Abstract:
Methods and apparatus are provided for connecting wires from a primary vehicle to a towing vehicle through an improved wire harness connector. There is described an assembly of a vehicle bumper with a connector attached to the bumper. The bumper has a set of holes, snap-fit holes, and locking holes, that allow the connector to attach. The connector includes a set of snap-fits and at least one depressable lock. The snap-fits are configured so as to insert through snap-fit holes thereby restricting movement of the connector. The lock is also configured to pass through the locking hole thereby restricting movement of the connector.

Description:
TECHNICAL FIELD  
       [0001]     The present invention generally relates to a wire harness connector. More particularly, the present invention relates to a seven point wire harness connector for use with a trailer with brakes, and methods for attaching the connector to the towing vehicle.  
       BACKGROUND  
       [0002]     A variety of vehicles exist that include, as part of their design, the ability to tow a trailer. By way of showing just a partial example, many trucks, SUVs, and other such vehicles exist that are designed to tow any number of trailers such as boat trailers, horse trailers, camping trailers, construction-related trailers, sports-related trailers, etc. When a vehicle such as a truck or SUV tows a trailer, it is also known to provide an electrical connection between the primary (towing) vehicle and the trailer. The electrical connection allows the trailer to indicate signals such as lights, brake signals, and turn signals that are provided by the primary vehicle. A seven point wire connector is known as one of several kinds of electrical/wire connection between the primary and towing vehicles.  
         [0003]     Current designs of wire connectors typically include a receiving housing and a projecting housing. The receiving housing may be attached to the primary vehicle. Wire leads from the various electrical and signal functions of the primary vehicle are gathered in the receiving housing. A wire harness that collects these leads may be disposed in the housing. The receiving housing and projecting housing are designed such that they may be mechanically interconnected. Matching contacts positioned in the receiving housing and projecting housing are brought into electrical contact when the two parts are connected. Wire leads that are collected in the projecting housing proceed to lights or other functions in the trailer. Thus, signals from the primary vehicle are passed to the trailer.  
         [0004]     There is an ongoing need to simplify the fabrication process of vehicles such as trucks and SUVs. Simplified constructions steps that eliminate unnecessary parts or construction steps reduce the time and cost of manufacture. Further, the elimination of redundant or unnecessary parts also saves weight on the vehicle. Even small improvements in weight and the manufacturing process are desired because, when accumulated with other such modifications, the economics and performance of the overall product can show measurable improvement. Thus, with respect to the current design of the seven point wire harness connector, it would be desired to streamline and improve its design and manufacture if possible.  
         [0005]     Accordingly, it is desirable to simplify the design of the wire harness connector as currently used. In addition, it is desirable to eliminate any unnecessary parts and manufacturing steps that are currently used in the manufacture of the wire harness connector. Furthermore, other desirable features and characteristics of the present invention will become apparent from the subsequent detailed description and the appended claims, taken in conjunction with the accompanying drawings and the foregoing technical field and background.  
       BRIEF SUMMARY  
       [0006]     An assembly is provided for use in providing an electrical connection from a vehicle having a bumper to a trailer attached to the vehicle. The assembly comprises a bumper attached to the vehicle. The bumper has a first side and a second side. The bumper also defines a number of snap-fit holes and at least one locking hole. The assembly also includes a connector having a number of snap-fits and at least one lock. The snap-fit may have a cap and stem which vary in thickness along at least one dimension. The snap-fit may be disposed within the snap-fit hole, thereby restricting movement of the connector with respect to the bumper. The lock may also be disposed within the locking hole thereby restricting movement of the connector.  
         [0007]     A method is also provided for attaching a connector, suitable for use as a wire harness trailer connector, to a vehicle bumper. The method comprises the steps of providing a vehicle bumper having a first side and a second side with at least one snap-fit hole and a locking hold; positioning a connector, having at least one snap-fit and a depressable lock, against a first side of the bumper; pressing the connector against the first side of the bumper so that the snap-fit passes through the snap-fit hole of the bumper and so that the lock depresses against the first side of the bumper; sliding the connector so that the snap-fit moves within the snap-fit hole and so that the lock extends within the locking hole thereby attaching the connector to the bumper. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0008]     The present invention will hereinafter be described in conjunction with the following drawing figures, wherein like numerals denote like elements whenever possible, and wherein  
         [0009]      FIG. 1  is a side view illustration of a prior art means of attaching a prior art connector to a primary vehicle;  
         [0010]      FIG. 2  is a side view of a connector according to an embodiment of the present invention;  
         [0011]      FIG. 3  is a front view of a connector according to an embodiment of the present invention;  
         [0012]      FIG. 4  is a top view of a connector according to an embodiment of the present invention; and  
         [0013]      FIG. 5  is a plan view of a vehicle bumper with holes stamped therein for receiving a connector, according to an embodiment of the present invention.  
     
    
     DETAILED DESCRIPTION  
       [0014]     The following detailed description is merely exemplary in nature and is not intended to limit the invention or the application and uses of the invention. Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, brief summary or the following detailed description.  
         [0015]     Referring now to  FIG. 1  there is illustrated an embodiment of a conventional connector assembly affixed to a vehicle. Elements of the assembly include bracket  11 , receiving connector  12 , and hitch  13 . Bracket  11  is welded to hitch  13  at weld point  14 . Connector  12  itself comprises various elements including wires  15 , housing  16 , cover  17 , and snap-fits  18 .  
         [0016]     In current practice, the assembly of connector  12  to a vehicle includes various steps relating to bracket  11 . Bracket  11  must be manufactured, it must be positioned in a configuration relative to hitch  13 , and bracket  11  must be welded to hitch  13 . Further, the weld  14  must be such so that the relative position of bracket  11  and connector  12  are not unduly affected. Cumulatively, these steps are expensive and time consuming. It would be desired to eliminate or simplify them if possible.  
         [0017]     Turning now to  FIG. 2 , there is shown a side view of a new receiving connector  21  (also referred to as a connector). Receiving connector  21  includes the elements of housing  22 , snap-fits  23  (or snap-fit projections), lock  24 , wires  25 , and cover  26 . It will be noted that several of the elements in receiving connector  21  are common with old receiving connector  12 . However, the known elements have been rearranged. Additionally, as explained in further detail below, the method of attaching connector  21  to a vehicle have been modified. Thus receiving connector  21  comprises a new design configuration with respect to prior art connectors.  
         [0018]     As is known in the art, housing  22  is preferably formed of a hardened thermoplastic. Injection molding is one method of manufacturing the housing.  FIG. 2  illustrates housing  22  as being square or box-like in its profile view. Other shapes are possible. In one embodiment, housing  22  is cut away or provided with apertures in order to achieve a material savings. Preferably snap-fits  23  and housing  22  are formed of a unitary piece.  
         [0019]     Still referring to  FIG. 2 , cover  26  may be mounted to housing  22  by a spring-loaded hinge. Cover  26  covers the opening of receiving connector  21  where a corresponding projecting connector would be inserted. Cover  26  also provides the function of protecting electrical contacts from exposure to rain, snow, debris, and other elements when connector  21  is not being used. A wire harness may be present within housing  22 . Electrical contacts may be included within the harness, or otherwise disposed within housing  22 . Preferably cover  26  protects exposed contacts. Additionally, features of connector  21  such as the contacts, harness and housing  22  may be configured so as to provide a seven point connector.  
         [0020]      FIG. 2  illustrates a preferred embodiment of snap-fits  23 . In this embodiment, each snap-fit  23  includes cap  31  and stem  32 . Cap  31  of snap-fit  23  has a larger width, seen from the side view, than the stem  32  of the snap fit  23 . However, as seen from the direction shown in  FIG. 3 , each snap-fit  23  has the same width, both cap  31  and stem  32 . Thus, the width of each cap  31  is larger than the width of each stem  32  in a first dimension, and the length of each cap  31  is the same as the length of each stem  32  in a second dimension. As will be described later, this feature is useful in attaching connector  21  to a vehicle.  
         [0021]     Lock  24 , as shown in  FIG. 2 , is also useful in securing connector  21  to a vehicle. Preferably lock  24  is biased or spring loaded. Lock  24  may be pushed down so that it recedes within a cavity provided in housing  21 . Upon releasing the compressive force from lock  24 , it returns to its original, extended position. This too is useful in attaching connector  21  to a vehicle.  
         [0022]     Referring now to  FIG. 3 , there is shown a front view of new receiving connector  21 . From this perspective there are shown additional features of connector  21 , according to a preferred embodiment. Lock  24  is shown to have an angled or sloping top surface. The top surface of lock  24  is angled with respect to the top surface of housing  22  as shown in  FIG. 3 . Lock  24  thus has a triangular profile in the direction illustrated in  FIG. 3 . Further, stiffening ribs  27  are shown in  FIG. 3 , which are a preferred though optional element. In this embodiment, housing  22  is shown to have openings where material is absent. Thus stiffening ribs  27  act to brace the structure of housing  22 . In the view of  FIG. 3 , cover  26  has been removed. The openings  28  are holes that would receive prongs from a projecting connector. Seven openings illustrate the connector  21  configured as a seven point connector. Additionally,  FIG. 3  illustrates that snap-fits  23  have a constant profile from this perspective.  
         [0023]     Now turning to  FIG. 4 , there is shown a top view of new receiving connector  21 . This illustrates how snap-fits  23 , seen from above, are preferably square or rectilinear in shape. In this embodiment, snap-fits  23  are positioned on a top surface  41  of connector  21 . Other configurations are possible.  
         [0024]     Having described the new receiving connector  21  from a structural standpoint, a method of using the same will now be described.  
         [0025]     The newly conceived receiving connector  21  is useful in that it has a simplified means of attachment to a vehicle. Whereas before the prior art connector  12  was attached to a bracket, now, the new receiving connector  21  attaches directly to a bumper surface of the vehicle. The need for a bracket  11 , bracket weld  14 , and the related positioning and manufacturing steps have been eliminated.  
         [0026]     In order to apply new receiving connector  21  to a vehicle, the vehicle must have a set of openings or holes in the bumper. Preferably, these holes are stamped in the bumper during its fabrication. Referring now to  FIG. 5 , there is shown one embodiment of a vehicle bumper with such openings.  FIG. 5  illustrates a bumper  50 . A conventional bumper  50  defines a first side  56  and second side, and  FIG. 5  illustrates one such side  56 . Snap-fit openings  51  appear in the bumper  50 . Also, lock opening  52  appears in the bumper. It will be noted that each of snap-fit openings  51  comprises a larger area  53  and smaller area  54 .  
         [0027]     The bumper openings  51 ,  52  are shaped and positioned so as to match the position and contours of snap-fits  23  and lock  24  of connector  21 . In particular, the larger area  53  of each snap-fit opening  51  should be shaped so as to allow cap  31  of each snap-fit  23  to pass therethrough. However, the smaller area  54  of each snap-fit opening  51  is shaped such that cap  31  cannot pass therethrough. The stem  32  of each snap-fit  23  can slide into the area defined by the smaller area  54  of snap-fit opening  51 . Thus, in order to affix connector  21  to a vehicle, connector  21  is first brought into proximity with a first side of bumper  50 . Snap-fits  23  fit within the area defined by the larger area  53  of each snap-fit opening  51 . Thus connector  21  is moved such that cap  31  of snap-fits  23  pass through larger area  53  of each snap-fit opening  51 . Connector  21  is moved until cap  31  extends beyond the opposite, or second, surface of bumper  50 . Stem  32  of each snap-fit  23  should have sufficient height so as to allow cap  31  to extend above bumper  50 . Doing this first brings lock  24  into contact with the first side of bumper  50 . As connector  21  is further moved against bumper  50 , the contact with bumper  50  depresses lock  24 .  
         [0028]     Once connector  21  is positioned against bumper  50  such that cap  31  of snap-fit  23  extends beyond the second surface of bumper  50 , connector  21  is moved in a lateral position such that stem  32  of each snap-fit  23  passes into the area defined by smaller area  54  of snap-fit opening  51 . By this movement, cap  31  of snap-fit  23  is moved away from larger area  53 . Connector  21  is moved in the lateral direction until stem  32  reaches the end of motion permitted by the area defined by smaller area  54 . Cap  31  cannot pass through smaller area  54 . Thus, once connector  21  has moved such that cap  31  is positioned over smaller area  54  of snap-fit opening  51 , connector  21  is restricted in its movement away from bumper  50 .  
         [0029]     Additionally, the lateral movement of connector  21  brings lock  24  into proximity with lock opening  52 . Once lock  24 , which has been depressed in a housing cavity due to contact with bumper  50 , has reached a position under lock opening  52 , lock  24  is allowed to rise to its normal position. By extending to its fully upright position, lock  24  engages with bumper  50  at the edge of lock opening  52 . This action now restricts the movement of connector  21  such that it is affixed to bumper  50 . Snap-fits  23  securely hold connector  21  against bumper  50  in snap-fit openings  51  because cap  32  cannot escape through the small area  54  of snap-fit opening, and lock  24 , engaged with bumper  50  at lock opening  52  prohibits lateral movement.  
         [0030]     It will be appreciated that connector  21  can be released from its attached position to bumper  50 . Lock  24  can be depressed, as by manual action. Depressing lock  24  then allows connector  21  to make lateral movement. In a reversal of those movements that placed connector  21  in the affixed position, connector  21  can be slid laterally so that each cap  31  is moved from a position above small area  54  to a position above larger area  53 . And, once each cap  31  is positioned above the larger area  53 , connector  21  can be moved away from bumper  50  by drawing each cap  31  through larger area  53 .  
         [0031]     It will be recalled that in a preferred embodiment lock  24  has, in one profile, a triangular shape. Referring again to  FIG. 3  the illustration shows lock  24  oriented in a way that will be termed directed toward the right side of the page. The triangle that represents lock  24  is situated such that the leg of the triangle is on the left side of the hypotenuse. Thus, a locking face  33  extends when lock  24  is extended. Lock also defines contact point  34 . With this orientation, it is preferred that connector  21  be slid toward the right side of the page when engaging with bumper  50 . In this manner, lock  24  slides in a manner such that lock  24  only contacts bumper  50  along contact point  34 . The bulk of lock  24  is not in contact with bumper  50  thus allowing an easy sliding motion. Further, once lock  24  extends into lock opening  52 , locking face  33  of lock  24  restricts movement of connector  21  in the lateral direction opposed to locking face  33 .  
         [0032]     Openings  51 ,  52  have been shown as generally rectilinear in certain portions. It will be appreciated that their size and shape may vary but must correspond to that of snap-fits  23  and lock  24 .  
         [0033]     The size and shape of housing  22 , and the positioning of openings  51 ,  52 , allows positioning of connector  21  in a desired location. Thus, for other design purposes it may be desired to have cover  26  in a given location when connector  21  is affixed to the primary vehicle. For example, the cover  26  should be positioned and aligned so as to allow easy mating of receiving connector  21  with a projecting connector. Thus, knowing a desired final location for cover  26  allows a designer to locate openings  51 ,  52  as well as to size housing  22  so as to allow this location.  
         [0034]     A preferred configuration for connector  21  is illustrated by comparing  FIG. 2  to  FIG. 1 .  FIG. 2  illustrates the new receiving connector  21  having a housing  22  with several surfaces. The snap-fit projections  23  are disposed on a first surface of the housing  22 ; and the depressable lock  24  is also disposed on the same surface. The cover  26 , however, defines a surface, a cover surface, that has an orientation approximately 90° to the surface where snap-fits  23  and lock  24  are located. This contrasts with the orientation of the prior art connector  12  in  FIG. 1 .  
         [0035]     While at least one exemplary embodiment has been presented in the foregoing detailed description, it should be appreciated that a vast number of variations exist. It should also be appreciated that the exemplary embodiment or exemplary embodiments are only examples, and are not intended to limit the scope, applicability, or configuration of the invention in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient road map for implementing the exemplary embodiment or exemplary embodiments. It should be understood that various changes can be made in the function and arrangement of elements without departing from the scope of the invention as set forth in the appended claims and the legal equivalents thereof.