Electrical connector assembly with connection assurance features

Claim 2

An electrical connector assembly comprising: first and second housings formed along a longitudinal axis and being configured to be mateable with one another at a mating interface that extends parallel to said longitudinal axis, said first and second housings being movable between initial and final mating positions, said second housing having an end wall containing a rack and a blocking member thereon, said rack and blocking member extending outward along said longitudinal axis first and second distances, respectively, from said end wall, said second distance being shorter than said first distance; and a lever member held by said first housing, said lever member including a cam arm having a first tooth engaging said rack on said second housing as said lever member is rotated through a range of motion from an insertion position to a final engaged position, wherein said first tooth includes a blocking ledge that extends inward from said first tooth along said longitudinal axis toward said first housing and beyond said first tooth, said blocking ledge passing said blocking member as said first and second housings are joined when said lever member is in said insertion position to permit mating, said blocking ledge engaging said blocking member as said first and second housings are joined when said lever member is not in said insertion position to prevent mating.

Claim 3

The electrical connector assembly of claim 1 , said blocking member being block shaped and having a side wall along a plane of a rim of the second housing that engages said cam arm.

Claim 4

The electrical connector assembly of claim 1 , wherein said blocking ledge extends perpendicularly inward from an inner surface of said cam arm toward said first housing, said blocking ledge passing alongside said blocking member when said first and second housing are in said initial mating position with said lever member in said insertion position.

Claim 5

The electrical connector assembly of claim 1 , wherein said lever member includes a release arm and said first housing has an end wall with a locking member, said locking member retaining said release arm to maintain said lever member in said insertion position with respect to said first housing, said second housing having a release member that engages said release arm to release and permit rotation of said lever member when said first and second housings are in said initial mating system.

Claim 6

The electrical connector assembly of claim 1 , wherein a wire shield extends from said first housing and covers a reception end thereof, said wire shield having feet extending from side walls and a tab extending from a rear wall, said first housing having slots receiving said feet and a catch releasably retaining said tab.

Claim 7

The electrical connector assembly of claim 1 , wherein said second housing carries said electrical contacts, said electrical contacts having top, intermediate, and bottom portions, said bottom portion having retention features, said second housing having a rear wall retaining said top portions and a template having a chamber receiving said bottom portions, said second housing and said template being mounted to each other to receive an encapsulate material in said chamber encasing said bottom portions about said retention features.

Claim 8

An electrical connector assembly comprising: first and second housings having ends configured to receive electrical contacts, said first and second housings being configured to be mateable with one another to join corresponding electrical contacts, said first and second housings being movable between initial and final mating positions, said second housing having an end wall containing a rack and a blocking member; and a lever member held by said first housing, said lever member including a cam arm engaging said rack on said second housing as said lever member is rotated through a range of motion from an insertion position to a final engaged position, wherein said first housing has a latch assembly that engages said lever member when said lever member is in said final engaged position, said latch assembly having a base piece and a latch cover, said base piece having first and second latches, said second latch engaging said latch cover when said latch assembly is in a pre-engagement stage, said lever member engaging said first latch when rotated to said final engaged position to bias said second latch away from said latch cover thereby enabling said base piece to slide into an engagement stage with respect to said latch cover.

Claim 9

An electrical connector assembly comprising: first and second housings having ends configured to receive electrical contacts, said first and second housings being configured to be mateable with one another to join corresponding electrical contacts, said first and second housings being movable between initial and final mating positions, said second housing having an end wall containing a rack and a blocking member; and a lever member held by said first housing, said lever member including a cam arm engaging said rack on said second housing as said lever member is rotated through a range of motion from an insertion position to a final engaged position, wherein said first housing has a latch assembly that engages said lever member when said lever member is in said final engaged position, said latch assembly having a base piece and a latch cover, said base piece having first and second latches, said second latch engaging said latch cover when said latch assembly is in a pre-engagement stage, said lever member engaging said first latch when rotated to said final engaged position to bias said second latch away from said latch cover thereby enabling said base piece to slide into an engagement stage with respect to said latch cover.

Claim 10

An electrical connector assembly comprising: first and second housings formed along a longitudinal axis and being configured to be matable with one another at a mating interface that extends parallel to said longitudinal axis, said first and second housings being movable between initial and final mating positions; a lever member held by said first housing, said lever member including a cam arm having a first tooth engaging said second housing as said lever member is rotated through a range of motion from an insertion position to a final engaged position; and said second housing having a rack and blocking member on an end wall thereof, said rack and blocking member extending outward along said longitudinal axis first and second distances, respectively, from said end wall, said second distance being shorter than said first distance, said blocking member engaging said lever member as said first and second housings are placed into said initial mating position when said lever member is rotated to an intermediate point along said range of motion beyond said insertion position, wherein said cam arm includes a blocking ledge that extends inward from an inner surface of said cam arm toward said first housing, said blocking ledge passing said blocking member when said first and second housings are in said initial mating position with said lever member in said insertion position.

Claim 11

An electrical connector assembly comprising: first and second housings formed along a longitudinal axis and being configured to be matable with one another at a mating interface that extends parallel to said longitudinal axis, said first and second housings being movable between initial and final mating positions; a lever member held by said first housing, said lever member including a cam arm having a first tooth engaging said second housing as said lever member is rotated through a range of motion from an insertion position to a final engaged position; and said second housing having a rack and blocking member on an end wall thereof, said rack and blocking member extending outward along said longitudinal axis first and second distances, respectively, from said end wall, said second distance being shorter than said first distance, said blocking member engaging said lever member as said first and second housings are placed into said initial mating position when said lever member is rotated to an intermediate point along said range of motion beyond said insertion position, wherein said cam arm includes a blocking ledge that extends inward from an inner surface of said cam arm toward said first housing, said blocking ledge passing said blocking member when said first and second housings are in said initial mating position with said lever member in said insertion position.

Claim 12

The electrical connector assembly of claim 8 , wherein said blocking member engages said cam arm as said first and second housing are placed into said initial mating position.

Claim 13

The electrical connector assembly of claim 8 , wherein said cam arm includes a first tooth with said blocking ledge, said blocking ledge engaging said blocking member as said first and second housings are placed into said initial mating position.

Claim 14

The electrical connector assembly of claim 8 , wherein said end wall includes a rack that extends further therefrom than said blocking member along a longitudinal axis, said blocking member being block shaped and having a side wall along a plane of a rim of the second housing that engages said cam arm.

Claim 15

The electrical connector assembly of claim 8 , wherein said lever member includes an arced resistance beam extending therefrom, said blocking member engaging said resistance beam as said first and second housings are placed into said initial mating position.

Claim 16

The electrical connector assembly of claim 8 , wherein said lever member includes an arced resistance beam and a support beam that intersect each other to form a contact surface, said contact surface engaging said blocking member as said first and second housings are placed into said initial mating position.

Claim 17

The electrical connector assembly of claim 8 , wherein said lever member includes an arced resistance beam and a support beam with an inner surface that intersect each other to form a contact surface, said blocking member sliding past said contact surface without engaging said contact surface and along said inner surface when said lever member is in said insertion position as said first and second housings are joined in said initial mating position.

Claim 18

The electrical connector assembly of claim 8 , wherein said lever member includes an arced resistance beam with an inner radial surface that rotates alongside said blocking member without engaging said blocking member when said lever member is in said insertion position as said first and second housings are joined in said initial mating position.