feedback counter element (34), which force feedback counter element (34) is adapted to engage with the at least one force feedback element (24) when the first connector member (20) is moved towards the sealing position,

wherein the engagement between the at least one force feedback element (24) and the at least one force feedback counter element (34) is formed such that force feedback can be provided to a user when the first connector member (20) is moved towards the sealing position.

7. The electrical connector assembly (1) according to claim 6, wherein the first connector member (20) is adapted to be movable about a first connector member closed path distance (28) from the open position to the sealed position,

wherein the at least one force feedback element (24) and the at least one force feedback counter-element (34) are formed to allow a resulting reaction force (F3) acting on the first connector member (20) to become minimal during the last 10%, preferably during the last 20%, of the first connector member closed path distance (28) of the first connector member (20).

8. The electrical connector assembly (1) according to claim 7, wherein the first connector member (20) has a first connector member closed path distance (28) from the open position towards the sealing position of up to 20mm, preferably up to 10mm, more preferably up to 5mm, most preferably up to 2.6 or 2.7 mm.

9. Electrical connector assembly (1) according to any of claims 6 to 8,

wherein the at least one force feedback element (24) of the first connector member (20) is a rigid member extending in the first direction (100),

wherein the rigid member comprises a protrusion (26) arranged at a central portion of the rigid member, wherein the protrusion (26) protrudes towards the at least one force feedback counter-element (34),

wherein the at least one force feedback counterpart element (34) is a flexible locking member extending against the first direction (100) and comprising a contact (36) arranged at a distal end of the flexible locking member, wherein the contact (36) protrudes towards the at least one force feedback element (24).

10. Electrical connector assembly (1) according to claim 9,

wherein the flexible locking member is adapted to:

a. preliminarily engaging the protrusion (26) of the rigid member with the contact (36) at a contact portion (38);

b. on further movement, deflection occurs as a result of the engagement with the projection (26), and

c. flexibly returning to its initial position after the contact portion (38) has passed the maximum protrusion width (W1) of the protrusion (26), wherein the deflected contact (36) urges the protrusion (26) in the first direction (100) towards the sealing position.

11. Electrical connector assembly (1) according to any of the preceding claims,

wherein the electrical connector assembly (1) is adapted to provide tactile feedback to a user pushing the first connector member (20) towards its sealing position when the first connector member (20) has reached its sealing position.

12. Electrical connector assembly (1) according to any of the preceding claims, wherein one of the connector members is a plug connector (10), preferably an SRS plug connector or an airbag squib connector.

13. Electrical connector assembly (1) according to any of the preceding claims, wherein the engagement between the first connector member (20), the flexible sealing element (50) and the second connector member housing (30) is formed such that the resulting reaction force (F3) acting on the first connector member (20) when the first connector member (20) is moved from the open position to the sealed position in the first direction (100):

a. -assumes a positive value at the beginning of the movement of the first connector member (20), so that the resulting reaction force (F3) acts against the direction of the first direction (100);

b. continuously increasing until said resultant reaction force (F3) reaches a single maximum, and then

c. Continuously decreases until the resulting reaction force (F3) assumes a minimum value in the sealing position.

14. Electrical connector assembly (1) according to any of the preceding claims, wherein the sealing wall (22, 32) for releasably engaging the flexible sealing element (50) is inclined with respect to the first direction (100) along the entire sealing area (40) such that a width (W2) of the sealing wall (22, 32) for releasably engaging the flexible sealing element (50) continuously decreases along the first direction (100).

15. Electrical connector assembly (1) according to any of the preceding claims,

wherein the first connector member (20) is a Connector Position Assurance (CPA) member and wherein the second connector member (10) is a plug connector and wherein the first direction (100) is a CPA member closing direction.

16. Electrical connector assembly (1) according to any of claims 1 to 14,

wherein the first connector member (20) is a counterpart connector and the second connector member (10) is a corresponding plug connector, and wherein the first direction (100) is a connector assembly mating direction.

17. A method for coupling an electrical connector assembly (1), comprising the steps of:

a. -providing an electrical connector assembly (1) according to claims 1 to 16;

b. moving the first connector member (20) from the open position to the sealed position to provide an electrical connection and a waterproof seal.

Technical Field

The present invention relates to the field of sealed electrical connector assemblies, and more particularly to SRS plug connectors or airbag squib connectors. The invention also relates to a corresponding method for coupling an electrical connector assembly. The electrical connector assembly according to the present invention is typically used in a vehicle, in particular in a vehicle electrical system.

Background

Electrical connector systems are used to connect electrical circuits, where typically male contact terminals mate with female contact terminals. In vehicles such as automobiles, a number of electrically driven Supplemental Restraint Systems (SRS) are required to ensure optimal interaction of safety components (e.g. between an airbag and a seat belt pretensioner) in the event of an accident.

Failure of the SRS components may have serious consequences for road users in an accident, and therefore, we strive to provide an electrical connector system that makes it possible to ensure working in a reliable and error-free manner. Since electrical connectors in vehicles are typically of small size, so-called Connector Position Assurance (CPA) members are often provided which can help a user to ensure proper alignment of any components of the electrical connector. Still further, it is desirable that the electrical connections established by the individual connectors be protected from any adverse environment (e.g., debris and moisture). Several methods are known in the art for providing sealed connector assemblies.

Reference US 7,997,940B 2 discloses an electrical connector assembly for an airbag igniter, wherein the plug member further includes an annular gasket seal surrounding the plug nose and below the plug body, the seal being adapted to seal a gap between the socket member and the plug member when the plug member is inserted into the socket member bore.

Reference US 9,337,571B 2 discloses a seal member configured to be mounted to an outer peripheral surface of a first connector housing of a pair of connector housings so as to seal a gap between the outer peripheral surface of the first connector housing and an inner peripheral surface of a second connector housing of the pair of connector housings. The inner peripheral surface of the seal member is formed with protrusions and grooves aligned in the axial direction of the seal member at a first wavelength, and the outer peripheral surface of the seal member is formed with protrusions and grooves aligned in the axial direction at a second wavelength. The first wavelength is equal to or smaller than the second wavelength, and the positions of the protrusions of the inner peripheral surface are offset in the axial direction from the positions of the protrusions of the outer peripheral surface.

According to prior art methods, a user must apply a relatively high force to mate, close and/or seal the individual electrical connectors. Furthermore, in the method according to the prior art, when a flexible seal is employed, the user closing the electrical connector by means of a pushing movement is often subjected to irregular forces due to additional friction and compression forces.

Disclosure of Invention

The above problems are at least partially solved by a sealed electrical connector assembly and a corresponding method of coupling an electrical connector assembly according to the present invention.

In particular, the invention proposes a sealed electrical connector assembly comprising: a first connector member and a second connector member, wherein the first connector member is adapted 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 substantially along a first direction, and wherein the second connector member comprises a second connector member sealing wall extending substantially along the first direction, wherein in the sealed position the first connector member sealing wall and the second connector member sealing wall face each other in a sealing area; a flexible sealing element, wherein in the sealing position the flexible sealing element is adapted to be arranged in the sealing region between and in contact with the sealing walls of the first and second connector members, wherein the flexible sealing element is fixed relative to one of the sealing walls and is adapted to releasably engage with a respective other one of the sealing walls to provide a watertight seal, wherein the sealing wall for releasably engaging the flexible sealing element is inclined relative to the first direction along the entire sealing region.

Thus, a sealed electrical connector assembly may be obtained which, in the sealed position, protects the contained components from any undesired environment (e.g. debris and moisture) while employing low sealing mating forces. The sealed electrical connector assembly according to the present invention may comprise any suitable connector assembly known in the art, such as a sealed connector comprising a CPA and/or a Terminal Position Assurance (TPA) member; such as a sealed connector partner formed by a male connector and a female connector, which may mate directly (e.g., via a latch) or may include a mating assist such as a lever or slider. The sealed electrical connector assembly may allow for a sufficient water resistance value to be obtained to obtain protection against moisture ingress. The plug connector may be a male or female connector comprising at least one electrical component (typically at least two electrical components) for electrically connecting electrical components (e.g. electrical components of a vehicle electrical system). If more than two electrical contacts are present, the connector may additionally be used for signal transmission purposes. The electrical component may be an electrical consumer, a power source, a cable, and/or a cable harness.

The first connector member and/or the second connector member may be formed as one integral part (e.g. by a moulding process) or may be formed from multiple parts assembled together. The second connector member and the first connector member may be formed in a circular manner such that the first connector member may be received in the circular aperture of the second connector member. Thus, the non-inclined sealing wall may be in the form of a cylinder and the inclined sealing wall may be in the form of a cone. Further, the two sealing walls may be formed in an inclined manner. Thus, the flexible sealing element may be in the form of a ring, which may be fixed to the non-inclined sealing wall. Thus, the flexible sealing element may be provided in the form of a mounted sealing ring which may thus be fixed or mounted by means of tension and/or friction with the non-inclined sealing wall. The sealing element may comprise any suitable flexible material that allows for a corresponding sealing function when compressed. Non-limiting examples may include elastomers such as thermoset elastomers, for example rubber and silicone. Further embodiments may include thermoplastic elastomers and polyurethanes. The shape and dimensions of the flexible sealing element may be suitably adapted such that when the flexible sealing element is compressed during the sealing movement (which may also be referred to as mating movement or closing movement) a mating smooth movement of the first connector member or any other counterpart relative to the second connector member is provided. The various components may be pre-assembled such that the pre-assembled plug connector already includes the first connector member in the open position, which is then mated with the corresponding counterpart connector. The open position of the first connector member is understood to be a position in which no sealing function is provided. Still further, it is also possible to provide the flexible sealing element in a pre-assembled manner together with the second connector member or the first connector member. The flexible sealing element may include any suitable form (e.g., one or more protrusions or lips) that allows for proper compression during engagement. The sealing wall may be inclined such that a constant inclination angle is provided in a first direction, which may also be referred to as a closing direction or a mating direction, and the form of the flexible sealing element may be adapted to this inclination angle to allow a preferably constant and uniform force build-up during the sealing movement of the first connector member without any undesired intermediate force peaks which may mislead a user to believe that the first connector member has been arranged in the sealing position, which may also be referred to as a mating position or a closing position. Still further, the elements of these sealed electrical connector assemblies according to the present invention prevent the need for high pushing forces when the first connector member is moved into its sealing position by a user, which may allow the user to obtain a faster and less tiring establishment of the respective electrical connection. Thus, the sealed electrical connector assembly according to the invention may be particularly reliable. The inclined sealing wall may further comprise a lead-in chamfer facilitating correct initial positioning of the flexible sealing element with the inclined sealing wall. Thus, a sealed electrical connector assembly may be obtained which allows to overcome negative effects, such as one or more undesired force peaks originating mainly from normal force components acting axially against the first direction. Still further, additional friction caused by the flexible sealing element may be reduced. The assembly according to the invention thus allows to avoid counteracting forces occurring in the axial direction as well as in the radial direction.

In a preferred embodiment, the flexible sealing element comprises at least two compressible lips extending towards the inclined sealing wall, wherein the at least two compressible lips are adapted such that the compression of the at least two compressible lips in the sealing position is substantially the same.

Thus, a uniform force distribution over the flexible sealing element may be obtained. This avoids a single sided load of only one lip, which could lead to damage and/or failure. Of course, this can also be adapted to a higher number of lips, so that the corresponding forces are thus distributed evenly over the lips. In addition, the compressible lip may be formed such that the engagement of the compressible lip with the inclined sealing wall is adapted, so that force peaks due to deformation of said lip may be prevented. A suitably formed compressible lip is provided which is adapted in form and/or material to the respective optimum contact and compression with the inclined sealing wall, allowing to accommodate the respective deformation of the lip and the frictional contact forces which may occur when the lip contacts the respective sealing wall. Thus, the size of the lips may be adapted to the inclined sealing wall surface and may for example be different for each lip, so that in the sealing state (which may be referred to as closed state or fitted state) the pressure on the inclined sealing wall surface is the same for each lip.

In a preferred embodiment, the angle of the inclined sealing wall is 1 to 20 °, preferably 3 to 15 °, and most preferably 5 to 10 °.

The angle, which may also be referred to as a tilt angle, is arranged with respect to a first direction of the first connector member, which may be along a vertical axis. The angle of inclination may be constant along the entire inclined sealing wall. Therefore, the change of the engaging force when the first connector member moves from the open position to the sealing position can be prevented. Thus, the inclination of the surface of the flexible sealing element may be adapted to provide sufficient contact with the inclined sealing wall to secure the sealing function. The choice of a larger or smaller angle of inclination may be selected based on the need for low mating force (small angle), short required travel distance (large angle), sufficient lip compression (large angle), and low tendency of the first connector member or other component to inadvertently move against the first direction (small angle).

In a preferred embodiment, the flexible sealing element is fixed relative to the second connector member sealing wall and is adapted to releasably engage with the first connector member sealing wall.

This may allow the flexible sealing element to be pre-assembled with the second connector member. Thus, the second connector member and the sealing element may be provided as one pre-assembled element, and the first connector member may subsequently be inserted into the respective hole of the second connector member. In another embodiment according to the invention, the flexible sealing element may be provided in a pre-assembled manner with the first connector member, which thus forms a pre-assembled element, which may then be inserted into a corresponding hole of the second connector member. This may facilitate assembly of the sealed electrical connector assembly according to the invention.

In a preferred embodiment, the contact between the flexible sealing element and the inclined sealing wall is formed such that a compressive sealing reaction force against the first direction increases substantially continuously when the first connector member is moved from the open position to the sealing position.

Thus, any undesired force peaks may be prevented, which may be experienced by a user pushing the first connector member into its sealing position. Furthermore, the increasing force may allow for a connector assembly in which a corresponding compensation force, which may be required, is easier to estimate and thus provided by corresponding means to compensate for the compression sealing reaction force. The avoidance of force peaks may also prevent damage and wear of the components encountering the forces. Within this specification, a reaction force refers to a force that may be experienced by a user when pushing the first connector member into the sealing position. Thus, the compressive sealing reaction force is understood to be the force experienced by the user due to the compression of the flexible sealing element and its corresponding friction with the second connector member sealing wall and the first connector member sealing wall.

In a preferred embodiment, the first connector member further comprises at least one force feedback element, and wherein the second connector member comprises a second connector member housing, wherein the second connector member housing comprises at least one force feedback counter element adapted to engage with the at least one force feedback element when the first connector member is moved towards the sealing position. The engagement between the at least one force feedback element and the at least one force feedback counter element is formed such that force feedback can be provided to a user when the first connector member is moved to the sealing position.

Thus, when the first connector member is arranged in the fully sealed position, the user may derive unambiguously from the force feedback experienced during mating and/or closing. Thus, intermediate force peaks may be avoided and any intermediate first connector member positions may be prevented which may result in an incomplete positioning of the first connector member and thus an incomplete sealing of the connector assembly. This improves the reliability of the seal during fitting and/or closing. Still further, a compressive sealing reaction force acting on the first connector member against the first direction may be at least partially compensated.

Compensation of the reaction force is understood to mean that the force which has to be applied by the user to overcome the frictional force and the compressive force of the sealing element is compensated. Thus, when the compression force of the flexible sealing element is large, this will result in a corresponding large reaction force. However, although the compressive force may increase even further when moving the first connector member towards its sealing position, as the flexible sealing element is further compressed, the user may be facilitated to overcome the reaction force and may be facilitated to push the first connector member further in the first direction. Thus, additional forces that may be caused by the flexible sealing element may be compensated. The force feedback element and the corresponding force feedback counter-element may be formed from any suitable flexible material, such as plastic. The force feedback arrangement described above may be provided as a separate locking means or in addition to another locking means, for example a conventional locking latch may be provided between the respective male and female housings. Still further, the arrangement may be adapted such that two symmetrical flexible members will work symmetrically against a central "rigid" member. In this case, the "rigid" member will be symmetrically loaded, thus no additional support or guiding force is required. This will result in a reduction of friction.

In a preferred embodiment, the first connector member is adapted to be movable with respect to a first connector member closure path distance from the open position to the sealing position, wherein the at least one force feedback element and the at least one force feedback counter-element are formed to allow a resulting reaction force acting on the first connector member to be minimized in the last 10%, preferably in the last 20%, of the first connector member closure path distance of the first connector member. In a preferred embodiment, the first connector member closed path distance from the open position towards the sealing position is up to 20mm, preferably up to 10mm, more preferably up to 5mm, most preferably up to 2.6 or 2.7 mm.

Thus, the force level of the force feedback element may advantageously reduce or counteract the force level due to the sealing, which latter force level may occur due to compression and friction at the end of the movement of the first connector member. According to the invention, the force feedback may be provided such that a large force difference between a maximum positive force value at the beginning of the closing movement and a minimum force value at the end of the movement may be obtained, which force difference may still be a positive force value. Thus, a reduction of the force during movement can be achieved, which results in an improved force feedback. In another preferred embodiment, the resultant reaction force acting on the first connector member becomes negative, causing the first connector member to be urged towards the sealed position. Thus, the user may be facilitated to complete the sealing movement of the first connector member. It will be appreciated that the reaction force experienced by the user against his or her thrust may be represented by a positive sign. Thus, if the reaction force is negative, it is to be understood that the direction of action of the force is such that the first connector member is urged towards its sealing position without further urging by the user. Thus, the first connector member may automatically snap into its sealing position and a misalignment of the intermediate position may be prevented. As an example, the first connector member may e.g. snap into the sealing position at the last 20% (corresponding to 2mm) of the total distance, if the first connector member has to be moved a total distance of 10mm from the open position to the sealing position. That is, the first connector member travels the last 2 millimeters toward the sealed position without requiring the user to apply further force. Of course, other absolute or relative first connector member closure path distance values may be employed as desired.

In a preferred embodiment, the at least one force feedback element of the first connector member is a rigid member extending in the first direction, wherein the rigid member comprises a protrusion provided at a central portion of the rigid member, wherein the protrusion protrudes towards the at least one force feedback counter-element. The at least one force feedback counter element is a flexible locking member extending against the first direction and comprising a contact arranged at a distal end of the flexible locking member, wherein the contact protrudes towards the at least one force feedback element. It should be understood that the flexible locking member may also be oriented in a direction different from the first direction, as long as a suitable interaction between the flexible locking member and the correspondingly formed counterpart is enabled. For example, the flexible locking member may be formed as a horizontally oriented arm. In a preferred embodiment, the flexible locking member is adapted to:

a. preliminarily engaging the projection of the rigid member with the contact at a contact portion;

b. on continued movement, deflection occurs due to the engagement with the projection, and

c. flexibly returning to its original position after the contact portion passes a maximum protruding width of the protrusion, wherein the deflected contact urges the protrusion in the first direction toward the sealed position.

Thus, a stress may be applied to the first connector member, which makes it possible to achieve the snap-in function described above. The contact portion is understood to be the region where contact between the projection and the contact takes place. Of course, the above-described configuration may also be provided in reverse, such that the force feedback element of the first connector member may be provided as one or more flexible members and the force feedback counterpart element of the second connector member housing may be provided as one or more rigid members, or both parts may be provided as flexible members, as long as a suitable force distribution is provided that may allow for force feedback and/or compensation during sealing movement of the first connector member. As will be appreciated by the skilled person, the amount of "rigidity" and "flexibility" of the two members may of course depend, for example, on the material and the size and shape of the respective members. That is, the rigid member may also be allowed to deflect somewhat. However, a flexible member will be understood to be a member that deflects to a greater extent than the rigid member during engagement of the two members. The protrusion and the contact may also be provided at other suitable portions of the force feedback element of the first connector member or the force feedback counterpart element of the second connector member, respectively.

In a preferred embodiment, the electrical connector assembly is adapted to provide tactile feedback to a user pushing the first connector member (20) towards its sealing position when the first connector member has reached its sealing position.

Thus, the user can clearly distinguish whether the first connector member has reached its final sealing position. Thus, any component of the sealed electrical connector assembly according to the present invention can be prevented from being misaligned due to incomplete positioning of the first connector member. The feedback may also be instead of or in addition to any further suitable indication (e.g. a visual indication or an acoustic indication, such as a click sound when the first connector member has reached its sealing position). The tactile feedback may also be different from the "click" effect when the final position is reached. The tactile feedback may accordingly be a sudden drop in force after a sharp lift, which may occur before the first connector member reaches its final position. Such behavior may provide certain inertial effects that may avoid incompletely mated positions.

In a preferred embodiment, one of the connector members is a plug connector, preferably an SRS plug connector or an airbag squib connector. Such connectors are currently used, for example, in airbag systems of automobiles. However, the invention is not limited to this application but may be used in any suitable electrical connector application.

In a preferred embodiment, the engagement between the first connector member, the flexible sealing element and the second connector member housing is formed such that when the first connector member is moved in a first direction from an open position to a sealed position, the resultant reaction force acting on the first connector member:

a. assuming a positive value at the beginning of the movement of the first connector member, so that the resulting reaction force acts against the direction of the first direction;

b. continuously increasing until the resultant reaction force reaches a single maximum, and then

c. Continuously decreases until the resultant reaction force assumes a minimum value in the sealing position.

Thus, a sharp force increase with a maximum value at the beginning of the movement may be provided, which may be between one third and one half of the movement, and then a constant decrease of the force may be obtained until the end of the movement. According to the invention, the minimum force value in step c) may remain positive at the end of the movement. This may occur, for example, due to high friction or unfavorable space constraints. According to the invention, the engagement of the first and second connector members may be configured such that a large force difference between a single maximum force value in step b) and a minimum force value at the end of the movement in step c) may be obtained. Thus, a strong force reduction during the movement can be achieved, which leads to an improved force feedback. In a preferred embodiment, the reaction force in step c) assumes a negative value, such that the resulting reaction force acts in a direction towards the first direction, urging the first connector member into the sealing position. Thus, as already discussed above, the force may advantageously become negative at the end of the movement in order to close itself by the last few percent of the distance. A high maximum force value may be important to give the user more feedback and to make use of inertial effects to ensure a complete closing operation. In general, the force variation may occur due to any tolerance of the components, especially in multi-cavity molds. These force alterations may compromise the positive tactile feedback to the user, however, this may be avoided by the sealed electrical connector assembly according to the present invention.

In a preferred embodiment, the sealing wall for releasably engaging the flexible sealing element is inclined with respect to the first direction along the entire sealing area, such that the width of the sealing wall for releasably engaging the flexible sealing element decreases continuously along the first direction.

Thus, any alteration of the reaction force due to different tilting angles can be prevented, which may further improve the sealing function, the reliability of the sealed electrical connector assembly and the ability to provide an improved and clear tactile user feedback without any undesired force peaks.

In a preferred embodiment, the first connector member is a connector position assurance member, a CPA member, the second connector member is a plug connector, and the first direction is a CPA member closing direction.

The CPA member may thus ensure a correct alignment of the respective mechanical and/or electrical components of the electrical connector according to the present invention and may be adapted to interrupt the electrical connection between the respective plug connector and the respective counterpart connector as long as the CPA member is not placed in the correct sealing position. This facilitates the user to verify proper alignment and proper locking of the various mechanical and electrical components.

In a preferred embodiment, the first connector member is a counterpart connector, the second connector member is a corresponding plug connector, and the first direction is a connector assembly mating direction.

Therefore, when the plug connector is mated with the corresponding counterpart connector, the above-described function of providing a waterproof seal can be obtained between the plug connector and the corresponding counterpart connector.

In another embodiment according to the present invention, a waterproof seal may be provided between the CPA member and the plug connector when the CPA member is in the sealing position, and a further waterproof seal may be provided between the plug connector and the corresponding counterpart connector when the plug connector is in the sealing position, wherein the respective waterproof seal may be obtained as described above in relation to the above-described embodiments.

The skilled person will appreciate that the above preferred embodiments are described as examples only, and that the electrical connector assembly may of course comprise embodiments which may be a combination of the features described above or comprise embodiments which are differently configured from the embodiments described within this specification.

Furthermore, the invention proposes, inter alia, a method for coupling an electrical connector assembly, comprising the steps of:

a. providing an electrical connector assembly according to one of the above embodiments;

b. moving the first connector member from the open position to the sealed position to provide an electrical connection and a waterproof seal.

Thus, implementation of the electrical connector assembly according to the present invention may provide the advantages described above.

Drawings

The drawings that illustrate specific embodiments of the present invention are briefly described below.

Figure 1 schematically shows a cross-sectional view of an electrical connector assembly according to the invention, wherein the first connector member is a CPA member in an open position;

figure 2 schematically shows a cross-sectional view of an electrical connector assembly according to the invention, wherein the first connector member is a CPA member in a sealing position;

a) in fig. 3 schematically shows the flexible sealing element during displacement of the CPA member of the electrical connector assembly according to the present invention;

b) in fig. 3 schematically shows a reaction force originating from the flexible sealing element during displacement of the CPA member in the electrical connector assembly according to the present invention;

figure 4 schematically shows a close-up cross-sectional view of the force feedback element and the force feedback counter element of the electrical connector assembly according to the present invention, with the CPA member in an open position;

figure 5 schematically illustrates the reaction forces and the respective engagement positions of the force feedback element and the force feedback counter-element of the electrical connector assembly according to the present invention;

figure 6 schematically shows the reaction forces originating from the flexible sealing element and the CPA member during displacement of the CPA member in the electrical connector assembly according to the present invention and the total resulting reaction force;

figure 7 schematically shows a close-up cross-sectional view of a force feedback element and two force feedback counter-elements of an electrical connector assembly according to the present invention, with the CPA member in an open position;

figure 8 schematically illustrates a cross-sectional view of an electrical connector assembly according to another embodiment of the invention, wherein the first connector member is a plug connector in an open position;

figure 9 schematically illustrates a cross-sectional view of an electrical connector assembly according to another embodiment of the invention, wherein the first connector member is a plug connector in a sealed position;

figure 10 schematically illustrates the flexible sealing element during displacement of a plug connector of another embodiment of an electrical connector assembly according to the invention.

List of reference numerals

1 sealed electrical connector assembly

10 second connector member

12 cable

20 first connector member

22 first connector member sealing wall

23 introducing chamfers

24 force feedback element

26 convex

27 latch projection

28 first connector member closed path distance

30 second connector component housing

32 second connector member sealing wall

34 force feedback mating element

36 contact

38 contact part

40 sealing area

50 Flexible sealing element

52 compressible lip

60 mating connector

100 first direction

Angle of alpha-inclined sealing wall

Maximum protrusion width of W1 projection

Width of W2 sealing wall

F1 compressive seal reaction force

F2 CPA member closing reaction force

Resultant reaction force of F3

Detailed Description

In particular, fig. 1 shows a cross-sectional view of an electrical connector assembly according to the present invention with the first connector member 20 in an open position, the first connector member 20 being shown as a CPA member. The second connector member 10 is shown as a plug connector 10 adapted to mate with a corresponding counterpart connector 60, which together form a sealed electrical connector assembly 1. The counterpart connector 60 is shown in the disconnected state, but it should be understood that it may of course be arranged to mate with the plug connector 10. The plug connector 10 includes a second connector member housing 30, shown as connector housing 30, the second connector member housing 30 enclosing any other components (e.g., electrical components) of the plug connector 10. A cable 12 is connected to the plug connector 10 and provides an electrical connection to other components connected to the sealed electrical connector assembly 1. The plug connector 10 further comprises a CPA member 20 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 movable along the first or closing direction 100 to a sealing position while the connector housing 30 and its various components remain in a fixed position. The CPA member 20 comprises a first connector member sealing wall 22, which first connector member sealing wall 22 is shown at the top side of the CPA member 20 as CPA member sealing wall 22, which extends substantially along the closing direction 100. The CPA member sealing wall 22 is slightly inclined in the closing direction 100 so that it has a conical appearance. At the top side of the CPA member is provided a pushing surface that allows a user to push the CPA member 22 in a closing direction 100 approximately a first connector member closing path distance 28, which first connector member closing path distance 28 is shown as CPA member closing path distance 28 from the open position to the sealed position. The inclined CPA member sealing wall 22 is received by a corresponding aperture in the top side of the connector housing 30, which in this embodiment has a circular appearance. The inner wall of the circular receiving bore forms a second connector member sealing wall 32 (shown as connector housing sealing wall 32), which second connector member sealing wall 32 is provided with a flexible sealing element 50, which flexible sealing element 50 comprises two compressible lips 52, which are adapted such that the inclined CPA member sealing wall 22 can slide along said compressible lips 52 when the CPA member 20 is pushed into the sealing position.

CPA member 20 also includes internal components, such as force feedback elements 24, that facilitate mating and alignment of the mechanical and electrical components of plug connector 10 and mating connector 60. The 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 projection 26, which projection 26 is adapted to engage with a corresponding contact 36 of the 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 pushed accordingly.

Figure 2 schematically shows a cross-sectional view of the electrical connector assembly of figure 1 according to the present invention with the CPA member 20 in the sealing position. The mating connector 60 is also shown connected to the plug connector 10 to establish an electrical connection. After mating of the plug connector 10 and the counterpart connector 60, the CPA member 20 is brought into a sealing position, which allows the CPA member 20 to align with any mechanical and electrical components in the sealed electrical connector assembly 1, thereby enabling secure connection to be ensured. It can be seen that the CPA member 20 has been pushed towards the closing direction 100. The CPA member sealing wall 22 has moved along a compressible lip 52, the lip 52 being disposed in the sealing region 40 and being compressed in the sealing region 40, the sealing region 40 being the region where a watertight seal is formed between the CPA member sealing wall 22 and the connector housing sealing wall 32. The contacts 36 catch behind the notches of the projections 26.

A) in fig. 3 shows the compressible lip 52 of the flexible sealing element 50 during displacement of the CPA member 20 of the sealed electrical connector assembly 1 according to the present invention. The progression of movement is depicted in #1 to #4 of a) in fig. 3, such that the CPA member 20 moves in the closing direction 100 and travels through a CPA member closing path distance 28 from #1 to # 4. The flexible sealing element 50 is fixed to the connector housing 30. B) in fig. 3 shows a corresponding force-path diagram depicting the reaction forces occurring during the progress of the movement of the CPA member in the closing direction 100. The width W2 of the inclined CPA member sealing wall 22 decreases in the closing direction 100, which is illustrated by the angle a in #4 of a) in fig. 3 with respect to the closing direction 100 (vertical direction). The inclined CPA member sealing wall 22 comprises a lead-in chamfer 23, which lead-in chamfer 23 is inclined to facilitate the introduction of the flexible sealing element 50. #1 of a) in fig. 3 shows the situation when the upper one of the compressible lips 52 has come into contact with the inclined CPA member sealing wall 22. However, when the CPA member 20 is pushed towards the closing direction 100, the upper one of the compressible lips 52 is not engaged by the lead-in chamfer 23, but is in direct contact with the inclined CPA member sealing wall 22. This is reflected by the corresponding reaction force diagram of B) in fig. 3, wherein the compressive sealing reaction force F1 rises constantly as the upper lip is increasingly compressed further. In #2 of a) in fig. 3, the lower one of the compressible lips 52 only lightly contacts the CPA member sealing wall 22. #4 of a) in fig. 3 shows the CPA member 20 in a final and fully sealed position with the flexible sealing element 50 compressed in the sealing area 40 between the CPA member sealing wall 22 and the connector housing sealing wall 32. In this position, the corresponding compressive sealing reaction force F1 is at a maximum. As can be seen from B) in fig. 3, the engagement between the flexible sealing element 50 and the CPA member sealing wall 22 does not provide a significant force peak when the CPA member 20 is moved into the sealing position. Since the compressible lip 52 is correspondingly formed to cooperate with the inclined CPA member sealing wall 22, the overall force level is relatively low. As shown, the compressible lip is not compressed to the maximum extent at the beginning of the movement. The main contact pressure is applied at the last third of the movement of the CPA member.

Fig. 4 shows a close-up cross-sectional view of force-feedback element 24 and force-feedback counter-element 34 when CPA member 20 is in the open position. As shown, the contacts 36 of the force feedback mating element 34 are formed by the connector housing 30. The contact 36 is disposed between the latch protrusion 27 and the protrusion 26 of the force feedback element 24, wherein the protrusion 26 has a maximum protrusion width W1.

As further shown in fig. 5, the contacts are adapted to flexibly slide along the outer surface of the force feedback element 24 when the CPA member 20 is moved in the closing direction 100 from the open position to the sealing position. The position of the respective projection 26 of the force feedback element 24 and the contact 36 of the force feedback counterpart element 34 during the closing movement is shown in the sub-diagram of fig. 5. The contact portion 38 is shown as the area where contact between the protrusion 26 and the contact 36 occurs. At the beginning of the movement, the contact 36 is flexibly deflected by the rigid projection 26. The reaction force from the engaged force feedback element F2 (shown in fig. 5) increases accordingly and reaches a maximum at approximately 0, 8mm displacement. At the end of the first ramp angle, the force begins to decrease as the radius begins to the maximum width W1 (as shown in the left-most drawing of fig. 5). To avoid further increase in force as movement continues, the contact 36 is provided with a rearward angle on its front surface that is non-vertical when relaxed and vertical when bent. After passing the maximum width W1 of the projection 26, the force F2 decreases further until it obtains a negative value, which means that the CPA member 20 no longer needs to be pushed in the closing direction 100, but the contact 36 flexibly returns to its initial position so that it pushes the projection 26 in the closing direction 100 until the CPA member 20 reaches its sealing position.

Fig. 6 shows the reaction forces F1 and F2 and the total resulting reaction force F3 along the displacement of the CPA member 20 resulting from the compression of the flexible sealing element 50 and from the engagement of the CPA member 20 with the connector housing 30, respectively, in the sealed electrical connector assembly 1 according to the present invention. As can be seen, the resultant reaction force F3 is the sum of the compression seal reaction force F1 and the CPA member closing reaction force F2. As is apparent from the graph of force F2 resulting from the engagement of CPA member 20 with connector housing 30, said force F2 partially compensates for the constantly increasing compression sealing reaction force F1 resulting from the compression and friction force of flexible sealing element 50 in the last half millimeter of displacement of CPA member 20. Therefore, although the force F1 increases, the resultant reaction force F3 becomes negative. This allows CPA member 20 to be urged toward its sealing position without the user having to apply a pushing force. As is apparent from the graph F3, the interaction of the individual components of the plug connector 10 (i.e. the CPA member 20, the connector housing 30 and the flexible sealing element 50) enables a total force F3 to be obtained with a maximum displacement value of about 0.8mm and without further force peaks and negative force values at the end of the displacement. This in turn allows to provide the user with a suitable tactile feedback, wherein he or she can clearly determine the state of the CPA member 20 movement and its state during the closing movement.

Fig. 7 shows a close-up cross-sectional 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 CPA member 20 is in an open position. As shown, the contacts 36 of each of the two force feedback mating elements 34 are formed by the connector housing 30. The contacts 36 are each arranged between the latching projection 27 and a respective side of the projection 26 of the force feedback element 24, wherein the projection 26 has a maximum projection width W1. Thus, the two symmetrical flexible force feedback counter-elements 34 act symmetrically with respect to the central rigid force feedback element 24, so that the rigid force feedback element 24 is symmetrically loaded.

In particular, fig. 8 shows a cross-sectional view of another embodiment of an electrical connector assembly according to the present invention when the first connector member 20 (shown as the counterpart connector 20) is in an open or unmated position. The second connector member 10 is shown as a plug connector 10, which plug connector 10 is adapted to mate with a corresponding counterpart connector 20, which together form a sealed electrical connector assembly 1. The counterpart connector 20 is shown in the disconnected state, but it should be understood that it may of course be provided to mate with the plug connector 10. The plug connector 10 includes a second connector member housing 30, shown as connector housing 30, the second connector member housing 30 enclosing any other components (e.g., electrical components) of the plug connector 10. Wires 12 are connected to the plug connector 10 and provide electrical connections to other components connected to the sealed electrical connector assembly 1. The plug connector 10 further comprises a CPA member. Both the counterpart connector 20 and the CPA member are arranged to be received by the connector housing 30. In this embodiment, the CPA member, the counterpart connector 20 and the connector housing 30 are formed in a circular manner. The counterpart connector 20 is movable in the first or closing direction 100 to a sealing position, while the connector housing 30 and its various components are held in a fixed position. The counterpart connector 20 comprises a first connector member sealing wall 22, which first connector member sealing wall 22 is shown at the top side of the counterpart connector 20 as counterpart connector sealing wall 22, which extends substantially along the closing direction 100. The counterpart connector sealing wall 22 is slightly inclined in the closing direction 100 so that it has a conical appearance. The inclined counter connector sealing wall 22 is received by a corresponding hole at the bottom side of the connector housing 30, which hole has a circular appearance in this embodiment. The inner wall of the circular receiving hole forms a second connector member sealing wall 32 (shown as connector housing sealing wall 32), which second connector member sealing wall 32 is provided with a flexible sealing element 50, which flexible sealing element 50 comprises two compressible lips 52, which are adapted such that the inclined counter connector sealing wall 22 can slide along said compressible lips 52 when the counter connector 20 is pushed into the sealing position.

Fig. 9 schematically shows a cross-sectional view of the electrical connector assembly of fig. 8 according to the invention when the counterpart connector 20 is in a sealed position. The mating connector is also shown connected to the plug connector 10 to establish an electrical connection. After mating of the plug connector 10 and the counterpart connector, the counterpart connector 20 is brought into a sealed position, which enables the counterpart connector 20 to allow a secure electrical connection. As can be seen, the counterpart connector 20 has been pushed towards the closing direction 100. The mating connector sealing wall 22 has moved along a compressible lip 52, which compressible lip 52 is arranged in the sealing region 40 and is compressed in this sealing region 40, which sealing region 40 is the region where a watertight seal is formed between the mating connector sealing wall 22 and the connector housing sealing wall 32.

Fig. 10 shows the compressible lip 52 of the flexible sealing element 50 during displacement of the counterpart connector 20 of one embodiment of the sealed electrical connector assembly 1 according to the invention as shown in fig. 8 and 9. The progress of the movement is depicted in a) to C) in fig. 10, such that the counterpart connector 20 moves in the closing direction 100 and travels over the counterpart connector closing path distance 28 from a) to C). The flexible sealing element 50 is fixed to the connector housing 30. The width W2 of the inclined counterpart connector sealing wall 22 decreases in the closing direction 100, which is illustrated by the angle α in C) in fig. 10 with respect to the closing direction 100 (vertical direction). The inclined counter connector sealing wall 22 comprises a lead-in chamfer 23, which lead-in chamfer 23 is inclined to facilitate the introduction of the flexible sealing element 50. A) in fig. 10 shows the situation before the counterpart connector 20 contacts the flexible sealing element 50. B) in fig. 10 shows the situation when the lower compressible lip of the compressible lip 52 is in light contact with the inclined counter-connector sealing wall 22. C) in fig. 10 shows the counterpart connector 20 in a final and fully sealed position, wherein the flexible sealing element 50 is compressed in the sealing area 40 between the counterpart connector sealing wall 22 and the connector housing sealing wall 32. In which the corresponding compressive sealing reaction is at a maximum. This configuration substantially corresponds to the configuration of the first embodiment of the invention, for example depicted in fig. 3, and a similar reaction force behavior may be obtained such that the engagement between the flexible sealing element 50 and the counter connector sealing wall 22 does not provide a significant force peak when the counter connector 20 is moved into the sealing position. Since the compressible lip 52 is correspondingly formed to mate with the inclined mating connector sealing wall 22, the overall force level is relatively low. At the beginning of the movement, the compressible lip is not compressed to the maximum extent. The main contact pressure is applied at the last third of the movement of the counterpart connector.