WO2023089369A1

WO2023089369A1 - Electrical quick connector

Info

Publication number: WO2023089369A1
Application number: PCT/IB2021/060819
Authority: WO
Inventors: Manuel Martinez; Julien Locatelli
Original assignee: A. Raymond Et Cie
Priority date: 2021-11-22
Filing date: 2021-11-22
Publication date: 2023-05-25

Abstract

An electrical connector (10) includes a lock assembly (40) impaired from prematurely moving relative to the connector (10) to trigger deployment of a primary lock (50) of the lock assembly (40), which deployment secures that connector (10) to another connector (10). The lock assembly (40) can be part of a sleeve (41) slidably mounted to the connector (10). The primary lock (50) can include a locking arm (31) that lockably engages the other connector (10) to secure the connectors (20) in a fixed connection. The primary lock (50) is operable in a retracted mode where it does not interfere with movement of the locking arm (31). A secondary lock (60) is operable in a blocked mode where it engages a stop (61) of the other connector (10) to impair movement of the lock assembly (40) relative to the connector (10), and a freed mode where it clears the stop (61) so lock assembly (40) can move relative to the connector (10) to transition to the fixed connection. A related method of use is provided.

Description

ELECTRICAL QUICK CONNECTOR

BACKGROUND OF THE INVENTION

[0001] The present invention relates to connectors, and more particularly to connectors in the field of electrical or data transmission that automatically lock a connector and that impair premature displacement of a lock of the connector.

[0002] There are a variety of electrical connectors used in various applications. Most connectors are paired, so that one connector slides into another. Many connectors are in the form of complementary connectors, for example, male and female connectors that slide into and couple to one another. The male and female connectors include electrical contacts, optical fibers or other conductors that are oriented and alignable to provide adequate connection between one another when the male and female connectors are coupled to one another.

[0003] Many connectors are outfitted with locks that secure complementary connectors to one another, so they are not easily or inadvertently unlocked during installation or in use. This locking of the complimentary connectors can ensure that the electrical connection remains functional. If the connectors are not locked, they may be inadvertently decoupled during installation or in use, for example, upon impact, during movement, or under vibration. When this occurs, this can lead to malfunctions in the system in which the connector is implemented, due to interruption of the power or signals transmitted between connectors and their associated wiring. When the system is implemented in motor vehicles, this malfunction can immobilize the vehicle, create unsafe conditions for the vehicle occupants, require time and resource consuming repairs to identify and correct the malfunction and/or create expensive warranty issues.

[0004] Another issue with conventional connectors, particularly those with locks that secure connections to one another, is that the locks themselves can be prematurely activated. For example, some male connectors include a lock having a biasing arm w be slid along a female connector until the head is urged by the arm into a secondary recess in the female connector to lock the male and female connectors together. Sometimes, before the male connector is even engaged with the female connector, the lock can be slid or moved relative to the male connector. This can occur during transport of a batch of the connectors, via inadvertent deployment of the lock by a user, or upon unintentional contact or impact of the lock with another part in the vicinity of the connectors. When this occurs, the lock typically is not oriented or configured for easy activation. Accordingly, if a user notices the improper configuration, the user will have to reconfigure the lock, sometimes with a special tool, so that it is in the appropriate pre-deployed configuration before the male and female connectors are mated. This reconfiguration of the lock can consume time, which in turn can slow production, particularly when the reconfiguration necessitates a slowdown on an assembly line. In some cases, an inexperienced user might even break the lock or connectors, not knowing that the lock is pre-deployed and exerting excessive force on the parts. This may require replacement of the connectors and associated wiring, and in some cases completely stop an assembly line, which can be costly.

[0005] Accordingly, there remains room for improvement in the field of electrical connectors and the locks that secure complimentary connectors to one another.

SUMMARY OF THE INVENTION

[0006] An electrical connector includes a lock assembly having a primary lock, which when deployed secures that connector to another connector, and a secondary lock that impairs premature deployment of the primary lock.

[0007] In one embodiment, the lock assembly can be part of a sleeve slidably mounted to the connector. The lock assembly can include the primary lock and the secondary lock mounted on and moveable with the sleeve. The locks can be independent a another, and separately operable from one another.

[0008] In another embodiment, the primary lock of the connector can include a locking arm that lockably engages the other connector to secure the connectors in a fixed connection. The primary lock can be operable in a retracted mode, where it does not interfere with movement of the locking arm, in addition to the deployed mode, where it can maintain the locking arm in fixed engagement with a catch of the other connector to secure the connectors together in the fixed connection.

[0009] In still another embodiment, the locking assembly can include a secondary lock that is operable in a blocked mode, where it engages a stop of the connector to impair movement of the lock assembly relative to the connector. The secondary lock also can be operable in a freed mode, where it clears the stop so the lock assembly can move relative to the connector to transition to the fixed connection.

[0010] In yet another embodiment, the other connector can include the catch adjacent an opening. The sleeve can include a primary lock finger. The primary lock finger can project under the locking arm in the deployed mode. Accordingly, the primary lock finger can impair a head of the locking arm from moving out of the opening adjacent the catch in the deployed mode. With this engagement, the first and second connectors can be locked together in the fixed connection. In even another embodiment, the first connector can include an actuator aligned with the secondary lock. When the connectors are mated, the actuator can move toward the secondary lock. Engagement of the actuator with the secondary lock can transition the secondary lock to a freed mode so that the secondary lock clears the stop. With this configuration, the lock assembly can slide relative to the second connector and thereby actuate the primary lock, securing the first and second connectors together in a fixed connection. [0011] In a further embodiment, the second connector can be coni stop includes a first flange projecting from the first connector. The secondary lock can include an arm that is blocked from movement via the first flange when the secondary lock is in the blocked mode.

[0012] In still a further embodiment, the first connector can include an actuator finger that aligns with the arm when the second connector is installed relative to the connector. The actuator finger can move the arm so that the secondary lock transitions to the freed mode. The lock assembly can include a sleeve that can move when the secondary lock is in the freed mode, but that is restricted from moving when the secondary lock is in the blocked mode.

[0013] In still a further embodiment, a method of use is provided. The method can include: providing a first connector joined with a first wire; providing a second connector joined with a second wire, the second connector having a lock assembly including a locking arm, a primary lock in a retracted mode in which the primary lock does not interfere with movement of a locking arm, and a secondary lock in a blocked mode in which the secondary lock engages a stop to impair movement of the lock assembly relative to the second connector so that in the blocked mode, the lock assembly is impaired from moving relative to the second connector to prevent the primary lock from being prematurely converted to a deployed mode from the retracted mode; installing the second connector relative to the first connector; transitioning the secondary lock to a freed mode in which the secondary lock clears the stop so that the lock assembly can move relative to the second connector; transitioning the primary lock to the deployed mode in which the primary lock interacts with the locking arm to maintain the locking arm in locked engagement with the first connector to secure the first connector and the second connector together in the fixed connection.

[0014] In yet a further embodiment, the method can include: providing the lock assembly on a sleeve that is selectively slidable relative to the second connector; providing the first connector with an actuator finger; engaging the actuator finger with a st so that the secondary lock arm moves sufficiently to clear the stop in the freed mode; and sliding the sleeve so that a primary lock finger engages the locking arm to secure the locking arm relative to a catch of the first connector, thereby locking the first and second connectors in the fixed connection.

[0015] The current embodiments provide an apparatus and method for efficiently and reproducibly connecting wires, cables and other elements with an electrical connector. Where the lock assembly includes the secondary lock, the lock assembly is impaired from moving relative to the second connector to prevent the primary lock from being prematurely converted to the deployed mode. This can eliminate the need to reset the primary lock if inadvertently triggered or set. In turn, workers installing the connectors are not distracted with resetting the locks and diverting time from more productive assembly activity. This can save resources, and avoid needless disassembly and reassembly of a vehicle, machine or equipment to address a loose, or poor electrical connection therein caused by a failed or faulty connection between respective connectors.

[0016] These and other objects, advantages, and features of the invention will be more fully understood and appreciated by reference to the description of the current embodiment and the drawings.

[0017] Before the embodiments of the invention are explained in detail, it is to be understood that the invention is not limited to the details of operation or to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. The invention may be implemented in various other embodiments and of being practiced or being carried out in alternative ways not expressly disclosed herein. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of “including” and “comprising” and variations thereof is meant to encompass the items listed thereafter and e as well as additional items and equivalents thereof. Further, enumeration may be used in the description of various embodiments. Unless otherwise expressly stated, the use of enumeration should not be construed as limiting the invention to any specific order or number of components. Nor should the use of enumeration be construed as excluding from the scope of the invention any additional steps or components that might be combined with or into the enumerated steps or components.

BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Fig. 1 is a perspective view of an electrical connector of a current embodiment where a lock assembly in a locked mode holding a first connector and a second connector together in a fixed connection;

[0019] Fig. 2 is a perspective exploded view of the first and second connectors, and associated wires and terminals;

[0020] Fig. 3 is a perspective view of the second connector with a lock assembly including a primary lock in a retracted mode and a secondary lock in a blocked mode, before the second connector is installed relative to the first connector;

[0021] Fig. 4 is a side view of the secondary lock in a blocked mode;

[0022] Fig. 5 is a perspective view of the lock assembly and a sleeve thereof, further illustrating parts of the primary lock and secondary lock;

[0023] Fig. 6 is a side view of the secondary lock initially engaged by an actuator of the first connector and about to transition from the blocked mode;

[0024] Fig. 7 is a side view of the secondary lock after engagement by the actuator of the first connector and in a freed mode;

[0025] Fig. 8 is a side view of the secondary lock and after engagement by the actuator of the first connector and in a supplemental locked mode; and [0026] Fig. 9 is a perspective section view of the primary lock cngas arm of the second connector to secure the fixed connection with the primary lock in a deployed mode.

DETAILED DESCRIPTION OF THE CURRENT EMBODIMENTS

[0027] A current embodiment of the electrical connector is shown in Figs. 1-9 and generally designated 10. The electrical connector 10 can include a first connector 20 and a second connector 30 that are joined via a lock assembly 40. The lock assembly 40 can include a primary lock 50 and a secondary lock 60. The lock assembly 40 can be included in or associated with a sleeve 41 that moves relative to the second connector 30, optionally via sliding or other movement. The second connector 30 can include a locking arm 31 that is joined with a head 32 to a biased cantilevered configuration as described below. In the embodiment shown, movement of the sleeve 41 can transition the primary lock 50 from a retracted mode in which the primary lock does not interfere with movement of the locking arm 31 and/or the head 32, to a deployed mode in which the primary lock 50 interacts with a locking arm 31 and/or the head 32 to maintain the locking arm 32 in a locked engagement with the first connector 40, thereby securing the second connector in a fixed connection relative to the first connector as described below.

[0028] The lock assembly 40 can include the secondary lock 60, which can be distal from the primary lock 50 and separately operable therefrom. The secondary lock 60 can be operable in a blocked mode in which the secondary lock 60 engages a stop of the second connector 30 to impair sliding movement of the lock assembly 40 relative to the second connector 30. In turn, this can prevent premature deployment of the lock assembly 40 relative to the second connector 30. Accordingly, the lock assembly likely will not need modification or manipulation via manual or tooled input to reset the primary lock for deployment. The secondary lock 60 also can be selectively operable in a freed mode so that the secondary lock 60 clears the stop so the lock assembly, and the sleeve 41, can actuate, slide i relative to the second connector to transition the second connector to a fixed connection relative to the first connector. In this fixed connection, the first connector and the second connector are secured in locked engagement with one another and cannot be separated without the use of manual or tool directed input on the primary lock to disengage the primary lock and/or the locking arm to separate the first connector and the second connector.

[0029] As used herein, an electrical connector can include any connector that connects one element, feature or structure to another, where the structure conducts, transmits and/or transfers electrical power, electrical current, electrical signals, radiofrequency signals, electromagnetic signals, magnetic signals, data, information, or other items or signals. As described herein, such an electrical connector can connect electrical components, such as wires, cables, bus bars and other electrical conductors/elements, and/or other transmission components, such as fiber optics, data cables and the like, all of which are referred to herein as wiring or wires.

[0030] As illustrated in Figs. 1 and 2, the connector 10 can be used to connect the first connector 20, which is associated with a first wire 91, and the second connector 30, which is associated with a second wire 92. The first wire 91 and second wire 92 can be in the form of electrical wire having solid or braided metal wire, optionally copper or some other conductive metal therein. The respective ends of these wires can be joined with respective terminals 93 and 94, which can be in the form of male and female components that can be joined with one another when properly aligned. For example, the terminal 93 can be of a first dimension DI that is configured to fit within a compartment 94C of the second terminal 94. The second terminal 94 and the compartment 94C can be sized with a second dimension D2 such that the first terminal 93 can fit within the compartment 94C. The second dimension D2 can be greater than the first dimension DI. Optionally, when the terminals are connected, they can conduct electricity, data or other signals therethrough. In other applications, where tl are configured to transmit data through fiber optics or other materials, the terminals can be configured to join, meet or otherwise align with one another to transmit the signals transferred along the wires. Although not shown, the wires 91 and 92 can be multiplied and duplicated and configured in an array. One array of the first wires 91 can align with and can be joined with an array of the second wires 92. The connector 10, and the respective first 20 and second 30 connectors herein, can be likewise modified to accommodate multiple different terminals to align them and establish a complete connection between the wires. Further, although shown as generally cylindrical or round wires, the wires 91, 93 can be in the form of polygonal or elliptically sectioned cables or bus bars. When the wires are in the form of bus bars, they can be round bus bars and/or flat bus bars, depending on the application. The respective first and second connectors 20 and 30 likewise can include openings 200 and 300 that are similarly shaped relative to the wire or that include a sufficient seal and/or interface that allows the wires to stay registered with and seal with the respective connectors.

[0031] As shown, the terminals and ends of the wires can be constructed so that when the first connector 920 is joined with the second connector 30 and locked with one another as described below, the terminals 93, 94 can be securely joined with one another at a union, thereby completing the connection between the wires 91 and 92. In this configuration, the terminals 93, 94 can be housed substantially or entirely within the connector 10, and wholly or partially within each of the respective first connector 20 and the second connector 30.

[0032] Optionally, as mentioned above, the first 20 and second 30 connectors can be configured to seal around the wires and the connector. For example, as shown in Fig. 2, the connector 10 can include a first seal 29S and a second seal 39S. The first seal 29S can seal against the wire 91 and the second seal 39F can seal against the second wire 92. The opening 200 and 300 of the respective connectors can be outfitted with annular lock rings 29L and 39L, which can be positioned adjacent the flange or annular rings 20F connectors to secure the respective seals around the respective wires. Of course, in other applications, the openings 200 and 300 can be sealed with a sealant, such as silicone or some other gasket, to waterproof or render water resistant the electrical connector 10.

[0033] Further optionally, the connector 10 can include a main seal 10S which can interface with one or both of the connectors 20 and 30 so that these components are sealed relative to one another when they are locked relative to one another. Each of the seals can circumferentiate, surround or otherwise be disposed about their respective parts with which they mate. The 10S, 29S and 39S can be constructed from natural or synthetic rubber, silicone, nitrile, latex, polymers or other materials.

[0034] Returning to Figs. 1-2, the first connector 20 can include a first housing 21 and a second housing 22. When combined to make a full housing, the first and second housings can be locked relative to one another via one or more finger tabs or snaps 23. The first housing 21 and second housing 22 also can be structured to receive the seal 10S therebetween, for example, around an outer perimeter 2 IP of the first housing 21. The first housing 21 also can include a flanged 2 IF adjacent the perimeter 20 IP such that the second housing 22 can be installed in appropriate depth for the tabs 23 to engage one another and secure the first housing to the second housing of the first connector. Generally, these housings can create composite first housing of the connector, but it will be appreciated that one or both housings can be absent from the connector.

[0035] The first and second housings 21 and 22 can be joined to one another and can form the first connector 20. The housing can define a first internal compartment 24 therein. A portion of the first wire 91 and the terminal 93 can be disposed in this internal compartment 24. In some cases, the second housing 22 can include a support 25 that engages the first terminal 93 to hold it in a fixed position relative to the first connector 20 and optionally the housings 21 and 22. This can facilitate adequate alignment and connection between the t< upon installation of the second connector 30 relative to the first connector 20 to form a fixed connection of the connector 10.

[0036] The second housing 22 can include a catch 22C as shown in Figs. 2, 6, 8 and 9. This catch can include a lip 22L that is disposed adjacent an opening 220. The lip 22L can be configured to interfere with a head 32 that is joined with the locking arm 31 of the second connector 30 as described below. The catch 22C can extend around the opening 220 such that the head 32 is housed therein. Accordingly, it cannot be unintentionally bumped, touched or actuated to disengage the head 32 and locking arm 31 relative to the catch thereby allowing the second connector 30 to separate from the first connector 20.

[0037] The first connector 20 and second connector, as well as the lock assembly 40 and various components thereof, can be constructed from a variety of materials. Generally, however, they can be constructed from a polymer and/or composite material that is nonconductive such that the terminals and wires inside and connected in a fixed connection by the connector 10 are insulated and/or isolated from the environment. Of course, in other applications, where the wires are fiber optic constructions or configured for data transmission, where electrical isolation and/or insulation are not needed, the various components of the connector 10 optionally can be constructed from metal or other conductive materials.

[0038] Returning to the first connector 20, as described below, that connector can include one or more actuators 26A. These actuators can be disposed optionally on both sides of the longitudinal axis LA of the connector 10. As shown in Figs. 6 and 7, the actuators 26A can include or can be in the form of one or more projections, fingers, arms or other elements. These elements can be separated from one another a preselected distance D3 that is sufficient to straddle or otherwise clear the first stop 61 and the second stop 62. It also will be appreciated that these actuators and their components can be repeated on opposing or multiple sides of the first connector, with corresponding components of the secondary lock connector also duplicated accordingly.

[0039] The actuator 26A can be duplicated for redundancy, such that upper and lower actuators are present in a connector, with one being upside down or inverted relative to the other in some cases as shown. Only an upper actuator 26A will be described in detail here. The actuator 26A can extend from a forward face 22F of the second housing 22 and generally from the first connector 20. This extension can be sufficient to allow the second connector 30 to be installed between the respective actuators 26A and 26B on opposite sides of the housing 22 or connector when included. The first actuator 26A can include an arm portion 26C that extends to a ramped portion 26R. The ramped portion 26R can be inclined at an angle Al relative to the longitudinal axis LA of the connector as shown in Fig. 6. This angle Al can be an acute angle Al, which optionally can be between 10° and 90°, between 20° and 80°, between 30° and 60° or about 45°. Other angles can be used on this ramped surface, or the surface can be rounded or of other shapes depending on the application. The angle Al can match an angle of an engagement surface or other ramped portion 66R of a corresponding finger 66A of a secondary lock 60 as described below. The ramped portion 66R can be of a similar angle Al relative to the longitudinal axis LA, or some other angle. The ramped portion 26R and ramped portion 66R, however, can be at different angles Al relative to one another and/or the longitudinal axis.

[0040] Generally, the ramped portion 26R can be configured to engage the other ramped portion 66R so as to push the arm 66A in direction R1 so that the arm moves closer to the longitudinal axis LA or a plane Pl associated with the axis. When it does so, the outermost extremity of the finger 66 A can clear the stop 61 such that the finger can transition from a blocked mode shown in Fig. 6 to a freed mode shown in Fig. 7. There, the lock assembly 40 is free to be deployed so that the first connector and second connector can k another and the primary lock 50 can be actuated as described below.

[0041] As mentioned above, the secondary lock 60 can be joined with a sleeve 41 along with the secondary lock 50. The sleeve 41 can be slidable in direction SR relative to the second connector 30. The second connector 30 as mentioned above can include a locking arm 31 and a head 32 associated with the locking arm. This locking arm generally can be responsible for securing and locking the second connector 30 relative to the first connector 20. This locking arm can be repeated on an upper portion and a lower portion of the second connector to provide a secure connection both above and below the longitudinal axis LA of the connector. The locking arm 31 can be constructed in a cantilevered configuration relative to an upper surface 30U and lower surface 30L of the second connector 30. Generally, the locking arm can lay within the same plane as those surfaces.

[0042] Only the locking arm 31 on the upper surface 30U will be described here, but it is to be appreciated that the optional locking arm on the lower surface 30L can have similar structure, function and operation. The locking arm 31 can be constructed to include a slot 3 IS that is disposed adjacent the head 32 and generally parallel to the longitudinal axis LA of the second connector 30. The slot 3 IS can be sized to slidably receive a fin 51 of the primary lock 50 therein. The fin 51 can be joined with a primary lock finger 52 that extends forwardly of the fin 51, optionally toward the head 32, and /or away from a forward edge 41F of the sleeve. As shown in Figs. 3 , the fin 51 can be disposed in the slot 3 IS, while the primary lock finger 52 can be disposed below a lower surface 3 IL of the locking arm 31 as shown in Fig. 9. As described further below, the primary lock finger 52 can extend adjacent the locking arm 31, optionally, under it and under a portion of the head 32 in a deployed mode to prevent or impair the head 32 from moving out of the opening 220 adjacent the catch 22C in the deployed mode. Further, the primary lock finger 52 can prevent the locking arm from moving, and the head from exiting the opening substantially to disengage the head from the particular the lip 22L when the first connector 20 and the second connector 30 are in a fixed connection, shown generally in Figs. 1, 8 and 9.

[0043] The second connector 30 can include a housing 33. This housing 33 can include an internal compartment 33C that is surrounded by one or more supports 35. The supports can align and secure the second terminal 94 along the longitudinal axis or in some other orientation within the second connector 30 so the second terminal 94 can be satisfactorily joined with the first terminal 93 when the first and second connectors are joined with one another. The housing 33 can be constructed so that the sleeve 41 circumferentiates a portion of it and is slidable relative to the housing 33 in directions SR. When moved in direction SR, the lock assembly 40 can be reconfigured so that the primary lock 50 transitions from a retracted mode to a deployed mode to secure the locking arm in a fixed connection with the catch.

[0044] When the sleeve 41 is moved in direction SR, and the first connector is adequately aligned with and joined with the second connector 30, the actuator arms 26A can actuate the respective one or more fingers 66A, 66B so that they are displaced from alignment with the respective stops 61 and 62. With the secondary lock in the freed mode, the lock assembly 40 can move toward the first connector 20 in direction SR. Of course, the secondary lock 60 also can prevent or impair the lock assembly from moving in a direction opposite SR, and from moving in direction SR prematurely, before the second connector 30 and first connector 20 are brought into alignment with and engage one another properly.

[0045] With reference to Figs. 3-6, the secondary lock 60 will we described in more detail. Generally the secondary lock 60 can be separate and independently movable relative to the primary lock 50. As an example, the primary lock 50, with the fin 51 and finger 52, can be disposed on upper 41U and lower 41L sidewalls of the sleeve 41. These primary locks can be virtually identical to one another. The secondary lock 60 can be disposed on corresponding lateral sidewalls 41 SI and 41S2 disposed on opposite sides of the longitud sidewalls can connect to the upper and lower sidewalls of the sleeve so that the sleeve can at least partially or fully circumferentiate the housing of the second connector. As mentioned above, the secondary lock 60 can include one or more arms or sets of fingers or arms 66A and 66B which can be associated with the respective sidewalls.

[0046] Here, only the fingers or arms 66A will be described in further detail with reference to Figs. 4-6. The finger 66A can include a first arm portion 66A1 that extends to a head 66AH, which can include a ramped surface 66R. This ramped surface can interface with the above actuator fingers 26A, and in particular the ramped surface 26R thereof. The arms 66A can be configured in a cantilevered manner, extending from a junction 66U that is joined with the sidewall 41S2 of the sleeve. A respective arm 66 A can be biased and resiliently bent, deflected or move generally toward a centerline or axis AL when engaged by the actuator 26A. These arms can lay within a plane P2 and can move in that plane about the junction 66U, generally toward one another where opposing arms 66 Al and 66 A2 are included. Optionally, the arms of the secondary lock 60 can also move toward one another and toward the plane Pl. Further optionally, the primary locking finger 52 and its associated fin 51 can move in a third plane P3 that is generally parallel to the plane P2 and perpendicular to the plane Pl associated with the secondary lock arms 66A1 and 66A2. Of course, in other applications, the components of the primary lock and secondary lock can move in other planes transverse, perpendicular and/or parallel to one another.

[0047] As shown in Fig. 4, the stop 60 can include a first flange 61 that projects from a sidewall of the second connector 30. This first flange 61 can interfere with movement of the finger or arm 66A in direction R3 as shown there. The head 66H or end of the arm can bump against or engage the stop 60 and in particular the first flange or projection 61. In the locked mode shown in Fig. 4, this results in the sleeve 41 and the lock assembly 40 being impaired or prevented from transitioning, moving or sliding to a deployed mode in dii the end 30E of the second connector 30.

[0048] Optionally, the stop 60 can include a second flange 63 distal from the first flange 61 projecting from the sidewall of the housing 33. These flanges 61, 63 can form an opening 610 there between. The head 66H and arm 66 A can be disposed between the first flange 61 and second flange 63 in the opening 610 when the secondary lock 60 is in the blocked mode. In this blocked mode, the head 66H, and generally the arm 66A is restricted from moving beyond the opening 610 or beyond the stop 60 in the blocked mode. Again, with this configuration, the lock assembly 40 can be prevented from prematurely deploying to a configuration where the sleeve 41 moves in direction SR toward the end 30 E, such that the primary lock finger 52 is placed adjacent the locking arm 31 to hold the arm 31 and the head 32 in a fixed position relative to the sleeve. If this were to occur, then the locking arm 31 would not be able to resiliently bend, flex or move such that the head 32 can clear the lip 22L, and enter the opening 220, thereby securing the primary lock relative to the catch 22C.

[0049] As mentioned above, the secondary lock 60 can include another finger or arm 66B or 66A2 attached at the junction 66U to the sleeve, which can be movable like the arm 66 A or 66A1. That arm 66B can interface with another stop in the form of a lower flange 62 and associated second opening 620 in a manner similar to interaction of the arm 66A with the stop 61 and the respective opening 610. With optionally duplicated arms and stops, the lock assembly 40 can be further secured in place and blocked from premature deployment of the lock assembly and/or the primary lock. In this form, the secondary lock 60 can include first 66 A and second 66B arms supported by the sleeve 41. The stop can include an upper flange 61 and a lower flange 62 defining first and second openings 610 and 620. The first arm, in particular the head thereof, can be constrained in the first opening 610 in the blocked mode and the second arm, in particular the head thereof, can be constrained in tl

620 in the blocked mode.

[0050] As mentioned above, the arms and their respective heads can interact with the actuator fingers 26A, which can be aligned with the stops. The actuator fingers can urge the cantilevered arms 66 A, 66A1, 66B, 66 A2 away from the stops or generally out of alignment with those stops and the respective flanges so the cantilevered arms can clear the stops in a freed mode. In this freed mode, the sleeve 41 and lock assembly 40 can move in direction SR toward the end 30E of the second connector or generally toward the first connector 20. It will be appreciated that if the actuators do not engage the arms of the secondary lock 60, then the secondary lock, along with the sleeve 41 and the lock assembly 40 and the primary lock 50 cannot be deployed prematurely. The initial coupling of the first connector and the second connector to one another is what satisfactorily moves the actuator arms to engage the arms or fingers 66A, 66B of the secondary lock 60 to allow this movement.

[0051] A method of using the electrical connector 10 of the current embodiment will now be briefly described here. The method generally can include: providing a first connector 20 joined with a first wire 91; providing a second connector 30 having a lock assembly 40 including a locking arm 31, a primary lock 50 in a retracted mode in which the primary lock 50 does not interfere with movement of a locking arm 31, and a secondary lock 60 in a blocked mode in which the secondary lock engages a stop 61, 62 of the first connector 20 to impair movement of the lock assembly 40 relative to the first connector 20 so that in the blocked mode, the lock assembly 40 is impaired from moving relative to the first connector to prevent the primary lock 50 from being prematurely converted to a deployed mode from the retracted mode; installing the first connector 20 relative to the second connector 30; transitioning the secondary lock 60 to a freed mode in which the secondary lock clears the stop 61, 62 so that the lock assembly 40 can move relative to the second and first connectors; transitioning the primary lock 50 to the deployed mode in which the primary lock interacts wi

31 to maintain the locking arm 31 in locked engagement with the first connector 20 to secure the first connector 20 and the second connector 30 together in the fixed connection.

[0052] The method optionally can include providing the lock assembly 40 on the sleeve 41 that is selectively slidable relative to the second connector 30. The first connector can include one or more actuator fingers 26A. The actuator finger 26A can engage with one or more secondary lock arms 66A, 66A1, 66B, 66A2 so that the secondary lock arms move sufficiently to clear the stop in the freed mode. With this movement, the sleeve 41 can be moved or slid so that a primary lock finger 52 engages the locking arm 31 to secure the locking arm 31 relative to a catch 22C of the first connector 20, thereby locking the first 20 and second 30 connectors in the fixed connection.

[0053] Referring more particularly to Figs. 3-8, the method can include providing the second connector 30 with the terminal 94 disposed therein and the wire 92 extending therefrom. The lock assembly 40 and sleeve 41 can be disposed in the position as shown in Fig. 3. In this configuration, the primary lock 50 is not yet deployed, while the secondary lock 60 maintains the sleeve 41 and the lock assembly in a fixed position. This fixed position can be held in place via the secondary lock 60, where one or more cantilevered arms 66A and 66B interfere with one or more stops 61 and 62 on the sidewall of the second connector 30. In particular, as shown in Fig. 4, when it is attempted to move the sleeve 41 and the lock assembly 40 in direction SR, the head 66H moves in direction R3 and collides with the stop 61. Depending on the number of cantilevered arms or fingers, and secondary locks, this engagement can occur in several locations about the lock assembly. With this collision, the secondary lock 40 is in the blocked mode such that the sleeve 41 and the lock assembly 40 cannot move in direction SR substantially. As a result, the stock assembly 40 and in particular the primary lock 50 cannot be actuated to a deployed mode prematurely. Thus, in one example, when the second connector 30 is in a large batch of similarly structured second connectors, the sleeve 4] prematurely deploy the other components of the lock assembly 40.

[0054] However, when the second connector 30 is brought into close proximity to and aligned with the components of the first connector 20, such as shown in Fig. 6, the secondary lock 60 can be actuated to a freed mode, to allow full deployment of the lock assembly 40 and movement of the sleeve 41 in direction SR. In particular, the actuator fingers 26A and in particular the ramped surfaces 26R thereof can slidably and optionally frictionally engage the ramped surfaces 66R of the head 66H and/or the arm 66 A, 66 Al of the secondary lock 60. As a result, the arm 66A, 66A1 can move toward the longitudinal axis or the plane Pl. Thus, the head and arm are no longer aligned with the stop 61 as shown in Fig. 7. In this condition, the head 66H slides along the respective flange or stop 61 allowing the second connector 30 to be fully engaged with the first connector. The sleeve likewise can be moved further in direction SR priming the locking arm 31 and associated head 32 for engagement with the catch 22C of the first connector 20.

[0055] The sleeve 41 can continue to be moved in direction SR until the head 32 of the primary lock 50 clears the lip 22L. The primary lock finger 52 can be disposed under the locking arm 31 such that the locking arm cannot be substantially moved relative to the catch so that the catch and locking arm and/or head maintain the first connector and second connector in a fixed connection so they cannot be removed without manual or tool base interventions and manipulation. Optionally, in the configuration shown in Fig. 8, the secondary lock 61 also can interact with recesses 26R of the actuators 26 Al and 26A2, with the head 66H of the arms entering those recesses. This can provide additional locking of the first connector relative to the second connector via the actuators and arms of the secondary lock.

[0056] With this activity complete, and the first and second connectors joined in a fixed connection, the respective first terminal 93 and second terminal 94 also mate with one another so that the connection is completed between the first wire 91 and the sec< result, the connector 10 couples these wires for conveyance of electricity, data or other signals. Optionally, with the first connector and second connector joined with one another, these elements cannot be transitioned from the fixed connection between them without intervention via manual manipulation or the use of a tool to separate the components.

[0057] Directional terms, such as “vertical,” “horizontal,” “top,” “bottom,” “upper,” “lower,” “inner,” “inwardly,” “outer” and “outwardly,” are used to assist in describing the invention based on the orientation of the embodiments shown in the illustrations. The use of directional terms should not be interpreted to limit the invention to any specific orientation(s). [0058] In addition, when a component, part or layer is referred to as being “joined with,” “on,” “engaged with,” “adhered to,” “secured to,” or “coupled to” another component, part or layer, it may be directly joined with, on, engaged with, adhered to, secured to, or coupled to the other component, part or layer, or any number of intervening components, parts or layers may be present. In contrast, when an element is referred to as being “directly joined with,” “directly on,” “directly engaged with,” “directly adhered to,” “directly secured to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between components, layers and parts should be interpreted in a like manner, such as “adjacent” versus “directly adjacent” and similar words. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.

[0059] The above description is that of current embodiments of the invention. Various alterations and changes can be made without departing from the broader aspects of the invention as defined in the appended claims, which are to be interpreted in accordance with the principles of patent law including the doctrine of equivalents. This disclosure is presented for illustrative purposes and should not be interpreted as an exhaustive description of all embodiments of the invention or to limit the scope of the claims to the illustrated or described in connection with these embodiments. For example, and without limitation, any individual element(s) of the described invention may be replaced by alternative elements that provide substantially similar functionality or otherwise provide adequate operation. This includes, for example, presently known alternative elements, such as those that might be currently known to one skilled in the art, and alternative elements that may be developed in the future, such as those that one skilled in the art might, upon development, recognize as an alternative. Further, the disclosed embodiments include a plurality of features that are described in concert and that might cooperatively provide a collection of benefits. The present invention is not limited to only those embodiments that include all of these features or that provide all of the stated benefits, except to the extent otherwise expressly set forth in the issued claims. Any reference to claim elements in the singular, for example, using the articles “a,” “an,” “the” or “said,” is not to be construed as limiting the element to the singular. Any reference to claim elements as “at least one of X, Y and Z” is meant to include any one of X, Y or Z individually, any combination of X, Y and Z, for example, X, Y, Z; X, Y; X, Z; Y, Z, and/or any other possible combination together or alone of those elements, noting that the same is open ended and can include other elements.

Claims

CLAIMS What is claimed is:

1. An electrical connector comprising: a first connector; a first wire having a first terminal, the first wire joined with the first connector; a second wire having a second terminal; a second connector complimentary to the first connector and configured to be received by the first connector, the second connector joined with the second wire, the second connector including a locking arm movable relative to the second connector and configured to lockably engage the first connector to secure the second connector in a fixed connection relative to the first connector, the second connector including a stop distal from the locking arm; and a lock assembly slidably mounted relative to the second connector, the lock assembly comprising: a primary lock disposed adjacent and moveable relative to the locking arm, the primary lock operable in a retracted mode in which the primary lock does not interfere with movement of the locking arm, and in a deployed mode in which the primary lock interacts with the locking arm to maintain the locking arm in locked engagement with the first connector to secure the second connector in the fixed connection relative to the first connector, and a secondary lock distal from the primary lock and separately moveable relative to the second connector, the secondary lock operable in a blocked mode in which the secondary lock engages the stop of the second connector to impair slidable movement of the lock assembly relative to the second connector, and in a freed mode in which the secondary lock clears the stop so that the lock assembly can slide relative to the second connector to transition the second connector to the fixed connection relative to the first connector,

22 whereby in the blocked mode, the lock assembly is impaired from i the second connector to prevent the primary lock from being prematurely converted to the deployed mode.

2. The electrical connector of claim 1 comprising: an actuator joined with the first connector and aligned with the secondary lock; wherein engagement of the actuator with the secondary lock transitions the secondary lock to the freed mode so that the secondary lock clears the stop so that the lock assembly can slide relative to the second connector.

3. The electrical connector of claim 1, wherein the second connector includes a second housing, wherein the second wire includes a second terminal disposed in the second housing, wherein the lock assembly includes a lock sleeve at least partially disposed around the second housing.

4. The electrical connector of claim 3, wherein the secondary lock includes a cantilevered finger moveably joined with the lock sleeve, wherein the locking arm is movably joined with the lock sleeve distal from the cantilevered finger, wherein the primary lock includes a primary lock finger, wherein the cantilevered finger and the primary lock finger move in first and second planes distal from one another.

5. The electrical connector of claim 4, wherein the first plane and the second plane are parallel to one another.

6. The electrical connector of claim 1, wherein the first connector includes a first housing that defines a first compartment, wherein the first wire is connected to a first terminal disposed in the wherein the second connector includes a second housing that defines a second compartment, wherein the second wire is connected to a second terminal disposed in the first compartment, wherein the first housing receives the second housing, wherein the stop is disposed on the second housing, wherein the first housing includes an actuator that is engageable with the secondary lock so that the secondary lock transitions to the freed mode in which the secondary lock clears the stop so that the lock assembly can slide relative to the second connector to transition the second connector to the fixed connection relative to the first connector.

7. The electrical connector of claim 1, wherein the stop includes a first flange projecting from the first connector, wherein the secondary lock includes a secondary lock arm that is blocked from movement via the first flange when the secondary lock is in the blocked mode, wherein the first connector includes an actuator finger that aligns with the secondary lock arm when the second connector is installed relative to the connector, wherein the actuator finger moves the arm so that the secondary lock transitions to the freed mode, wherein the lock assembly includes a sleeve that is configured to move when the secondary lock is in the freed mode, but that is restricted from moving when the secondary lock is in the blocked mode.

8. The electrical connector of claim 7, wherein the stop includes a second flange distal from the first flange and projecting from the first housing, wherein the first flange and the second flange form an opening there wherein the arm includes a head, wherein the head is disposed between the first flange and the second flange in the opening when the secondary lock is in the blocked mode, wherein the head is restricted from moving beyond the opening in the blocked mode, wherein the actuator finger urges the head out from the opening in transitioning to the freed mode as a housing of the second connector enters a compartment of the first connector.

9. The electrical connector of claim 1, wherein the first connector includes a catch, wherein the locking arm includes a head, wherein the head engages the catch when the first connector and second connector are in the fixed connection, wherein the primary lock includes a primary lock finger, wherein the primary lock finger extends adjacent the locking arm in the deployed mode to impair the head from disengaging the catch when the first connector and second connector are in the fixed connection.

10. The electrical connector of claim 9, wherein the lock assembly includes a sleeve at least partially surrounding the second connector, wherein the sleeve includes the primary lock finger, wherein the primary lock finger projects under the locking arm in the deployed mode, wherein the primary lock finger prevents the head from moving out of an opening adjacent the catch in the deployed mode.

11. The electrical connector of claim 10,

25 wherein the secondary lock includes a finger that is displaced out of E stop in the freed mode, so that the lock assembly can move toward the first connector, wherein the primary lock includes a primary lock finger that maintains the locking arm in a fixed position relative to a catch when the primary lock is in the deployed mode.

12. An electrical connector comprising: a connector joined with a wire, the connector including a movable locking arm configured to lockably engage another connector to secure the connectors together in a fixed connection, the connector including a stop distal from the locking arm; and a lock assembly including a sleeve slidably mounted to the connector, the lock assembly comprising: a primary lock operable in a retracted mode in which the primary lock does not interfere with movement of the locking arm, and in a deployed mode in which the primary lock interacts with the locking arm to maintain the locking arm in locked engagement with the connector to secure the connectors together in the fixed connection, and a secondary lock operable in a blocked mode in which the secondary lock engages the stop to impair movement of the lock assembly relative to the connector, and in a freed mode in which the secondary lock clears the stop so that the lock assembly can move relative to the connector to transition the connectors to the fixed connection, whereby in the blocked mode, the lock assembly is impaired from moving relative to the connector to prevent the primary lock from being prematurely converted to the deployed mode.

13. The electrical connector of claim 12, wherein the secondary lock is distal from the primary lock and separately moveable relative to the connector from the primary lock.

14. The electrical connector of claim 12,

26 wherein the secondary lock includes first and second arms supporter wherein the stop includes an upper flange and a lower flange defining first and second openings, wherein the first arm is constrained in the first opening in the blocked mode, wherein the second arm is constrained in the second opening in the blocked mode.

15. The electrical connector of claim 13, wherein the other connector includes a catch adjacent an opening, wherein the sleeve includes a primary lock finger, wherein the primary lock finger projects under the locking arm in the deployed mode, wherein the primary lock finger impairs a head of the locking arm from moving out of the opening adjacent the catch in the deployed mode.

16. The electrical connector of claim 12 comprising: a first wire having a first terminal, the first wire joined with the connector; a second wire having a second terminal, the second wire joined with the other connector, wherein the first terminal is joined with the second terminal to complete electrical coupling of the first wire to the second wire.

17. The electrical connector of claim 12, wherein the sleeve includes a first wall and a second wall distal from the first wall, wherein the primary lock is joined with the first wall with a primary lock finger projecting from the first wall, wherein the secondary lock is joined with the second wall with a cantilevered arm projecting from the second wall.

18. The electrical connector of claim 17, wherein the other connector includes an actuator finger that aligns with the stop,

27 wherein the actuator finger urges the cantilevered arm away from tl cantilevered arm clears the stop in the freed mode, wherein the sleeve is configured to move toward the other connector in the freed mode.

19. A method of using an electrical connector, the method comprising: providing a first connector joined with a first wire; providing a second connector joined with a second wire, the second connector having a lock assembly including a locking arm, a primary lock in a retracted mode in which the primary lock does not interfere with movement of a locking arm, and a secondary lock in a blocked mode in which the secondary lock engages a stop to impair movement of the lock assembly relative to the second connector so that in the blocked mode, the lock assembly is impaired from moving relative to the second connector to prevent the primary lock from being prematurely converted to a deployed mode from the retracted mode; installing the second connector relative to the first connector; transitioning the secondary lock to a freed mode in which the secondary lock clears the stop so that the lock assembly can move relative to the second connector; transitioning the primary lock to the deployed mode in which the primary lock interacts with the locking arm to maintain the locking arm in locked engagement with the first connector to secure the first connector and the second connector together in the fixed connection.

20. The method of claim 19, comprising: providing the lock assembly on a sleeve that is selectively slidable relative to the second connector; providing the first connector with an actuator finger; engaging the actuator finger with a secondary lock arm so that the secondary lock arm moves sufficiently to clear the stop in the freed mode;

28 sliding the sleeve so that a primary lock finger engages the locking locking arm relative to a catch of the first connector, thereby locking the first and second connectors in the fixed connection.

29