BREAKAWAY ELECTRICAL CONNECTOR

A breakaway electrical connector is provided that includes a line side and a load side. The line side that is connectable to a line conductor, while the load side is connectable to a load conductor. The line side has a first magnet and a first plurality of contacts. The load side has a second magnet and a second plurality of contacts. The first and second magnets provide a magnetic connection force to maintain the line and load sides connected to one another with the first and second plurality of contacts electrically coupled to one another.

BACKGROUND

1. Field of the Invention

The present disclosure is related to electrical connectors. More particularly, the present disclosure is related to breakaway electrical connectors.

2. Description of Related Art

It is becoming common for vehicles such as, but not limited to tractor trailers, trains, campers, load trailers, and others, to have a temporary need for a supply of electrical power provided by something other than the engine of the vehicle that is supplying the driving power.

For example, refrigerated tractor trailers often have a need to power the refrigerators to maintain the cargo in a refrigerated state, while the truck is stopped as can occur at loading/unloading locations or when stationary during a driving break. In another example, camping trailers often have a need to power one or more consumer devices (lights, HVAC, etc.) when the camping trailer is a stationary location.

In order to maintain greenhouse gas emissions at a minimum, it is also common for such locations to have prohibitions against idling—namely require the user to stop the vehicle engine to prevent un-necessary use of fuels, while mitigating the amount of associated exhaust gases.

Many of these locations provide a power source, which allows the trailer to connect while stopped. These power sources typically involve an outlet or other plug for temporary connection by the trailer. These connections can be damaged in the event of an accidental drive off, namely when the trailer is moved without disconnection from the outlet or plug.

Accordingly, it has been determined by the present disclosure that there is a need for breakaway electrical connectors that overcome, alleviate, and/or mitigate one or more of the aforementioned and other deleterious effects of prior the art.

SUMMARY

A breakaway electrical connector is provided that includes a line side and a load side. The line side that is connectable to a line conductor, while the load side is connectable to a load conductor. The line side has a first magnet and a first plurality of contacts. The load side has a second magnet and a second plurality of contacts. The first and second magnets provide a magnetic connection force to maintain the line and load sides connected to one another with the first and second plurality of contacts electrically coupled to one another.

In some embodiments either alone or together with any one or more of the aforementioned and/or after-mentioned embodiments, the first and second magnets are arranged so that the first plurality of contacts can only be electrically coupled to the second plurality of contacts in a defined pattern.

In some embodiments either alone or together with any one or more of the aforementioned and/or after-mentioned embodiments, the first plurality of contacts each include a front portion, a rear portion, and a biasing member. The rear portion is connectable to the line conductor. The front portion is movable with respect to the rear portion along a connection axis. The biasing member normally biases the front and rear portions apart to define an air gap therebetween.

In some embodiments either alone or together with any one or more of the aforementioned and/or after-mentioned embodiments, the first plurality of contacts are configured so that the air gap of a first of the first plurality of contacts closes before the air gap of a remainder of the first plurality of contacts.

In some embodiments either alone or together with any one or more of the aforementioned and/or after-mentioned embodiments, the magnetic connection force is lower than a pull-apart strength of the line side and the load side.

In some embodiments either alone or together with any one or more of the aforementioned and/or after-mentioned embodiments, the line side has a first fitting configured to connect to the line conductor and the load side has a second fitting configured to connect to the load conductor. The magnetic connection force is lower than a pull-apart strength of the first and second fittings.

In some embodiments either alone or together with any one or more of the aforementioned and/or after-mentioned embodiments, the first magnet and the second magnet are multiple pole magnets.

In some embodiments either alone or together with any one or more of the aforementioned and/or after-mentioned embodiments, the first and second magnets each have polarities arranged so that the first plurality of contacts can only be electrically coupled to the second plurality of contacts in a defined pattern.

In some embodiments either alone or together with any one or more of the aforementioned and/or after-mentioned embodiments, the first magnet is a plurality of first magnets and the second magnet is a plurality of second magnets.

In some embodiments either alone or together with any one or more of the aforementioned and/or after-mentioned embodiments, the first and second plurality of magnets are arranged so that the first plurality of contacts can only be electrically coupled to the second plurality of contacts in a defined pattern.

DETAILED DESCRIPTION

Referring to the drawings and in particular with simultaneous reference toFIGS.1-5, an exemplary embodiment of a breakaway electrical connector according to the present disclosure is shown and is generally referred to by reference numeral10.

Connector10includes a line side12and a load side14connected to line conductor16and a load conductor18, respectively. In the illustrated embodiment, sides12,14each have a water-tight compression fitting20for connection to conductors16,18. Fitting20allows sides12,14to be wired directly to the existing conductors16,18on vehicles and stationary power supplies.

Of course, it is contemplated by the present disclosure for sides12,14to be connected to conductors16,18in any desired manner.

Connector10includes one or more magnets22arranged on each of line side12and load side14. In the illustrated embodiment, sides12,14each have four magnets22. Of course, it is contemplated by the present disclosure for sides12,14to have more or less than four magnets22each.

Advantageously, connector10provides an industrial grade, horsepower rated connector with sides12,14that are magnetically secured to one another via magnets22with a magnetic force that can be disconnected or broken apart when sufficient axial and/or transverse loading—such as can occur in accidental drive off situations—without damage to either side12,14, conductors16,18, or fittings20.

Stated differently, the magnetic connection provided to connector10by magnets22is sufficient to maintain sides12,14connected to one another during normal operation, but this magnetic connection is less than the pull-apart strength of sides12,14and of fittings20, as well as being less than a tensile strength of conductors16,18. As used herein, the term “pull-apart strength” shall mean the strain relief limits of fittings20.

In the illustrated embodiment, connector10is shown as a four-contact connector where line and load sides12,14each have a ground contact24, a neutral contact26, and one or more hot contacts28,30(two shown).

Of course, it is contemplated by the present disclosure for connector10to be configured with any desired configuration of contacts. Moreover, it is contemplated by the present disclosure for connector10to be configured for use with one or more different voltages such as, but not limited to, voltages from 12 to 480.

Connector10can include one or more alignment features.

In some embodiments, line side12can have a guide opening32and load side14can have a corresponding guide protrusion34. Opening32receives protrusion34so as to align line side12and load side14to one another during assembly. In the illustrated embodiment, opening32and protrusion34are shown centrally arranged in sides12,14, respectively and have symmetrical configurations with four sides arranged in a cross-shape.

Of course, it is contemplated by the present disclosure for opening32and protrusion34to have any desired configuration. For example, opening32and protrusion34can have non-symmetrical shapes and/or can be non-concentrically arranged. In these embodiments, the shapes and/or arrangement of opening32and protrusion34can ensure proper connection of line side12and load side14to one another via alignment of contacts24,26,28,30.

In some embodiments either alone or in combination with opening32and protrusion34, connector10can be configured so that the arrangement of magnets22provide, in addition to the aforementioned magnetic connection force, alignment of contacts24,26,28,30.

The alignment via magnets22can be seen with reference to the end views of sides12,14shown inFIGS.3and5. The polarity of the magnets22have been arranged in a manner that sides12,14can only be assembled such that contacts24,26,28,30of the two sides are properly mated.

For example, sides12,14can be configured such that magnets22having a positive or southern polarity are arranged on the left-hand side of ground and neutral contacts24,26, while the magnets having a negative or north polarity are arranged on the right-hand side of ground and neutral contacts24,26.

Due to this exemplary arrangement of magnets22with respect to ground and neutral contacts24,26, the magnets22would repel sides12,14from one another during attempts to assembly connector10such that side12with ground24at the top and neutral26at the bottom to side14with neutral26at the top and ground24at the bottom. Further, this exemplary arrangement of magnets22with respect to ground and neutral contacts24,26, results in the magnets22attracting sides12,14towards one another during attempts to assembly connector10such that sides12,14both having ground24at the top and neutral26at the bottom.

Of course, the present disclosure contemplates other arrangements of magnets22and contacts24-30with respect to one another that ensures the desired alignment of the contacts on sides12,14.

In some embodiments either alone or in combination with the alignment capability provided by opening32/protrusion34and/or magnets22, connector10can be configured so that one or more of contacts24-30can function as alignment features.

The alignment via contacts24-30can be seen with reference to the perspective views of sides12,14shown inFIGS.2and4. Here, it can be seen that contacts24,26,28,30on load side14protrude or extend outward, while the contacts on the line side12are recessed inward.

The recessed contacts24-30of line side12are configured to receive the protruding contacts24-30of load side14so as to align the line and load sides to one another during assembly.

In the illustrated embodiment, the recessed and protruding contacts24-30are shown having a common size and shape. Of course, it is contemplated by the present disclosure for only the contacts on sides12,14that are intended to mate with one another to have a common shape to provide further alignment assurance.

As shown, connector10is configured so that line side12includes opening32and recessed contacts24-30—which correspond to an outlet, while load side14includes protrusion34and protruding contacts24-30—which correspond to a male plug. In this configuration, connector10is configured to provide a familiar look and feel to normal outlets and plugs.

Line side12is connected to a power source and, thus, can present a hazardous condition much like an electrical outlet if one were to contact one or more of contacts24-30. Thus, the recessed nature of contacts24-30on line side12can provide a degree of safety to prevent inadvertent electrical communication with the contacts.

Of course, it is contemplated by the present disclosure for the recessed and protruding components to be formed on sides12,14in any desired manner.

In some embodiments, connector10can be configured to provide for a specific order of connection among contacts24,26,28,30.

For example, connector10can be configured so that ground contacts24on sides12,14mate before any of the remaining contacts26,28,30mate with one another. Further, connector10can be configured so that neutral contacts26on sides12,14mate after ground contacts24are mated, but before hot contacts28,30mate. Finally, connector10can be configured so that hot contacts28,30on sides12,14mate after ground and neutral contacts24,26are mated with one another, respectively.

Connector10is further configured to so that this order of mating (i.e., ground first, neutral second, and hot last) occurs in reverse during disconnection of line and load sides12,14.

Accordingly, connector10can be configured so that the distance each pair of mating contacts are recessed in and/or protrude from line and load sides12,14, respectively, provide the desired ordered mating of contacts24-30.

In some embodiments, connector10can be leave one or more of the contacts24-30on line side12unenergized until at least partially mated with load side14. In this manner, line side12is presented with a dead front end—namely with one or more of contacts24-30in a de-energized state—until the line side is mated with load side14.

The specific order of mating of contacts24-30and the dead front end of line side12are described in more detail with simultaneous reference toFIGS.6-9.

Connector10is shown inFIGS.6-8via a first cross section that passes through ground contact24and neutral contact26such that the order of mating and dead front end of connector10are discussed with respect to contacts24,26. Connector10is shown inFIG.9via a second cross section, taken ninety degrees from the first cross section ofFIGS.6-8, that passes through hot contacts28,30.

FIG.6illustrates connector10in a normal or disconnected state. Here, guide protrusion34of load side14is being received in guide opening32into line side12so as to start the mating of the line and load sides—while none of the contacts24,26,28,30have yet mated with one another.

Ground contact24has a front portion24a, a rear portion24b, and a biasing member24c. Front portion24ais positioned for connection with the corresponding ground contact24of load side. Front portion24ais movable along an axis of the mating movement of connector10and is normally biased by biasing member24caway from rear portion24b. Rear portion24bis operatively connected to supply conductor (not shown) and, thus, is energized by the supply conductor.

In the normal position shown inFIG.6, biasing member24cforms an air gap24dbetween front and rear portions24a,24bof ground contact24. Biasing member24cis electrically isolated from at least one—and preferably both—front and rear portions24a,24bof ground contact24. In this manner, ground contact24is configured so that electrical energy cannot be conducted from rear portion24bto front portion24ain the normal position.

Neutral contact26is similarly constructed and, thus, also has a front portion26a, a rear portion26b, and a biasing member26cthat result in an air gap26dbetween the front and rear portions in the normal position ofFIG.6.

Although not shown, hot contacts28,30are also similarly constructed and, thus, have an air gap between the front and rear portions in the normal position ofFIG.6.

As shown, the front portions24a,26aof contacts24and26(as well as the unshown contacts28,30) on line side12, although connected to the supply conductor, are not energized—providing the line side of connector10with a “dead front end”.

Here, ground contact24of line side12and ground contact24of load side14have contacted with one another. It can be seen that the force of contacts24of line and load sides12,14on one another has compressed biasing member24cto the point where air gap24dhas been closed with front and rear portions24a,24bof ground contact24of the line side in electrical contact with one another. This position places the front portion24ain electrical communication with the supply conductor through rear portion24band places front portion24ain electrical communication with the corresponding ground contact24on load side14.

It can also be seen that air gap26dof neutral conductor26remains—with front and rear portions26a,26bof the neutral contact26electrically isolated from one another, such that the front portion26ais electrically isolated from supply conductor.

Air gap26dremains due to one or more dimensions of connector10.

In one embodiment, line side12can be configured such that neutral contact26is recessed more as compared to ground contact24. In other embodiments, load side14can be configured such that ground contact24protrudes more as compared to neutral contact26. In still other embodiments, line side12can be configured such that air gap24dof ground contact24is smaller than air gap26dof neutral contact26.

Of course, it is contemplated by the present disclosure for connector10include one or more of these or other dimensional constraints sufficient to ensure that during mating of line and load sides12,14the front and rear portions24a,24bmate prior to the front and rear portions26a,26b.

Although not shown, it can be appreciated that since hot contacts28,30are also similarly constructed, these hot contacts also still have an air gap between the front and rear portions in the partially connected state ofFIG.7.

FIG.8illustrates connector10in a second partially connected state, namely after mating of ground contacts24and neutral contacts26.

Here, it can be seen that biasing member26chas also been compressed to a point where air gap26dhas been closed with front and rear portions26a,26bof neutral contact26in electrical contact with one another. This position places the front portions24a,26ain electrical communication with the supply conductor through rear portions24b,26band places front portions24a,26ain electrical communication with the corresponding ground and neutral contacts24,26on load side14.

FIG.9illustrates connector10in a connected state, namely after mating of ground contacts24, neutral contacts26, and hot contacts28,30.

Biasing members28c,30chave also been compressed to a point where the respective air gaps have been closed with front and rear portions hot contacts28,30in electrical contact with one another, respectively. To provide the aforementioned front dead end, connector10is configured so that the air gaps of hot contacts28,30are closed after air gap26dof neutral contact26.

Disconnection of line and load sides12,14is the reversal of the above-described process, where hot contacts28,30reform the respective air gaps prior to neutral contact26, which in turn reforms its air gap prior to ground contact24.

In some embodiments, one or more of contacts24,26,28,30are recessed in a manner so as to form an insulating shield around the contact so that in the event of arcing at the air gaps during connection and disconnection are protected.

It should be recognized that connector10is illustrated by way of example only as having multiple magnets22on each of line and load sides12,14. However, it is contemplated by the present disclosure for connector10to include embodiments having a single magnet122on each side12,14. Magnet122is described in more detail with reference toFIG.10.

Magnet122is illustrated as a two-pole magnet—namely having both a positive or southern polarity and a negative or northern polarity. Connector10can be configured to have one magnet122on line side12and one magnet122on load side14. The magnets122are positioned on sides12,14with the polarity arranged in a manner that the sides can only be assembled with contacts24,26,28,30of the two sides properly mated. As shown, one magnet122(left hand side ofFIG.10) can have the southern polarity at the top and the other magnet122(right hand side ofFIG.10) can have the southern polarity at the bottom.

Of course, it is contemplated by the present disclosure for sides12,14to have the single magnets122with other arrangements that ensure contacts24,26,28,30of the two sides are properly mated. Moreover, it is contemplated by the present disclosure for connector10to have more that one magnet122on each side12,14and/or to include a combination of single pole magnets22and multipole magnets122.

Connector10provides the advantage of eliminating of costly and untimely repairs of damaged electrical wiring systems due to accidental drive off while sides12,14are connected. Connector10further provides these benefits together with an easy to mate configuration, which provides multiple levels of security to eliminate incorrect mating of the line to the load, yet can break away under excessive stress.