Abstract:
An electrical connector system for use with an electrically powered accessory mounted to a vehicle is disclosed. The electrical connector system includes a connector adapted to be mounted to the vehicle as well as a cord having a first end adapted to be electrically coupled to the accessory and a second end having a plug. The plug is adapted to be electrically coupled to a power source remote from the vehicle, is removably coupled to the connector and includes a flexible finger having a tab engaging the connector. The electrical connector system also includes an indicator mounted to the connector and in electrical communication with the plug. The indicator is operable to provide a visual indication when electrical power is present at the plug.

Description:
BACKGROUND AND SUMMARY 
     The present disclosure relates generally to electrically powered accessories for motor vehicles and, more particularly, to an electrical connector and indicator system for motor vehicles. 
     Various electrically powered devices are designed for use with vehicles including automobiles, light-duty trucks and heavy-duty vehicles. The electrically powered devices include cold weather starting aids such as radiant heaters, engine block heaters, fluid heaters, battery warmers, and the like, and may be generally fixed to the automobile and operationally connected to an appropriate component of the vehicle engine. The operation of these devices generally occurs upon connection to a power source external to the vehicle. As such, a factor in the sales and use of these devices may be the simplicity with which the device can be electrically connected to the power source. To address this concern, cord sets have been developed that include a receptacle connected to the vehicle body for mounting an electrical cord that is connected to the electrically powered device. The power cords of the cord sets terminate at a male or female plug that is coupled to the receptacle. A counterpart plug external to the vehicle is selectively coupled to the receptacle to allow electrical connection of the device to the power source. 
     Cord sets for selectively electrically connecting an electrically powered automobile accessory to a power source are commercially available for use with heavy-duty vehicles today. Specifically, the assignee of the present disclosure and others have manufactured cord set receptacles that are generally cylindrical in shape and include a cylindrical housing open at one end to accommodate a male plug. The cylindrical housing may be normally closed at an opposite end by a spring biased cover. 
     The present disclosure relates to an electrical connector system for use with an electrically powered accessory mounted to a vehicle. The electrical connector system includes a connector adapted to be mounted to the vehicle as well as a cord having a first end adapted to be electrically coupled to the accessory and a second end having a plug. The plug is adapted to be electrically coupled to a power source remote from the vehicle, is removably coupled to the connector and includes a flexible finger having a tab engaging the connector. The electrical connector system also includes an indicator mounted to the connector and in electrical communication with the plug. The indicator is operable to provide a visual indication when electrical power is present at the plug. 
     Furthermore, an electrical connector system for use with an accessory mounted to a vehicle is disclosed. The electrical connector system includes a connector having first and second housings integrally formed with a plate. First and second plugs are adapted to be electrically coupled to a power source remote from the vehicle and removably coupled to the first and second housings, respectively. An indicator in electrical communication with the first plug is adapted to be mounted to the connector at a visible location and is operable to provide a visual indication when electrical power is present at the plug. 
     Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The present disclosure will become more fully understood from the detailed description and the accompanying drawings, wherein: 
         FIG. 1  is a schematic illustration of an exemplary vehicle equipped with an electrical connector system; 
         FIG. 2  is a perspective view of an electrical connector system; 
         FIG. 3  is an exploded perspective view of the electrical connector system; 
         FIG. 4  is a fragmentary perspective view showing the electrical connector system; 
         FIG. 5  is another fragmentary perspective view of the electrical indicator system; and 
         FIG. 6  is a fragmentary sectional view of a visual indicator of the electrical connector system; 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the disclosure, its application, or uses. 
       FIG. 1  depicts a vehicle  10  including an engine  12  and a powered automobile accessory  14 , such as an engine block heater. A first cord set  16  has a first end  18  electrically connected to the accessory  14  and a second bifurcated end  20 . One portion of bifurcated end  20  terminates at a plug  22 . The other end terminates at an indicator  24 . Plug  22  is coupled to a dual entry connector  26  that is mounted to the vehicle  10 . An auxiliary cord  28  includes a plug  30  for selectively interconnecting first cord set  16  to an external power source  32  via plug  22 . The power source  32  includes an alternating current electrical outlet such as those generally mounted in the walls of building structures or at “shore stations” for vehicles. 
     A second cord set  34  has a first end  36  connected to a cab power system  38 . Cab power system  38  may include a number of alternating current outlets located within the cabin of vehicle  10  to allow a user to power common household accessories such as video monitors and DVD players positioned within the vehicle cabin. A second end  40  of second cord set  34  terminates at a plug  42 . Plug  42  is also coupled to dual entry connector  26 . An auxiliary cord  44  includes a plug  46  for selectively interconnecting second cord set  34  to power source  32  via plug  42 . Power source  32  provides alternating current for use in cab power system  38 . It should be appreciated that auxiliary cord  28  may be used in cooperation with plug  42  instead of auxiliary cord  44 . In use, zero, one or two auxiliary cords may be coupled to dual entry connector  26  depending on the electrical needs of the user. 
       FIGS. 2-6  depict dual entry connector  26  in communication with first cord set  16  and second cord set  34 . Dual entry connector  26  includes first and second substantially cylindrically-shaped hollow housings  52 ,  54  integrally formed with a plate  56 . First and second covers  58 ,  60  are rotatably coupled to plate  56  via a hinge pin  62 . Hinge pin  62  is supported by multiple stanchions  64  integrally formed with and extending from plate  56 . A spring  66  biases first and second covers  58 ,  60  toward closed positions depicted in  FIG. 2 . First and second covers  58 ,  60  are selectively moveable to opened positions ( FIG. 4 ) rotated about hinge pin  62  ninety degrees or more to allow access to first and second cavities  67 ,  68  formed within housings  52 ,  54 , respectively. 
     Plate  56  includes a plurality of apertures  70  sized for receipt of fasteners (not shown). A gasket  72  is constructed from a resilient material and is operable to form a seal between plate  56  and a panel of exemplary vehicle  10 . Gasket  72  includes apertures  74 ,  76  sized to allow housings  52 ,  54  to pass therethrough. Gasket  72  also includes additional apertures  78  sized and positioned to accept the fasteners extending through apertures  70 . 
     Seals  79  are coupled to first and second covers  58 ,  60  to selectively engage housings  52 ,  54  to seal off cavities  67  and  68 . Mechanical connections are made to couple plugs  22  and  42  to dual entry connector  26 . Plugs  22  and  42  are coupled to housings  52 ,  54  in substantially the same manner. Accordingly, only one connection will be described in detail. Plug  22  includes a substantially cylindrically shaped body  80  having flats  82  and  84  formed thereon. Flats  82 ,  84  extend substantially parallel to one another on opposite sides of body  80 . First and second fingers  86 ,  88  are integrally formed with body  80  and longitudinally extend from flats  82 ,  84 , respectively. Each of the fingers  86 ,  88  includes a first end  90  fixed to body  80  and a second end  92  cantilevered and spaced apart from body  80 . Fingers  86 ,  88  are preferably constructed from an elastomeric material that allows each finger to be deflected upon receipt of a force. When the force is removed, the fingers return to the unbiased positions shown in  FIG. 5 . A tab  94  radially outwardly extends from each of fingers  86 ,  88 . By applying a force to free end  92 , finger  86  may be deflected to vary the radial position of tab  94 . Tab  94  includes an angled surface  96  and a partial cylindrical surface  98 . 
     First housing  52  and second housing  54  are substantially similar to one another. Accordingly, like reference numerals including prime suffixes are shown to represent like elements. For clarity, only first housing  52  will be described in detail. First housing  52  includes a first cylindrically shaped portion  100  and a second cylindrically shaped portion  102 . Cylindrically shaped portion  100  includes an inner cylindrical surface  104  sized to receive plug  30  of auxiliary cord  28 . Cylindrical portion  100  terminates at an end wall  106 . Second cylindrical portion  102  extends from end wall  106  in a direction opposite from cylindrically shaped portion  100  and includes an inner cylindrical surface  108  having a diameter smaller than inner cylindrical surface  104 . A land  110  radially inwardly extends from inner cylindrical surface  108  and acts as a stop to limit axial travel of plug  22  relative to dual entry connector  26 . Second cylindrical portion  102  includes first and second transversely oriented apertures  112 ,  114  sized to receive tabs  94 . Apertures  112  and  114  may be coaxially aligned with one another. 
     In the undeformed state shown in the Figures, tabs  94  radially outwardly extend a distance greater than the diameter defined by inner cylindrical surface  108 . To couple plug  22  to dual entry connector  26 , a user axially displaces plug  22  into second cylindrically shaped portion  102  of housing  52 . During axial translation, angled surfaces  96  engage inner cylindrical surface  108  causing fingers  86 ,  88  to radially inwardly deflect. Deflection of fingers  86 ,  88  allows plug  22  to continue to enter second cylindrically shaped portion  102 . As tabs  94  enter apertures  112 ,  114 , fingers  86 ,  88  spring back to their undeformed state. Further axial travel of plug  22  in the insertion direction is limited by an end face  116  of plug  22  engaging land  110 . Once tabs  94  are positioned within apertures  112 ,  114 , axial travel of plug  22  in a direction attempting to separate plug  22  from dual entry connector  26  will be resisted by cylindrical surface  98  in engagement with the wall of apertures  112 ,  114 . 
     If disconnection of first cord set  16  from dual entry connector  26  is desired, a user applies force to ends  92  of fingers  86 ,  88  to radially inwardly deflect tabs  94 . Once tabs  94  are clear of second cylindrical portion  102 , a user may axially move plug  22  relative to dual entry connector  26 . 
     Plug  22  includes a male live terminal  120 , a male neutral terminal  122 , and a male ground terminal  124 . Each of the terminals  120 ,  122  and  124  is electrically coupled to a wire. In particular, ground terminal  124  electrically conducts with a ground wire  126 . Live terminal  120  is electrically and mechanically coupled to a supply wire  128 . Live terminal  120  is also electrically coupled to a first lead wire  129  of indicator  24 . A resistor (not shown) may be placed in series between live terminal  120  and indicator  24  as desired. 
     A neutral wire  130  is electrically coupled to neutral terminal  122 . A second lead wire  132  of indicator  24  is electrically coupled to neutral wire  130 . A first signal may be emitted from indicator  24  when power source  32  is electrically coupled to terminals  120 ,  122  and  124 . Depending on the particular indicator wiring, indicator  24  may be a single color or a dual color light-emitting-diode (LED). If a dual color LED is implemented a circuit may be constructed such that the first signal corresponds to the LED emitting a green light. If current is flowing through plug  22  such as when accessory  14  is operating, a second signal is emitted from indicator  24 . The second signal is a red light emitted from the LED. 
     Alternatively, the first signal may be a constantly illuminated lamp or LED. The second signal from indicator  24  may be a flashing light. One skilled in the art will appreciate that any number of different visual indications may be emitted from a single indicator  24 . The various other signals are intended to be within the scope of the disclosure. 
     Plug  42  also includes a plurality of terminals electrically coupled to wires. Specifically, plug  42  includes a male live terminal  140  electrically coupled to a supply wire  142 . A ground terminal  144  electrically conducts with a ground wire  146 . A neutral terminal  148  is electrically coupled with a neutral wire  149 . In the embodiment shown, each of terminals  140 ,  144  and  148  are shaped as male terminals. It is contemplated that female terminals and/or a combination of male and female terminals may be utilized without departing from the scope of the present disclosure. Plug  42  is substantially similar to plug  22 . As such, like reference numerals having prime suffixes have been used to depict like elements. 
     Indicator  24  may be secured to first cover  58  with a threaded housing  150  and a nut  152 . Housing  150  includes a substantially cylindrically-shaped hollow portion  154  and a radially enlarged portion  156 . Nut  152  includes an internal thread threadingly engaging an external thread of portion  154  on threaded housing  150 . Nut  152  is positioned within a pocket  158  formed on a downstanding flange  160  of first cover  58 . Portion  154  extends through an aperture  162  extending through flange  160 . Indicator  24  is positioned at the end of threaded housing  150  such that first and second lead wires  129  and  132  extend through housing  150  while a lamp portion  164  of indicator  24  protrudes outwardly from the end of threaded housing  150 . Nut  152  secures indicator  24  to panel first cover  58  and positions lamp portion  164  to slightly protrude beyond nut  152 . It should be appreciated that the mounting arrangement and positioning of indicator  24  relative to dual entry connector  26  is merely exemplary and that it is contemplated that indicator  24  may be mounted in any number of locations on external surfaces of the vehicle or within the passenger cabin. 
     A wire trough  170  ( FIG. 5 ) is integrally formed with plate  56  and stanchions  64  as shown in  FIG. 5 . Pairs of crimps  172  define local reduced diameter portions of wire trough  170 . Crimps  172  assist to retain lead wires  129  and  132  in trough  170 . A wire clip  174  and crimps  176  may be formed on first cover  58  to maintain a desired position of lead wires  129  and  132  adjacent to or in engagement with an inner surface of first cover  58 . It should be appreciated that downstanding flange  160  of first cover  58  may be positioned to extend substantially parallel to the ground. While first cover  58  is in the closed position, indicator  24  faces the ground. However, when an operator opens first cover  58  and electrically couples power source  32  to plug  22 , indicator  24  will be facing the operator and may be easily viewed. 
     Furthermore, the foregoing discussion discloses and describes merely exemplary embodiments of the present disclosure. One skilled in the art will readily recognize from such discussion, and from the accompanying drawings and claims, that various changes, modifications and variations may be made therein without department from the spirit and scope of the disclosure as defined in the following claims.