Shock absorber with an electrical connector

A shock absorber is disclosed which electrically communicates with an external source of electrical potential. The shock absorber comprises a valve for electrically controlling the flow of damping fluid in the working chamber of the shock absorber. The shock absorber further comprises a connector for allowing the valve to be electrically connected to the source of electrical potential. The connector comprises an adapter shaft communicating with the piston rod of the shock absorber, a first connector assembly connected to the adapter shaft, and a second connector assembly connected to the first connector assembly.

BACKGROUND OF THE INVENTION 
1. Field of the Invention 
This invention relates to automotive suspension systems, and more 
particularly to an electrical connector for shock absorbers. 
2. Description of Related Art 
Shock absorbers are used in connection with automotive suspension systems 
to absorb unwanted vibrations which occur during driving. To absorb this 
unwanted vibration shock absorbers are generally connected between the 
body and the suspension of the automobile. A piston is located within the 
shock absorber and is connected to the body of the automobile through a 
piston rod. Because the piston is able to limit the flow of damping fluid 
within the working chamber of the shock absorber when the shock absorber 
is compressed, the shock absorber is able to produce a damping force which 
counteracts the vibration which would otherwise be transmitted from the 
suspension to the body The greater the degree to which the flow of damping 
fluid within the working chamber is restricted by the piston, the greater 
the damping forces which are generated by the shock absorber. 
In selecting the amount of damping that a shock absorber is to provide, 
three vehicle performance characteristics are often considered: ride 
comfort, vehicle handling and road holding ability. Ride comfort is often 
a function of the spring constant of the main springs of the vehicle, as 
well as the spring constant of the seat, tires, and the shock absorber. 
Vehicle handling is related to the variation in the vehicle's attitude 
(i.e., roll, pitch and yaw). For optimum vehicle handling, relatively 
large damping forces are required to avoid excessively rapid variation in 
the vehicle's attitude during cornering, acceleration, and deceleration. 
Road holding ability is generally a function in the amount of contact 
between the tires and the ground. To optimize road holding ability large 
damping forces are required when driving on irregular surfaces to prevent 
loss of contact between the wheels and the ground for an excessive period 
of time. 
Because different driving characteristics depend on the amount of damping 
forces the shock absorber provides it is often desirable to have a shock 
absorber in which the amount of damping forces generated by the shock 
absorber is adjustable One method for selectively changing the damping 
characteristics of a shock absorber is disclosed in U.S. Pat. No. 
4,597,411. In this reference, a solenoid is used to selectively open and 
close an auxiliary opening in a base valve of a shock absorber The base 
valve then regulates the pressure inside one portion of the working 
chamber of the shock absorber so as to control damping Another method for 
selectively changing the damping characteristics of a shock absorber is 
disclosed in PCT No. WO86/06807 published Nov. 20, 1986. In one 
embodiment, this reference discloses the use of a pressure sensor to count 
the number of compression-rebound cycles of the absorber, as well as an 
accelerometer attached to the wheel support to determine the vertical 
velocity of the body of the automobile. The damping characteristics of the 
absorber are then changed in response to the vertical velocity of the 
body. 
A further method for selectively changing the damping characteristics of 
shock absorbers is disclosed in co-pending U.S. Pat. No. 4,867,475. In 
this patent, the shock absorber includes a rotary valve which is able to 
change the amount of damping fluid flowing between the upper and lower 
portions of the working chamber in response to the angular displacement of 
the rotary valve. The angular displacement of the valve is in turn 
controlled by a D.C. motor and a disk shaped contact clement which 
provides information concerning the angular location of the shaft of the 
D.C. motor. 
As will be seen from the above examples, methods for selectively varying 
the damping characteristics of shock absorbers generally use electrical 
current to either control a motor or the application of a magnetic field 
to a biasing member such as a valve plate or a solenoid Accordingly, a 
need exists for an electrical connector which can deliver current from a 
power source to the electrical components in a shock absorber which are 
used to adjust damping characteristics. 
SUMMARY OF THE INVENTION 
Accordingly, it is a primary object of the present invention to provide an 
electrical connector which enables the electrical components in a shock 
absorber to receive current from a source of electrical potential located 
externally of the shock absorber. A related object of the present 
invention is to provide a connector which enables data from the electrical 
components inside a shock absorber to be delivered to processing 
electronics located outside the shock absorber so that the data may be 
evaluated. 
Another object of the present invention is to provide an electrical 
connector which is compact and is less likely to mechanically interfere 
with the other components of the automobile. In this regard, a related 
object of the present invention is to provide an electrical connector 
having minimum length when assembled. 
It is a further object of the present invention to provide a positive 
secure strain relief to the solenoid/actuator joined between an electrical 
connector and a flex circuit wire. 
Another object of the present invention is to provide an electrical 
connector which is able to function under harsh environmental conditions 
which may occur under the hood and outside the underchassis of the 
automobile. 
It is a further object of the present invention to provide a locking system 
on electrical connectors into a projectile deflection shield in the event 
of a small stone or such that may impact the connector system due to its 
locations. 
Another object of the present invention is to incorporate identical parts 
of electrical connectors used in both front and rear shock absorbers. 
It is a further object to provide a less expensive and relatively simple 
connector arrangement which may be used with shock absorbers. 
Another object of the present invention is to provide an electrical 
connector assembly having male and female portions which will resist 
rotation and maintain electrical contact within the assembly when subject 
to harsh environmental conditions.

DESCRIPTION OF THE PREFERRED EMBODIMENTS 
Referring to FIG. 1, a plurality of four shock absorbers 10 in accordance 
with the preferred embodiments of the present invention are shown. The 
shock absorbers 10 are depicted in operative association with a 
diagrammatic representation of a conventional automobile 12. The 
automobile 12 includes a rear suspension 14 having a transversely 
extending rear axle assembly (not shown) adapted to operatively support 
the vehicle's rear wheels 18. The rear axle assembly is operatively 
connected to the automobile 12 by means of a pair of shock absorbers 10 as 
well as by the helical coil springs 20. Similarly, the automobile 12 has a 
front suspension system 22 including a transversely extending front axle 
assembly (not shown) to operatively support the front wheels 26. Front 
axle assembly is operatively connected to the automobile 12 by means of a 
second pair of shock absorbers 10 and by the helical coil springs 28. The 
shock absorbers 10 serve to damp the relative movement of the unsprung 
portion (i e., the front and rear suspensions 22 and 14) and the spring 
portion (i.e., the body 30) of the automobile 12. While the automobile 12 
has been depicted as a passenger car, the shock absorber 10 may be used 
with other types of automotive vehicles as well. 
With particular reference to FIG. 2, the shock absorber 10 according to the 
first preferred embodiment of the present invention is shown with the 
adapter shaft exposed The shock absorber 10 comprises an elongated tubular 
pressure cylinder 32 defining a damping fluid-containing working chamber 
34. Disposed within the working chamber 34 is a reciprocal piston 36 that 
is secured to one end of an axially extending piston rod 38. The piston 36 
includes a circumferential groove (not shown) operable to retain a piston 
ring 40 as is well-known in the art. The piston ring 40 is used to prevent 
damping fluid from flowing between the outer periphery of the piston 36 
and the inner diameter of the pressure cylinder 32 during movement of the 
piston 36. A base valve, generally designated by the numeral 42, is 
located within the lower end of the pressure cylinder 32 and is used to 
control the flow of damping fluid between the working chamber 34 and an 
annular fluid reservoir 44 The annular fluid reservoir 44 is defined as 
the space between the outer periphery of the pressure cylinder 32 and the 
inner periphery of a reservoir tube or cylinder 46 which is arranged 
essentially around the exterior of the pressure cylinder 32. The 
construction and operation of the base valve 42 may be of the type shown 
and described in U.S. Pat. No. 3.771.626, which is hereby incorporated by 
reference. 
The upper and lower ends of the shock absorber 10 are provided with 
generally cup shaped upper (not shown) and lower end caps 48 respectively. 
The lower end caps 48 are secured to opposing ends of the reservoir tube 
46 by a suitable means such as welding. Suitable end fittings 52 and 54 
are secured to the upper end of the piston rod 38 and the lower end cap 48 
for operatively securing the shock absorber 10 between both the body and 
the axle assembly of the automobile 12 Those skilled in the art will 
appreciate that, upon reciprocal movement of the piston 36, damping fluid 
within the pressure cylinder 32 is transferred between the upper and lower 
portions of the working chamber 34 and the annular fluid reservoir 44. By 
controlling the flow of damping fluid between the upper and lower portion 
of the working chamber 34, the shock absorber 10 is able to controllably 
dampen relative movement between the body and the suspension of the 
automobile 12 so as to optimize both ride, comfort and road handling 
ability. The piston 36 is provided with a valving arrangement for 
selectively controlling the flow of damping fluid between the upper and 
lower portions of the working chamber 34 during reciprocal movement 
thereof. 
To support the piston 36 within the pressure cylinder 32, the piston 36 has 
a central bore (not shown) operable to receive an axially extending piston 
post 56. The piston post 56 has an upper portion 56 with an internally 
threaded central bore adapted to threadably engage an externally threaded 
lower end portion of the piston rod 38 The piston post 56 further includes 
a radially extending step (not shown) having an outside diameter greater 
than the diameter of the central bore of the piston 36 Because the 
radially extending step is disposed above the piston 36, the step limits 
upward movement of the piston 36 relative to the piston post 56. In 
addition, a piston retaining nut 58 is provided having an internally 
threaded bore which threadably engages an externally threaded lower 
portion of the piston post 56 at a position below the piston 36. Because 
the outside diameter of the piston retaining nut 58 is greater than the 
diameter of the central bore of the piston 36 the nut 58 prevents downward 
movement of the piston 36 relative to the piston post 56. The piston post 
56 and the piston retaining nut 58 also serve to secure the innermost 
portions of two valve disks 60 and 62 which serves to regulate the flow of 
damping fluid between the upper and lower portions of the working chamber 
34. In this regard, the innermost portion of the valve disk 60 engages 
both the radially extending step of the piston post 56 and the upper 
surface of the piston 36. In addition, the radially innermost portion of 
the valve disk 62 engages the lower surface of the piston 36 and the 
piston retaining nut 58. 
To bias the valve disks 60 and 62 against the piston 36, a pair of 
coaxially arranged, axially spaced, helical coil springs 64 and 66 are 
provided. The helical coil spring 64 is disposed coaxially with the piston 
post 56 between a radially extending step formed on the piston post 56 and 
a first intermediate backing plate 65 which is located coaxially with, and 
adjacent to, the upper surface of the valve disk 60. By means of the first 
intermediate backing plate 65, the helical coil spring 64 is able to 
resiliently and yieldably bias the valve disk 60 against the upper surface 
of the piston 36. Similarly, the helical coil spring 66 is disposed 
between a radially extending flange on the piston retaining nut 58 and a 
second intermediate backing plate 68 which is located adjacent to, and 
coaxially with, the valve disk 62. The helical coil spring 66 is therefore 
able to resiliently and yieldably bias the valve disk 62 against the lower 
surface of the piston 36 via the second intermediate backing plate. 
As described above, the flow of damping fluid between the upper and lower 
portions of the working chamber 34 is controlled by the position of the 
valve disks 60 and 62. When the valve disk 60 is displaced in an upward 
direction from the piston 36, the amount of fluid flowing from the lower 
portion of the working chamber 34 to the upper portion of the working 
chamber 34 increases thereby producing a soft compression stroke. When the 
valve disk 62 is displaced in a downward direction from the piston 36, the 
amount of fluid able to flow from the upper portion of the working chamber 
34 to the lower portion of the working chamber 34 increases thereby 
producing a soft rebound stroke. The position of the valve disks 60 and 62 
are controlled by a solenoid (not shown) which is disposed within the 
piston 36 and is electrically actuated while the valve disks 60 and 62 and 
the solenoid are used for regulating the flow of damping fluid between the 
upper and lower portions of the working chamber 34, other valve means may 
also be used. 
To provide means for securing the shock absorber 10 to a female connector 
assembly described below, the shock absorber 10 includes an annular 
adapter shaft 70 The annular adapter shaft 70 is disposed partially within 
a radially extending passage 72 in the shock absorber 10 which 
communicates with an axially extending passage 74. While the annular 
adapter shaft 70 may be secured to the shock absorber 10 by resistive 
welding, other suitable means may be used. The annular adapter shaft 70 
includes a central bore 76 of sufficient diameter to accommodate a female 
connector assembly described below, as well as a radially extending flange 
78 having an annular groove 80 disposed on the outer periphery thereof The 
annular groove 80 is used for receiving a plurality of locking members of 
a latching cap described below to secure the latching cap to the shock 
absorber 10. The annular adapter shaft 70 also includes a circular 
aperture 82 in close proximity to the end furthest from the piston rod 38 
which is used to receive a flexible locking beam in the female connector 
assembly. Finally, the annular adapter shaft 70 also includes an axially 
extending anti-rotation slot 84 in the end of the annular adapter shaft 70 
furthest from the piston rod 38 which is used to receive an anti-rotation 
key in the female connector assembly as described below. 
To provide first means for electrically accessing the components inside the 
shock absorber 10, a female connector assembly 86 is provided. The female 
connector assembly 86 includes a reduced diameter portion 88 having an 
open end 90 When assembled in the manner shown in FIG. 6, the open end 90 
of the reduced diameter portion 88 is located within the radially 
extending passage 72 so as to allow a flex cable 94 inside the axially 
extending passage 74 to enter the female connector assembly 86. 
The female connector assembly 86 further comprises a plurality of axially 
extending grooves 96 disposed on the interior of the female connector 
assembly 86. The axially extending grooves 96 are used to receive a 
plurality of female contacts 98 which are stake fit within the axially 
extending grooves 96 Each lead from the flex cable 94 is electrically 
connected to one of the female contacts 98. While the female contacts 98 
may be made from tempered phosphor bronze with tin plating and copper 
flash, other suitable materials may be used. 
To permit assembly of the female connector assembly 86 the female connector 
assembly 86 is formed in two annular portions 100 and 102 which are 
connected by a hinge 103. The hinge 103 allows the annular portion 100 to 
be separated from the annular portion 102 to allow female contacts 98 to 
be inserted within the axially extending grooves 96 of the female 
connector assembly 86. Once the female contacts 98 are located within the 
female connector assembly 86, the annular portion 100 is angularly 
displaced about its hinge 103 so that the annular portion 100 closes about 
the annular portion 102. Further, by closure of the annular portion 100 
about the annular portion 102, the female connector assembly 86 is able to 
provide strain relief for the flex cable 94 so as to minimize the 
possibility that the leads of the flex cable 94 will become detached from 
the female contacts 98. 
The female connector assembly 86 also comprises an anti-rotation key 104 
which radially extends from the leftmost portion of the female connector 
assembly 86. The anti-rotation key 104 mates with the axially extending 
anti-rotation slot 84 in the annular adapter shaft 70 which thereby 
prevents rotation of the female connector assembly 86 during use In 
addition, the female connector assembly 86 further includes a radially 
extending flexible locking beam 105. When the female connector assembly 86 
is inserted into the adaptor shaft 70, the flexible locking beam 105 
engages the aperture 82 so as to secure the female connector assembly 86 
to the annular adaptor shaft 70. 
To provide second means for electrically accessing the components in the 
shock absorber 10, a male connector assembly 106 is provided. The male 
connector assembly 106 includes a first hinged portion 108 and a second 
hinged portion 110. The first hinged portion 108 comprises an annular body 
112 with a sufficient inside diameter to receive the female connector 
assembly 86 The annular body 112 includes a plurality of axially extending 
projections 114 which are disposed on the interior surface of the first 
hinged portion 108. The axially extending projections 114 are used to 
secure a plurality of male contacts 119 by stake fittings in a position in 
which male contacts 119 engage the female contacts 98 in the female 
connector assembly 86. While the male contacts 119 may be made from 
tempered phosphor bronze with tin plating and copper flash, other suitable 
materials may be used. The first hinged portion 108 further comprises a 
radially extending projection 122 which mates with a radially extending 
projection 116 in the second hinged portion 110. The radially extending 
projections 116 and 122 are used to accommodate a radial projection of an 
insulator boot described below. 
The annular body 112 further comprises a coaxial annular groove 120 on its 
interior surface. The coaxial annular groove 120 is used to receive an 
annular seal 121 which also engages the female connector assembly 86 when 
installed. The annular seal 121 is used to prevent moisture and other 
contaminants from adversely influencing electrical communication between 
the female connector assembly 86 and the male connector assembly 106. 
An insulator boot 123 is also provided which is used for insulating 
adjacent male and female contacts 119 and 98 when the female connector 
assembly 86 is inserted into the male connector assembly 106. The 
insulator boot 123 has a radially extending projection 124 which 
encompasses the radially extending projection 122 of the first hinged 
portion 108 and the radially extending projection 116 of the second hinged 
portion 110 Accordingly, electrical wiring 126 carrying current from a 
source 125 of electrical potential is able to pass through the radial 
extending projections 116 and 122 and be insulated by projection 124 of 
the insulator boot 123 and thereby allowing contact between the leads of 
the electrical wiring 126 and the male contacts 119. The insulator boot 
123 may preferably be made from Santoprene thermoplastic rubber, though it 
is to be understood that other suitable material may be used. The 
insulator boot 123 also forms a seal with the radially extending flange 78 
to provide protection from harsh environmental conditions. 
To provide means for securing the male connector assembly 106 to the female 
connector assembly 86 and to provide a protective covering for the male 
connector assembly 106 so as to resist impact of road debris, a latching 
cap 128 is provided. The latching cap 128 secures the male connector 
assembly 106 to the female connector assembly 86 by allowing the latching 
cap 128 to engage the shock absorber 10. The latching cap 128 is 
cylindrically shaped and includes a plurality of axially extending 
circumferentially spaced locking members 130 on its periphery. Each of the 
locking members 130 include projecting leg portions 132 which are adapted 
to engage the annular groove 80 in the annular adapter shaft 70. In 
addition, the latching cap 128 includes a plurality of stanchions 134 
which permit limited rotation of the locking members 130 with respect to 
the axis of the annular adapter shaft 70 so as to allow engagement of the 
locking members 130 in the annular groove 80. Accordingly, when the 
latching cap 128 is displaced towards the annular adapter shaft 70, the 
projecting leg portions 132 slip over a portion of the radially extending 
flange 78 on the annular adapter shaft 70 until the projecting leg 
portions 132 engage the annular groove 80, thereby securing the male 
connector assembly 106 to the female connector assembly 86. Finally, the 
latching cap 128 has an axially extending groove 136 on its surface to 
accommodate the radial extending projection 124 of the insulator boot 123. 
During assembly, the annular adapter shaft 70 is inserted into the radially 
extending passage 72 in the shock absorber 10 and is secured by resistive 
welding. The flex cable 94 is then fed through the axially extending 
passage 74 in the piston rod 38 and through the central bore 76 of the 
annular adapter shaft 70 The flex cable 94 is then passed through the end 
70 of the female connector assembly 86 so that the leads of the flex cable 
94 may be soldered to the female contacts 98 which have been stake fit 
into the radially extending grooves 96. The female connector assembly 86 
is then inserted into the central bore 76 of the annular adapter shaft 70 
in such a manner so that the anti-rotation key 104 is disposed within the 
axially extending anti-rotation slot 84 of the annular adapter shaft 70. 
In addition, the flexible locking beam 105 is then disposed in the 
aperture 82 of the annular adapter shaft 70 so as to secure the female 
connector assembly 86 to the annular adapter shaft 70. 
After the electrical wiring 126 from the source 125 of electrical potential 
has been inserted through the radially extending projection 124 of the 
insulator boot 123, the leads of the electrical wiring 126 are attached to 
the male contacts 119 which have been stake fit into the axially extending 
projections 114 in the interior surface of the annular body 112. After the 
second hinged portion 110 is closed over the first hinged portion 108, the 
latching cap 128 is placed over the male connector assembly 106 and is 
displaced toward the annular adapter shaft 70 so as to cause the 
projecting leg portions 132 of the locking members 130 to engage the 
annular groove 80. If the latching cap 128 is to be removed, the locking 
members 130 are depressed at a portion away from the shock absorber 10 
thereby causing the projecting leg portions 132 to be removed from the 
annular groove 80 so as to cause disengagement of the latching cap 128 
from the annular adapter shaft 70. 
The present invention will now be described according to the second 
preferred embodiment as shown in FIGS. 7-10. To provide means for 
interfacing the shock absorber 10 with a female connector assembly 
described below, the piston rod 138 includes an annular adapter shaft 
portion 170. The annular adapter shaft 170 includes an axially extending 
passage 176 of sufficient diameter to accommodate a female connector 
assembly, as well as an annular groove 180 disposed on the outer periphery 
thereof. The annular groove 180 is used for receiving a plurality of 
connector mating locking beams of the male connector assembly described 
below to thereby secure the male connector assembly to the shock absorber 
10. The annular adapter shaft portion 170 also includes an aperature 182 
in close proximity to the end of the piston rod 138 which is used to 
receive a flexible locking beam in the female connector assembly described 
below. Finally, the annular adapter shaft portion 170 also includes an 
axially extending anti-rotation slot 184 in the end of the annular adapter 
shaft portion 170 furthest from the piston rod 138 which is used to 
receive an anti-rotation key in the female adapter assembly. 
To provide first means for electrically accessing the components inside the 
shock absorber 10, a female connector assembly 186 is provided. The female 
connector assembly 186 includes a reduced diameter portion 188 having an 
open end 190. When assembled in the manner shown in FIG. 8, the open end 
190 of the reduced diameter portion 188 is located within the axially 
extending passage 176 in the piston rod 138 so as to allow a flex cable 
194 inside the axially extending passage 176 to enter the female connector 
assembly 186. 
The female connector assembly 186 comprises a plurality of axially 
extending grooves 196 disposed on the interior of the female connector 
assembly 186. The axially extending grooves 196 are used to receive a 
plurality of female contacts 198 which are stake fit within the axially 
extending grooves 196. Each lead from the flex cable 194 is electrically 
connected to one of the female contacts 198. While the female contacts 198 
may be made from tempered phosphor bronze with tin plating and copper 
flash, other suitable materials may be used. 
To permit assembly of the female connector assembly 186, the female 
connector assembly 186 is formed in two annular portions 200 and 202 which 
are connected by a hinge 203 The hinge 203 allows the annular portion 200 
to be separated from the annular portion 202 to allow female contacts 198 
to be inserted within the axially extending grooves 196 of the female 
connector assembly 186. Once the female contacts 198 are located within 
the female connector assembly 186, the annular portion 200 is angularly 
displaced about its hinge 203 so that the portion 200 closes about the 
annular portion 200. Further, by closure of the annular portion 200 about 
the annular portion 202, the female connector assembly 186 is able to 
provide strain relief for the flex cable 194 so as to minimize the 
possibility that the leads of the flex cable 194 will become detached from 
the female contacts 198. 
The female connector assembly 186 also has an anti-rotation key 204 which 
radially extends from the leftmost portion of the female connector 
assembly 186. The anti-rotation key 204 mates with the axially extending 
anti-rotation slot 184 in the adapter shaft portion 170 which thereby 
prevents rotation of the female connector assembly 186 during use. In 
addition, the female connector assembly 186 further includes a radially 
extending flexible locking beam 205. When the female connector assembly 
186 is inserted into the adaptor shaft 170, the flexible locking beam 205 
engages the aperture 182 so as to secure the female connector assembly 186 
to the adaptor shaft 170. 
To provide second means for electrically accessing the components in the 
shock absorber 10, a male connector assembly 206 is provided. The male 
connector assembly 206 includes a first hinged portion 208 and a second 
hinged portion 210. The first hinged portion 208 comprises an annular body 
212 with a sufficient inside diameter to receive the female connector 
assembly 186. The annular body 212 includes a plurality of inwardly 
extending axial projections 214 which are disposed on the interior surface 
of the first hinged portion 208. The inwardly extending axial projections 
214 are used to secure a plurality of male contacts 219 by stake fitting 
in a position in which male contacts 219 engage the female contacts 198 in 
the female connector assembly 186. While the male contacts 219 may be made 
from tempered phosphor bronze with tin plating and copper flash, other 
suitable materials may be used The first hinged portion 208 further 
comprises a radially extending projection 216 which mates with a radially 
extending projection 222 in the second hinged portion 210. The radially 
extending projections 216 and 222 are used to accommodate a radial 
projection of an insulator boot described below. 
The annular body 212 further comprises a coaxial annular groove 220 on its 
interior surface. The coaxial annular groove 220 is used to receive an 
annular seal 221 which also engages the female connector assembly 186 when 
installed. The annular seal 221 is used to prevent moisture and other 
contaminants from adversely influencing electrical communication between 
the female connector assembly 186 and the male connector assembly 206. 
To provide means for securing the male connector assembly 206 to the female 
connector assembly 186, the male connector assembly 206 includes a 
plurality of axially extending circumferentially spaced connector mating 
locking beams 230 on its periphery. The connector mating locking beams 230 
include projecting leg portions 232 which are adapted to engage the 
annular groove 180 in the annular adapter shaft portion 170. In addition, 
the male connector assembly 228 includes a plurality of stanchions 234 
which permit limited rotation of the connector mating locking beams 230 
with respect to the axis of the annular adapter shaft portion 170 so as to 
allow engagement of the connector mating locking beams 230 in the annular 
groove 180. Accordingly, when the male connector assembly 206 is displaced 
towards the adapter shaft portion 170, the projecting leg portions 232 
slip over a portion of the annular adapter shaft portion 170 until the 
projecting leg portions 232 engage the annular groove 180, thereby 
securing the male connector assembly 206 to the female connector assembly 
186. 
An insulator boot 223 is also provided which is used for insulating 
adjacent male and female contacts 219 and 198 when the female connector 
assembly 186 is inserted into the male connector assembly 206. The 
insulator boot 223 has a radially extending projection 224 which is able 
to mate with the radially extending projection 216 of the first hinged 
portion 208 and the radially extending projection 216 of the second hinged 
portion 210. Accordingly, electrical wiring 226 carrying current from a 
source of electrical potential is able to pass through the radial 
extending projection 224 of the insulator boot 223 and thereby allowing 
contact between the leads of the electrical wiring 226 and the male 
contacts 219. The insulator boot 223 may preferably be made from 
Santoprene thermoplastic rubber, though it is to be understood that other 
suitable materials may be used. 
During assembly, the flex cable 194 is fed through the axially extending 
passage 172 in the piston rod 138 and through the axially extending 
passage 176 of the annular adapter shaft portion 170. The flex cable 194 
is then passed through the end 190 of the female connector assembly 186 so 
that the leads of the flex cable 194 may be soldered to the female 
contacts 198 which have been press fit into the axially extending grooves 
196 of the female connector assembly 186. The female connector assembly 
186 is then inserted into the axially extending passage 176 of the annular 
adapter shaft portion 170 in such a manner that the anti-rotation key 204 
is disposed within the axially extending anti-rotation slot 184 of the 
annular adapter shaft portion 170. In addition the flexible locking beam 
205 is then disposed in the aperture 182 of the annular adapter shaft 
portion 170 so as to secure the female connector assembly 86 to the 
annular adapter shaft portion 170. 
After the electrical wiring 226 has been inserted through the radially 
extending projection 224 of the insulator boot 223, the leads of the 
electrical wiring 226 are attached to the male contact 219 which have been 
stake fit into the axially extending projections 214 in the interior 
surface of the annular body 212 After the second hinged portion 210 is 
closed over the first hinged portion 208, the male connector assembly 206 
is displaced toward the annular adapter shaft portion 170 so as to cause 
the projecting leg portions 132 of the connector mating locking beams 230 
to engage the annular groove 180. If the male connector assembly 228 is to 
be removed, the connector mating locking beams 230 are depressed at a 
portion away from the shock absorber 10 thereby causing the projecting leg 
portions 232 to be removed from the annular groove 180 so as to cause 
disengagement of the male connector assembly 206 from the annular adapter 
shaft portion 170. 
In accordance with another embodiment of the present invention, as depicted 
in drawings 11-20, a means for preventing rotation between the above 
described connector assemblies is provided wherein the contact elements 
within the connector assemblies remain in electrical communication 
regardless of the harsh environmental conditions surrounding the 
connectors. 
As stated above, to provide a first means for electrically accessing the 
components inside the shock absorber 10, a female connector assembly 250 
is provided. The female connector assembly 250 includes a reduced diameter 
portion 251 which, when assembled, is located within a radially extending 
passage 72 within the shock absorber 10 so as to allow a flex cable 94 
inside the axially extending passage 74 to enter the female connector 
assembly 250. 
The female connector assembly 250 is formed in two annular portions 248 and 
249 which are connected by a hinge 255. The hinge 255 allows the annular 
portion 249 to be separated from the annular portion 248 to provide access 
to contact elements 260, described below, disposed within the female 
assembly 250. Once the flex cable 94 is attached to the contact elements 
260 located within the female connector 250, the annular portion 249 is 
angularly displaced about the hinge 255 so that the annular portion 249 
closes about the annular portion 248. By closure of the annular portion 
249 about the annular portion 248, the female connector assembly 250 is 
able to provide strain relief for the flex cable 94 so as to minimize the 
possibility that the leads of the flex cable 94 will become detached from 
the contact elements 260. 
The female connector assembly 250 also comprises an anti-rotation key 253 
which radially extends from the female connector assembly 250. The 
anti-rotation key 253 mates with an axially extending anti-rotation slot 
84 in the annular adapter shaft 70 to prevent rotation of the female 
contact assembly 260 during use. 
The female connector assembly 250 has a cavity 252 formed within an axially 
disposed surface. In accordance with the present embodiment, the cavity 
252 is defined by a substantially circular cross-sectional surface 254 
axially extending through the interior of the female connector assembly 
250 with a wedge-shaped protrusion 256 extending radially inward and 
axially through the cavity 252. The cavity 252 is further defined by 
hollowed-out leg portions 258 radially extending beyond the radius of the 
circular portion 254 of the cavity 252 along each side of the wedge-shaped 
protrusion 256. An end view of the female assembly showing the 
configuration of cavity 252 is given in FIG. 11. 
A plurality of female contact elements 260 are disposed radially about the 
circular portion of the cavity 252. The contact elements 260 more 
particularly comprise female tuning fork contact elements 260, as shown in 
FIGS. 12 and 13. The contacts 260 are axially extended through the female 
assembly 250 and can either be molded within the insulated material during 
manufacturing or stake-fit within axially extending grooves 259. 
The tuning fork element 260 has a forked end member 261 comprising two 
axially extending arm sections 262 separated by a void 263 within which 
extend tab portions 264 which engage the male contact elements, as 
described below The tuning fork element 260 also includes an offset 
portion 265 to accommodate the reduced diameter portion 251 of the female 
connector assembly 250. The flex cable 94 is electrically connected to the 
offset portion 265, which is easily accessible when the female connector 
250 is in an open position. The tuning fork contact element 260 further 
has notches 266 which grips the electrically insulated material within the 
female connector 250. The offset portion 265 has a substantially square, 
tapered end profile 267, as shown in FIG. 14. FIG. 14 is a view of the end 
profile of the female connector assembly 250 which is inserted within the 
radially extending passages 72 and connected with the flex cable 94. While 
the contacts may be made from tempered phosphor bronze with tin plating 
and copper flash, other suitable materials may be used. 
To provide second means for electrically accessing the components in the 
shock absorber a male connector assembly 270 is provided. The male 
connector assembly 270 includes a first hinged portion 272 and a second 
hinged portion 271. The first hinged portion 272 comprises an annular body 
with a sufficient inside diameter to receive the female connector assembly 
250. The annular body includes a centrally located, axially extending 
protrusion 274 which has a cross-sectional profile substantially identical 
to the cross-sectional profile of cavity 252 within the female connector 
assembly 250 shown in FIG. 11. FIG. 15 shows the end view of the male 
connector assembly 270 within which the female connector 250 is inserted. 
Radially disposed about the center protrusion 274 are contact element 
channels 276 which axially extend through the annular body 272. The 
contact element channels 276 align with the female contact elements 260 
within the female connector 250 upon assertion of the central projection 
274 of the male connector assembly 270 into the cavity 252 of the female 
connector assembly 250. Once the male connector assembly 270 is connected 
with the female connector assembly 250, the cavity 252 in the female 
connector assembly 250 mechanically communicates with the central 
protrusion 274, preventing rotation between the male and female 
connectors. When the two connectors are connected, male contact elements 
280 are inserted within the contact element channels 276 in the annular 
body of the male contact assembly 270. 
The male contact element 280 has a first and second end portion, the first 
end portion having a sloped and tapered, knife-like edge 282 which is 
seated within the forked member 262 of the tuning fork element 260 in the 
female connector assembly 250 when in use. The tapered end 282 separates 
the arm sections 262 and allows the tab portions 264 to maintain a 
constant contact with the body 284 of the male connector element 280, 
hence insuring the electrical connection even during the most adverse 
conditions. The second end portion of the male connector element 280 
comprises an offset tab portion 288 at approximately a 90.degree. angle to 
the body of the element with annular void 290 disposed therein. This tab 
288 allows insertion and removal of the element 280 within the element 
channels 276 and further provides contact for electrical wiring (not 
shown) carrying current from a source 125 of electrical potential FIG. 18 
is an end view of male connector 270 with the male contact elements 280 in 
channels 276. Thus, current is carried through the electrical wiring (not 
shown) to the male contacts 280 that are inserted within the contact 
element channels 276 to come into contact with the tuning fork elements 
260 which are connected to the flex cable 94. 
The present invention has been described in an illustrative manner, and it 
is to be understood that the terminology which has been used is intended 
to be in the nature of words of description rather than of limitation. It 
will be seen that the present invention enables the electrical components 
in the shock absorber to receive current from a source of electrical 
potential, as well as enabling data from electrical components inside the 
shock absorber to be delivered to processing electronics located outside 
the shock absorber. Further, because the electrical connectors of the 
present invention is compact and is of reduced length, the present 
invention is less likely to interfere with the other components of the 
automobile. In addition, by providing a hinged female connector, the 
present invention is able to provide strain relief for the flex cables 
used to carry electrical signals to and from the electrical components in 
the shock absorber. The present invention is able to operate under harsh 
environmental conditions and is able to resist impact of road debris. 
Further, the present invention incorporates similar components in each 
embodiment. 
Obviously, many modifications and variations of the present invention are 
possible in light of the above teachings. For example, the invention may 
be used to allow data from the electrical components inside a shock 
absorber to be delivered to processing electronics located outside the 
shock absorber or vice versa so that the data may be evaluated. Further, 
the piston 36 may be similar to a full displacement 32 millimeter piston 
available from Monroe Auto Equipment Company, though having an outside 
diameter of 35 millimeters. In addition, the insulator boot may be 
overmolded into the male connector assembly. It is, therefore, to be 
understood that within the scope of the appended claims, the present 
invention may be practiced otherwise than as specifically described.