Electrical connector for high voltage having secondary locking

Abstract

 A high voltage electrical connector (2, 102, 202, 202a, 302, 304) having a housing (4, 104, 204, 204a, 304, 404) with a plurality of terminal receiving channels (22, 122, 222, 222a, 322, 422) extending therethrough where each channel includes an opening (40, 140, 240, 240a, 340, 440) into the channel, an electrical terminal (24, 124, 224, 224a, 324, 424) positioned in the channel and a secondary locking member (26, 126, 226, 226a, 326, 426) for retaining the terminal. The connector characterized in that with the secondary locking member received within the opening in a locked position, the channel forms essentially a longitudinal channel completely surrounding the terminal along its length, thereby preventing lateral voltage jump over.

Description

[0001] This invention relates to electrical connectors, and in particular electrical connectors for high voltage requiring a secondary locking.

[0002] In many applications it is desirable to have mating electrical connectors interconnect multiple electrical lines. In some instances at least one of the lines will be carrying a high voltage signal. In these cases it is especially important to fully isolate the high voltage interconnection from the adjacent lines as voltage will attempt to travel the path of least resistance to ground. In cases where the line is not adequately isolated from the adjacent lines, it is possible for the voltage to "jump" from one line to the other. The worst case for jump over being when one of the adjacent lines carries a high voltage and the other runs directly to ground. Once a "jump" has occurred, a line will be carrying more voltage than it should while the intended line is carrying less, possibly leading to improper functioning of the device or damage thereto.

[0003] One way of dealing with a problem such as this is to simply keep the high voltage lines spaced a sufficient distance from any other object. This becomes a problem when it is desired to utilize an electrical connector which will typically bring a number of terminals into close proximity within a connector housing. As the voltage requires a short and direct air path, relatively speaking with respect to the difference in potential, to "jump", it is desirable to place the terminal within a continuous cavity that does not open into an adjacent cavity. In this situation the only possible "jump" is out the ends of the cavity.

[0004] Typical automotive electrical circuitry requirements involve low voltage DC currents. At these levels the "jump-over" is not a problem. Lately, as the electrical sophistication of automobiles increases, some of the circuits incorporated therein carry higher voltages. It is also true that there is an ongoing process of size reduction that results in an increase density of electrical contacts and conductive lines being incorporated into a single connector housing. Inherently, when increasing the density, the space between adjacent contacts and conductive lines is reduced, thereby making it essential to have dielectric material between adjacent lines as it is only the effective distance that enables the close spacing requirements to be met without "jump-over"

[0005] One problem being faced is that the electrical connectors used in automotive applications almost inevitably include a secondary locking member that assures that the contacts are retained within the connector housing in spite of the vibration and handling they are subjected to in the environment within which they operate. Secondary locks involve a member that is movable between an unlocked position outside of the contact channel so that the contact may be inserted or removed and a locked position where the secondary locking member is positioned in the channel to interfere with a part of the contact to prevent inadvertent dislodgement.

[0006] There are many variations of secondary locking connectors in the industry today. Some of them include arms that reach into the cavity from one of the ends thereof to abut the terminal. However, other useful secondary locks, especially in instances where it is necessary for the secondary locking member to engage the contact somewhere along the contacts length, are disposed in the middle of the connector housing which then includes an opening in the surrounding cavity wall in order for the secondary locking member to be able to engage the contact within the cavity.

[0007] However, a problem occurs when it is necessary to incorporate a secondary locking member of this type into the connector having a high voltage line therein. The problem being that this opening, necessary for the secondary locking member to engage the contact, has now created an path having a reduced distance to an adjacent terminal through which a sufficiently high voltage may "jump". Once an opening in the dielectric has been created, it is likely that a path to ground having less resistance than the resistance of the conductive line through which the voltage is meant to travel will be found.

[0008] It is known to overcome this problem by creating maze-like fingers that extend into the direct path between adjacent lines so that the opening is in effect blocked. This maze-like path has increased the effective distance through which the voltage must "jump". While this solution works in many applications, it is difficult to incorporate these small fingers of complex shapes within an already small connector housing. The fingers not only are difficult to mould and subject to damage but due to their small size are not as effective as desired.

[0009] It is an object of this invention to provide a high voltage electrical connector having a secondary locking member that prevents voltage "jump-over".

[0010] It is another object of this invention to provide a high voltage electrical connector having a secondary locking member that accesses a terminal within a cavity through an opening therein and fully seals the channel of a housing wherein a high voltage electrical contact is received from adjacent cavities which include electrical contacts in order to prevent voltage jumping.

[0011] It is another object to provide a connector having a compact and efficient design without the need for additional features.

[0012] The objects of this invention are accomplished by providing a housing having a plurality of terminal receiving channels extending therethrough where each channel includes an opening into the channel and each channel includes an electrical terminal. A secondary locking member having an unlocked position outside of said channel, and a locked position extending through the opening into the channel is provided so that the terminal is prevented from being dislodged from the channel. The connector being characterized in that the terminal receiving channel, with the locking member within the opening in the locked position forms a continuous longitudinal channel longitudinally surrounding the terminal therein, whereby voltage carried between adjacent terminals is prevented from jumping laterally therebetween.

[0013] The invention will now be described by way of reference to the drawings, where;

Figure 1 is a partially cut-away top view of a high voltage electrical connector according to the present invention and showing a representational mating connector in phantom form;

Figure 2 is an end sectional view of the high voltage electrical connector of Figure 1 taken along line 2-2;

Figure 3 is a partially broken-away, side sectional view of a second embodiment of a high voltage electrical connector according to the present invention;

Figure 4 is a sectional end view of the electrical connector of Figure 3 taken along line 4-4;

Figure 5 is a side view of a third embodiment of a high voltage electrical connector according to the present invention;

Figure 6 is an end sectional view of the high voltage electrical connector of Figure 5 incorporating contacts having a rectangular cross-sectional structure;

Figure 7 is an end sectional view of a high voltage electrical connector similar to that of Figure 5 incorporating contacts having a circular cross-sectional structure;

Figure 8 is an end sectional view of a fourth embodiment of a high voltage electrical connector according to the present invention;

Figure 9 is a side sectional view of the high voltage electrical connector of Figure 8 taken along line 9-9;

Figure 10 is an end sectional view of a fifth embodiment of a high voltage electrical connector according to the present invention; and

Figure 11 is a side sectional view of the electrical connector of Figure 10.

[0014] With reference now to Figures 1 and 2, a first embodiment of an electrical connector according to the present invention is shown generally at 2. The connector 2 includes an outer housing 4 having resilient latching arms 6 that engage a mating component 8 in order to keep the electrical connector 2 engaged therewith. The outer housing 4 further includes a forwardly extending circumferential wall 10 that forms a shroud for receiving a mating portion of the mating component 8 therein. Contained within the outer housing 4 is an inner housing 12, shown in this embodiment as being of snapped-in construction with the outer housing 4. The inner housing 12 includes a front mating end 14 and a rear cable exit end 16. The cable exit end 16 being adapted to receive a boot (not shown) for strain relief and environmental sealing. Disposed upon the inner housing 12 is a elastic seal 18, so that an environmentally sealed electrical connection may be formed between the mating components 2, 8. Forward of the seal 18 are a plurality of openings 20 that correspond to terminal receiving channels 22 extending through the inner housing 12 from the mating end 14 to the cable exit end 16 wherein the contact 24 is disposed, as seen in Figure 2.

[0015] A comb-like secondary locking member 26 is constructed such that a pair of teeth 28a, 28b will extend through each of the openings 20 in order to surround the contact 24. Figure 2 shows the secondary lock member 26 in an unlocked position outside of the channels 22. Each tooth 28 includes a free end 30. The free ends 30 of adjacent pairs of teeth 28a, 28b are spaced apart such that in the unlocked position the teeth do not enter into the cavity. Each tooth 28a, 28b includes opposingly facing relieved surfaces 31 separated so that the opposing surfaces 31 span the channel 22. The relieved surfaces 31 intersect shoulders 32 which extend towards each other until reaching locking shoulder 34 to define a slot having a base 36. The surfaces 34 form shoulders fitting about the contact 24 in order to retain the contact. Each channel 22 at the location of the secondary locking member 26 include open side surfaces 38 an upper surface 40 and lower surface 42, designated with respect to Figure 2. When the secondary lock member 26 is moved to the locked position, shoulders 32 correspond to lower surface 42 and the base 36 corresponds to the upper surface 40. IN addition the free ends 30 may be received in indented seats (not shown) to assure that a voltage path des not exist under tooth 28. The side surfaces 34 extend into the channel 22 to prevent inadvertent dislodgement of the electrical connector 22 and in doing so, complete the channel 22 at open sides 38, the top 40 being closed by the locking member 26. The width of the secondary lock member 26 is such that the teeth 28 are closely received in the opening 20. It is readily apparent that by doing so, the openings 20, required for insertion of a secondary locking member 26 into the housing 12 and the openings 38, 40 are sealed, thereby forming essentially a continuous channel fully surrounding the terminal.

[0016] With reference now to Figures 3 and 4, a second embodiment of a high voltage electrical connector according to the present invention is shown generally at 102. The electrical connector 102 is similar to that described above and includes an outer housing 104 for mating with a mating component 108. The outer housing 104 including forwardly extending arms 110 to form a shroud wherein the mating component 108 is received in order to form a sealed fit as described above. The electrical connector 102 further includes an internal housing 112 having a forward end 114 and a rearward end 116. The inner housing 112 is retained within the outer housing 104 by resilient retention arms 117 which engage the inner housing 112 and further act to abut a resilient seal 118 seated on the inner housing and configured to interact with the mating component 108 to form an environmentally sealed electrical connection at the front end 114 of the housing 112. Disposed toward the front end 114 of the inner housing 112 is a secondary locking member 126.

[0017] The secondary locking member 126 is also a comb-like structure having teeth 128 extending to a free end 130. Along each of the teeth 128 is a relieved portion 131 constructed so that when the secondary locking member is in an unlocked position, terminals (not shown) may be inserted or removed from the cavity 122. Inward along the tooth 128 is a locking shoulder 134. Locking shoulder 134 is constructed to extend into the channel 122 when the locking member 126 is in the fully latched position, as described below.

[0018] In this embodiment, the channels 122 are cylindrical in nature in order to receive a cylindrical contact. The channel 122 has an inner wall 138 that is open at 140 in order for the locking shoulder 134 of teeth 128 of the secondary locking member 126 to enter the channel 122. Opposite the opening 140 is an opposing wall 144 that backs-up the tooth 126 to retain the tooth 128 in proper position.

[0019] The secondary locking member 126 includes latching members 146 having a latch 148 at the free end for selectively engaging notches 150 in end walls 152 in order to define the unlocked and the locked positions. In Figure 4, the secondary locking member 126 is shown between the locked and unlocked position. When in the locked position, the locking shoulder 134 will extend completely across the opening 140. The opening 140 is completely filled, thereby blocking any path for voltage "jump-over" that would have a lower effective distance than through the wall 138 of the channel 122.

[0020] Now with reference to Figures 5-7, a third embodiment of a high voltage electrical connector will be described. Similarly to those described above, this connector 202 includes an outer housing 204 having a shroud portion 210 for receiving a mating component (not shown). Contained within the outer housing 204 is an inner housing 212 having a cable receiving end 216. The inner housing 212 has a elastic seal member 218 disposed thereupon. In this embodiment, the shroud portion 210 includes engaging channels 211 for receipt of the mating component.

[0021] The inner housing 212 includes terminal receiving channels 222 extending therethrough for receiving terminals 224 therein. Figure 6 discloses an embodiment constructed for the receipt of terminals 224 having a rectangular cross-section, while Figure 7 discloses similar structure for channels 222a constructed to receive terminals 224a having a circular cross-section. Due to the similarity between these two embodiments, only the embodiment of Figure 6 will be described in detail. However, these embodiments are illustrative of construction of a multiple row, high voltage electrical connector, which while only showing two rows, one row of which includes only a single position, it is fully envisioned that more rows, having greater or lesser numbers of terminal receiving channels, could easily be constructed.

[0022] With reference to Figure 6, this partial sectional view is taken at a similar location within the connector 202 as in the previous sections. Each of the channels 222 has an inner surface 238 generally surrounding the electrical terminal 224 therein along its longitudinal axis. The channel 224 is open on one side 240 to expose the terminal 224 to the secondary locking member 226. The secondary locking member 226 includes teeth 228 having relieved portions 231 that are constructed to correspond to the channels 222 when the secondary lock member 226 is in the unlocked position (as shown in Figure 6). In this position, the terminals 224 may be inserted or removed from the high voltage electrical connector 202. Adjacent to the relieved portions 231 are secondary locking shoulders 234 constructed to extend into the channels 222 so that the terminals 224 are prevented from being dislodged therefrom. Between the relieved portion 231 and the locking shoulder 234 is a shoulder 232, that when the secondary locking member 226 in the locked position, has passed across the open side 240 of the channel 224 such that the locking shoulder 234 extends completely across the open side 240 in order to seal the channel 222, thereby sealing any opening 240 in the channel 222 that would provide a lower effective distance between adjacent terminals 224.

[0023] In this embodiment, the locked and unlocked positions of the secondary locking member 226 are established in a manner similar to that described with reference to Figures 3 and 4. However, in this instance the structure is reversed. A latch 248 is disposed upon one of a plurality of guide rails 249 to engage notches 250 in the teeth 228 of the secondary locking member 226. The guide rails 249 add structural integrity to the secondary locking member 226 similar to the back-up surface 144 of the embodiment of Figure 4 by maintaining the position of the teeth 228. As mentioned above, the embodiment shown in Figure 7 is similar to that just described. The important features of Figure 7 have been indicated by reference numbers that correspond to the above description with the addition of designation "a". The primary difference being the incorporation of radial relieved portions 231a to accommodate the radial contact channel 222a.

[0024] With reference now to Figures 8 and 9, a further embodiment incorporating the present invention into a cylindrical-style connector is shown generally at 302. As best seen in Figure 11, the high voltage electrical connector 302 includes an outer shell 304 constructed to receive a mating component 308 within a shroud portion 310. An inner housing 312 having a front end 314 and a rear end 316 is retained therein. An elastic seal member 318 is disposed about the inner housing 312 in order to form an environmental seal with the mating component 308. Terminal receiving channels 322 extend between the front end 314 and the rear end 316 of the inner housing 312. In the embodiment shown, these channels 322 are constructed for the receipt of cylindrical contacts 224. A secondary locking member 326 is disposed upon the front end 314 of the inner housing 312.

[0025] As shown in Figure 8, this embodiment includes 3 terminal receiving channels 322 having internal walls 338 with cylindrical contacts 324 disposed therein, an opening 340 is disposed along the channel 322. The secondary locking member 326 is of sleeve-like construction and contains a plurality of inwardly directed teeth 328. Each tooth 328 includes a locking shoulder 334 that when the secondary locking member 326 is in the unlocked position, is disposed outside of the channel 322 so that the electrical terminals 324 may be moved into and out of the channel 322 freely. The secondary locking member 326 further includes latches 348 that are retained in notches 350 when in the unlocked position. When the secondary locking member 326 is moved in the direction of arrow A, the latches 348 disengaged from the notches 350 and sit against back-up shoulder 351 to establish the locked position. In the locked position, the locking shoulder 344 extends through an opening 340 into the channel 322 in order to close the opening 340 and prevent inadvertent dislodgement of the electrical terminal 324 therein. As the open portion 340 of the channel 322 extends only partially around, the secondary locking member is prevented from further rotation in the direction of arrow A. Furthermore, once again, the individual channels 222 are effectively sealed to form basically a continuous sleeve of dielectric material therealong in order to prevent "jump-over".

[0026] With reference now to Figures 10 and 11, another cylindrical embodiment of a high voltage electrical connector this time incorporating terminals having a rectangular cross-section is disclosed generally at 402. As shown in Figure 11, the electrical connector 402 includes an outer housing 404 having a shroud portion 410 for receiving a mating component 408. In this embodiment, the outer housing 404 is integrally moulded to a rear end portion 416 of the inner housing 412. The integrally moulded rear end portion 416 carries a resilient sealing member 418 for forming an environmentally sealed fit between the electrical connector 402 and a mating component 408. Extending forwardly from the rearward portion 416 is a post 413. Disposed upon the post 413 is a second forward portion 414 of the inner housing 412. The second forward portion 414 includes the terminal receiving channels 422a, which in conjunction with those of the rearward portion 416 extend between the rear receiving end 416 and the front end of the inner housing 414. The channel 422 is made up of both a portion 422b within the integrally moulded rear section 412 and a forward portion 422a. A space 440 across the channel 422 is defined by a shoulder 425. Sandwiched between the two portions of the inner housing 412, 412a is the secondary locking member 426. The secondary locking member 426 is to be received within the space 440. The secondary locking member 426 is constructed such that radial openings 447 therein are received upon guide members 449. With the two portions 422, 422a of the channels properly aligned, the front portion 414 of the inner housing 412 may be locked in place. This may be accomplished by any number of conventional techniques for interlocking dielectric material, for example an adhesive or epoxy bonding agent, ultrasonic welding, or heat staking.

[0027] With reference now to Figure 10, the secondary locking member includes a relieved portion 431 or opening constructed so that in the unlocked position, as shown, a locking shoulder 434 is disposed outside of the channel 422 enabling insertion and removal of the electrical terminal 424 therefrom. When the secondary locking member 426 is rotated in the direction of arrow B, this locking shoulder enters the channel 422 in order to prevent inadvertent dislodgement of the electrical terminal 424 therein. In this embodiment, the locked and unlocked positions are established by a latch 448 on the secondary locking member 426 that is movable between notches 450 in the front portion 412a of the inner housing 412. As the secondary locking member 426 is sandwiched between portions 412, 412a of the inner housing which contain aligned front and rear portions of the terminal receiving channel 422, 422a and the locking shoulder 434 is one side of a continuous internal surface, the opening 440 between the integrally moulded inner housing portion 412 and the attached front portion 412a is completely closed, whereby the secondary locking member 426 effectively blocks any opening which could provide a lower resistance path to ground for voltage "jump-over".

[0028] It is an advantage of this invention that the electrical connector is of a familiar configuration. It is another advantage of this invention that the electrical connector amy be constructed in a variety of configurations using various contact styles. It is yet another advantage of this invention that it is simple to produce, compact and user friendly. It is still another advantage of this invention that it is possible to create environmentally sealed versions. It is yet another advantage that voltage "jump-over" may be prevented in a connector using a secondary locking member without the need to incorporate additional structure into the connector housing, such as maze-like fingers or a separate shroud. It is also an advantage that the secondary locking member provides a lateral partition across the channel to block voltage jump in that direction.

Claims

1. An electrical connector (2,102,202,202a,302,402) comprising a housing (4,104,204,204a,304,404) having a plurality of terminal receiving channels (22,122,222,222a,322,422) extending therethrough for receiving an electrical terminal (24,214,224,224a,324,424) therein where each channel includes a transverse opening (40,140,240,240a,340,440) and a secondary locking member (26,126,226,226a,326,426) having a locked position where a portion of the member extends into the channel to prevent withdrawal of the terminal when positioned therein and an unlocked position where the terminal may pass into or out of the cavity, where at least two of said plurality of receiving channels are in communication by way of the openings; characterized in that in the locked position the secondary lock is received within the opening to form the terminal receiving channel such that the channel is essentially a continuous form and the communication between the two cavities is blocked by the secondary locking member.

2. The electrical connector of claim 1, characterized in that the secondary locking member (26,126,226,226a) is movable linearly between the locked and unlocked position.

3. The electrical connector of claim 1, characterized in that the secondary locking member (326,426) is movable in a radial manner between the locked and unlocked positions.

4. The electrical connector of anyone of the previous claims, characterized in that the channel (122,222a,322) has a circular cross section.

5. The electrical connector of anyone of claims 1-4, characterized in that the channels (22,222,422) have a rectangular cross-section.

6. The electrical connector of anyone of the previous claims, characterized in that the housing includes a support (144,249) spaced from the opening such that when the secondary lock is received therein the support member supports the secondary lock.

7. The electrical connector of anyone of the previous claims, characterized in that the secondary lock includes a relieved portion (31,131,231,231a) having corresponding to the shape of the channel, where said relieved portion extends beyond the channel when the secondary lock is in the locked position.

Drawing