Abstract:
A wiring harness electrical connector is provided having a detachable and re-attachable mounting system to permit the attachment of the connector on a frame surface of a semi-trailer, or workpiece, from the rear or interior side of the of the frame or workpiece without disruption to the integrally formed and moisture proof encasing of the connector.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims priority to U.S. Provisional Application No. 61/359,189 filed Jun. 28, 2010 and titled Power Input Electrical Connector. 
     
    
     FIELD OF THE INVENTION 
       [0002]    This application relates to the field electrical connectors. More particularly, this application relates to connectors used to connect the electrical wiring harnesses of over-the-road trailers, and in particular, trailers connected in double trailer arrangement. 
       BACKGROUND OF THE INVENTION 
       [0003]    Semi-trailer tractor trucks also known as a semi, or tractor-trailer, will frequently be configured to tow a second semi-trailer behind the first in a configuration known as a “double trailer”. In such a configuration it is necessary that the tail lamps, running lamps, brake lights, and signal lights of the towed trailer be connected into the tractor so proper illumination and turn and brake signals are operating on the rear-most trailer. This is typically accomplished by providing a wiring harness that travels the length of the first trailer to communicate electrical signals generated by the tractor to the rear-most trailer. The wiring harness allows the rear-most trailer to be connected into the electrical system of the tractor thereby receiving the electrical impulses that cause illumination of the tail lamps, running lamps, brake lights, and signal lights of the towed trailer. The wiring harness must be affixed to the trailer and at the front and/or rear of the trailer. The end terminal or socket of the wiring harness must be installed into a portion of the frame of the trailer. Generally, such installation comprises the placement of the receptacle or socket (typically known as an SAE standard J560 connector) within a round hole or void that has been made in a front or rear metal frame piece of the trailer. It will be appreciated that a first end of the wiring harness has an electrical connector located in an opening on the forward facing surface of the trailer, (or workpiece) and is commonly referred to as the “Nose Plug.” A second electrical connector is located in an opening on the rearward facing surface of the trailer and may be referred to as the “Tail Plug.” Both plugs or receptacle or sockets are defined in SAE specification J560. The connector at the rear of the trailer is suitable for connecting another tandem trailer and serves as the power output connector to the trailer in-tow or dolly in-tow. 
         [0004]    The challenge in trailer wiring is ensuring a waterproof seal at the trailer&#39;s power connector. The electrical connector is exposed to all forms of weather and highway driving speeds and vibrations. This environment and these conditions make it essential that any connector be sealed against the elements and that the integrity of such sealing against the elements be maintained during installation to avoid corrosion of the connector and wiring harness. Generally, this requirement for excluding moisture and dirt has resulted in wiring harnesses that are fully formed with integral receptacles or socket and with molded plastic covers that extend the length of the wiring harness and the receptacles. Therefore, installation of a wiring harness requires either insertion of one end of the harness through a mounting hole in the trailer frame and pulling the 30 to 60 feet of wire through the hole or having a connector that can be mounted in the hole from the back-side of the hole. The first of these installation methods can result in the scraping and cutting of the wiring harness on the edges of the metal in which the hole or void is made. 
         [0005]    Therefore, it would be beneficial to have a receptacle or socket that allows for rear installation of the socket onto the trailer frame to avoid pulling the whole of the wiring harness through the hole in the trailer frame. It would be a further benefit if the socket is integrally sealed against moisture with the wires or electrical leads that are attached to the connector. It would be a further benefit if the means for attaching the connector avoids the creation of entry points for moisture of areas that will retain moisture and lead to corrosion of the electrical components and connections of the socket or connector. 
       SUMMARY OF THE INVENTION 
       [0006]    The present electrical connector comprises a standard J560-type receptacle or connector with a sealed, molded plastic unitary cover that extends over the length of the wire bundle and over the connector body to provide a moisture proof housing. The front of the connector is provided with surrounding collar that is separable into at least two segments, a detachable retaining clip segment and a non-detachable lip segment. The detachable retaining clip, when removed, reduces the overall dimension of the connector exterior to permit the insertion of the connector through a hole, void or opening in a trailer frame that is dimensioned to receive a SAE standard J560 connector therein. Once the non-detachable lip segment of the connector is inserted through the hole, void or opening in the trailer frame the retaining clip may be reattached to form a collar to retain and secure the connector within the a hole, void or opening and to the trailer frame. 
     
    
     
       DESCRIPTION OF THE DRAWINGS 
         [0007]    Preferred embodiments of the invention, illustrative of the best modes in which the applicant has contemplated applying the principles, are set forth in the following description and are shown in the drawings and are particularly and distinctly pointed out and set forth in the appended claims. 
           [0008]      FIG. 1  shows a front and right side perspective view of the assembled electrical connector having the retainer clip  12  in position on the connector body to form a collar; 
           [0009]      FIG. 2  is a cross-section view taken along line  2 - 2  of  FIG. 1  and showing retainer clip  12  in position on connector body  14  with terminals  16  inserted into apertures  18  of connector body  14  and showing a wiring harness  20  having conductors  22  extending therefrom and connecting with terminals  16  surrounding wiring harness  20  and connector body  14  is over-mold cable retainer  24 ; 
           [0010]      FIG. 3  is a front and right side perspective view of electrical connector  10  in a partially exploded view showing retainer clip  12  separated from connector body  14  and showing electrical connector  10  in an installed environment in which a void or hole  26  is provided in a work piece  28  and connector body  14  is passed through void  26  to then allow installation of retainer clip  12  on the opposite side of the bulkhead from cable retainer  24 ; 
           [0011]      FIG. 4  shows a rear and left side perspective view of the connector body  14  of  FIG. 1  with the terminals wiring harness retainer clip and cable retainer removed and showing the seven apertures  18  of one embodiment for receiving terminal  16  therein and showing cavity  30  on connector body  14 , which receives finger  32  that projects from retainer clip  12  (see  FIG. 3 ) and showing shoulder  34  which contacts retainer clip  12  to support retainer clip  12  and showing seating trough  36  on connector body  14 , which receives ridge  38  of retaining clip  12  therein to assist in retaining connector body  14  within void  26  of bulkhead  28 . Also shown are grooves  40  at the rear of apertures  18 , which receive terminal retention tabs  42  of terminal  16  therein; 
           [0012]      FIG. 5  shows a front elevation view of connector body  14  showing apertures  18  therein which receive terminals  16  and showing flange receivers  44  therein which receive spring flanges  46  of terminal  16  to prevent rearward movement of terminal  16  within connector body  14 . Access voids  48  are shown which allow the plastic material that forms over-mold cable retainer  24  to flow through connector body  14  during formation of the over-mold cable retainer; 
           [0013]      FIG. 6  shows a front top and left side perspective view of retainer clip  12  with securing apertures  50  therein; 
           [0014]      FIG. 7  shows a rear bottom and right side perspective view of retainer clip  12 ; 
           [0015]      FIG. 8  shows a front top and right side perspective view of terminal  16 ; 
           [0016]      FIG. 9  shows a front and left side perspective view of electrical connector  10  with retaining clip  12  removed; and 
           [0017]      FIG. 10  shows a front and right side exploded view of electrical connector  10  and also showing connector seal  52  which is formed simultaneously with the formation of over-mold cable retainer  24  as plastic material forming over-mold cable retainer  24  is forced through access voids  48  in connector body  14 . 
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0018]    As required, detailed embodiments of the present inventions are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure. 
         [0019]    Referring now to  FIG. 1 , electrical connector  10  is shown completely assembled but not shown installed as it would be for use in a structure requiring an electrical connector. Electrical connector  10  is generally comprised of a retainer clip  12  which connects to a connector body  14  with the retainer clip  12  being removable and installable as needed to permit insertion of connector body  14  through an aperture or hole in a structure such as a truck trailer. 
         [0020]    Referring now to  FIG. 10 , the component parts of electrical connector  10  and their relationships to one another will be described. In  FIG. 10 , electrical connector  10  is shown in an exploded view. Connector clip  12  is shown space above the position it connects to on connector body  14 . Terminals  16  are shown just prior to their insertion into terminal apertures  18  of connector body  14 . A wiring harness  20  having conductors  22  is shown in position for connection to terminals  16 . Over-mold cable retainer  24  is shown removed from connector body  14  and connector seal  52  is shown separated from connector body  14 . It will be appreciated by those skilled in the art that after the assembly of wiring harness and conductors  22  to terminal  16  and the insertion of terminal  16  into connector body  14  that a liquid plastic material is then injected into a mold form containing the connector body and the terminals and the wiring harness. A liquid plastic material is injected to form the shape of over-mold cable retainer  24 . During the formation process of over-mold cable retainer  24 , a portion of the injected liquid plastic is allowed to pass through access voids  48  in connector body  14  (best seen in  FIG. 5 ) to provide the formation of connector seal  52  simultaneously with the formation of over-mold cable retainer  24 . Therefore a simultaneously molded unitary structure comprised of over-mold cable retainer  24  and connector seal  52  is constructed. It will be appreciated by those skilled in the art that the presence of connector seal  52  prevents moisture and debris from coming in contact with the terminals of electrical connector  10  when a complementary male connector is inserted into the female electrical connector  10  shown in the present embodiment. 
         [0021]    Referring now to  FIG. 2 , the construction of electrical connector  10  is shown in cross-section view wherein it may be seen that terminals  16  are inserted into apertures  18  which are provided within connector body  14 . As will be discussed hereinafter, terminal  16  are securely mounted within apertures  18  and structures are present to prevent both rotation of  16  within apertures  18  and the rearward movement of terminals  16  out of apertures  18  after the insertion of terminal  16  into the back end or rear of connector body  14 . It is shown in  FIG. 2  that conductors  22  are connected to terminal  16  with such connection being made by soldering or welding connectors  22  to the surface of a flat spade extension from the rear of terminal  16 , or alternatively, conductor  22  may be crimped into connection with terminal  16  using a crimp connection  54  as is shown in  FIG. 8 . 
         [0022]    Still referring to  FIG. 2 , conductors  22  are contained within wiring harness  20  which serves to maintain the seven conductors of the present embodiment in a single manageable group. Retainer clip  12  is shown in position on connector body  14  in  FIG. 2  and the entirety of connector body  14  having terminal  16  therein with conductors  22  connected thereto and the wiring harness grouping of conductors  22  all being surrounded by the plastic of over-mold cable retainer  24  as a result of the injection molding process to produce over-molding cable retainer  24  and connector seal  52 . 
         [0023]    Referring now to  FIG. 3 , the method of use and installation of electrical connector  10  will be described. One typical use of electrical connector  10  is to install the electrical connector into a pre-existing wall or bulkhead of a vehicle such as a truck trailer. In a typical application, electrical connectors of the type to which electrical connector  10  belongs are installed in tandem tractor-trailer configurations wherein power and signal light and brake light connections must be communicated from a first trailer to a second trailer. In view of the long length of the wiring harnesses used in such an application and the need to have a weather resistant cable connection it is advantageous to avoid feeding a long length of wiring harness through an aperture. Also, it is advantageous to avoid disassembly of the electrical connector to install it on the vehicle or bulkhead or workpiece involved. The reason for this will be apparent to those skilled in the art. The feeding of long lengths of wiring harness through apertures can result in the scraping of the covering of the wiring harness and potential cutting of the wiring harness and insulating material around conductors thereby compromising the integrity of the wiring harness. The assembly and disassembly of the electrical connector to permit its mounting on the vehicle or workpiece will compromise the weather resistant nature of the assembly such assembly and disassembly requires removable parts with connecting crevices which can permit the intrusion of dirt and moisture into the device thereby compromising the quality of the electrical connections. Therefore, the present structure is designed with these issues in mind to provide a complete sealed integrally formed structure which does not require assembly or disassembly of the electrical connector and related components for installation into the workpiece or vehicle. Further, the manner of installation avoids the need to feed the entire length of wiring harness through an aperture which may have sharp edges which could scrape and cut and compromise the quality of the insulation on the conductors. 
         [0024]    In  FIG. 3 , a workpiece or bulkhead or vehicle surface  28  is shown in broken lines indicating it to be environmental structure. Also is shown a void or hole or aperture  26  in the workpiece which is sized to permit the passage of connector body  14  of electrical connector  10  there-through once retaining clip  12  has been removed from connector body  14 . Also shown in  FIG. 3  are secondary voids  56 , which permit insertion of a fastener therethrough to enable securing of electrical connector  10  to bulkhead  28  once installation and assembly of electrical connector  10  is complete. Upon insertion of electrical connector  10  (without retaining clip  12 ) through void  26  in bulkhead  28 , lip  58  extending downwardly from the bottom of connector body  14  becomes positioned on the opposite side of the void  26  from the remainder of connector body  14 . Lip  58  serves to properly orient connector body within void  26  to position the structures of connector body  14  which connectably mate with retaining clip  12  on the outside of the void  26 . It will be noted that for purposes of this description, the location “outside the void” will be taken to mean on a first side of the bulkhead  28  in which the void  26  is established and the phrase “inside the void” will mean the position on a second side of bulkhead  28 . Upon seating of lip  58  outside void  26 , and on a first side of bulkhead  28 , it will be possible to connect retainer clip  12  to those portions of connector body  14 , which also are positioned outside of void  26  by the seating of lip  58  against bulkhead  28  outside of void  26 . These additional parts and features of connector body  14  will be described hereinafter in detail, but they generally can be described as those features of connector body  14  which are adapted to receive therein retainer clip  12  and to mate with structures on retaining clip  12  to seat and lock retainer clip  12  to connector body  14  and thereby to seat and lock electrical connector  10  within void  26  on bulkhead  28  with certain features of electrical connector  10  outside void  26  and certain features of electrical connector  10  inside void  26 . 
         [0025]    As may be seen in  FIG. 3 , the features that are generally inside void  26  on a second side of bulkhead  28  are over-mold cable retainer  24  and wiring harness  20  and conductors  22  and terminal  16  and terminal apertures  18  and the features that are outside void  26 , on a first side of bulkhead  28 , are retaining clip  12 , lip  58 , seating trough  36 , cavity  30  and shoulder  34  of lip  58 . Once connector body  14  has been positioned as previously described in void  26 , bulkhead  28  and retaining clip  12  is attached to connector body  14 , the resultant structure will appear as is shown in  FIG. 1  (however  FIG. 1  does not show the environmental structure of  FIG. 3 ). It will be appreciated by those skilled in the art that securing apertures  50  of retaining clip  12  align with secondary voids  56  of bulkhead  28  to permit passage of a fastener therethrough to complete the installation of electrical connector  10  on bulkhead  28  of a vehicle or trailer or other structure. 
         [0026]    Still referring to  FIG. 3 , it now can be appreciated that the structure shown in  FIG. 9  are those portions of electrical connector  10  which are manipulated as a unit for insertion through void  26  in bulkhead  28 .  FIG. 9  also provides yet another view of shoulder  34  and cavity  30  and seating trough  36  which receive finger  32  and ridge  38  of retainer clip  12  and which serve to provide a positive connection between connector body  14  and retainer clip  12  and prevent retraction of connector body  14  back through void  26  in bulkhead  28  once retaining clip  12  is installed. 
         [0027]    Referring now to  FIGS. 4 and 5 , the structure of connector body  14  will be described in additional detail. In  FIG. 4  a first end  60  of connector  14  is shown having terminal apertures  18  therein. Terminal apertures  18  receive terminals  16  and secure terminals  16  within apertures  18  by grooves  40  which receive terminal retention tabs  42 . The tabs  42  engage in grooves  40  and by such connection to connector body  14  eliminate any rotational movement of terminal  16  around the longitudinal axis of terminal  16 . In this manner, rotational forces on the connection between terminal  16  and conductors  22  is provided and integrity of the soldering or crimping connection between conductors  22  and terminal  16  is enhanced. Also shown in  FIG. 4  are two retaining ridges  62  which extend outwardly from the central longitudinal axis of connector body  14 . It will be appreciated by those skilled in the art that these features operate to provide protrusions that are surrounded by the liquid plastic that is injected to form over-mold cable retainer  24 . Protrusions  62  operate to assist in securing the connection between container body  14  and over-mold cable retainer  24  to prevent slippage and separation between container body  14  and over-mold cable retainer  24  after the formation of the cable retainer. This is of particular importance as these features are adjacent to access voids  48  in container body  14  which allow the flow of liquid plastic material therethrough to permit the formation of connector seal  52  within the receptacle area  64  of container body  14 . 
         [0028]    Still referring to  FIG. 5 , the front of terminal apertures  18  is shown. Flange receivers  44  are positioned in terminal apertures  18 . Flange receivers  44  are provided to capture therein spring flanges  46  which extend from terminal  16 . It can be appreciated by those skilled in the art that upon insertion of terminal  16  into apertures  18  of connector body  14  that spring flanges  46  become slightly depressed as they move through terminal apertures  18 . Upon coming into contact with flange receivers  44  which are larger than the general diameter of terminal apertures  18 , spring flanges  46  can return to their original position and become captured within receivers  44 . This capture of spring flanges  46  within flange receivers  44  operates to prevent the subsequent rearward withdrawal of terminal  16  from engagement with terminal apertures  18 . In this manner rearward directed stresses transmitted via wiring harness  20  and/or over-mold cable retainer  24  to the connection of terminal  16  within terminal apertures  18  is resisted and the integrity of electrical connector  10  is enhanced. 
         [0029]    Referring now to  FIGS. 6 and 7 , retainer clip  12  will be more fully described. In  FIG. 6 , retaining clip  12  is shown having securing apertures  50  extending therethrough to permit the passage of fasteners therethrough for the securing of electrical connector  10  onto a workpiece  28  or bulkhead of a truck  28  after assembly of retaining clip  12  onto connector body  14  has been completed. Retaining clip  12  is provided with ridge  38  which extends from retaining clip  12  for connection into seating trough  36  of connector body  14  ( FIG. 4 ). It will be appreciated by those skilled in the art that ridge  38  fits into seating trough  36  and therefore separate forward motion or rearward motion of retaining clip  12  with respect to connector body  14  is inhibited. Also shown in  FIG. 6  is finger  32  which projects outwardly from ridge  38  and which is intended for reception within cavity  30  on connector body  14 . As cavity  30  is a further intrusion into the surface of connector body  14  as compared to the distance of intrusion provided by seating trough  36 , it will be appreciated that as connector clip  12  is guided into seating trough  36  of connector body  14  that finger  32  rides along flat segment  36 A of seating trough  36  after which finger  32  of retaining clip  12  is forced into cavity  30  on connector body  14  by retaining clip  12 . This forcing of finger  32  into cavity  30  is achieved as the insertion of retaining clip  12  into seating trough  36  causes an outward expanding forced to be delivered to retaining clip  12  as it passes along the track created by seating trough  36  and flat segment  36 A. Upon finger  32  reaching cavity  30 , finger  32  is pressed inwardly to relieve the outward, expansive pressure that has been delivered to retaining clip  12  by movement past the diameter of connector body  14 . The forces involved here are generated by the presence of a finger  32  on each side of retainer clip  12  thus providing of opposed fingers  32  on either side of retaining clip  12  (best seen in  FIG. 7 ). This gap between fingers  32  as indicated by Arrow A is narrower than the diameter of flat segments  36 A on either side of connector body  14 . This different spacing therefore causes the slight expansion of retaining clip A as it is inserted onto connector body  14  and results in the inward movement of fingers  32  into cavities  30  of connector body A to positively capture retaining clip  12  on connector body  14 . As previously described, once retaining clip  12  is seated and captured by connector body  14 , fasteners may be passed through securing apertures  50  and through workpiece  28  to secure electrical connector  10  to the workpiece. 
         [0030]    Referring now to  FIG. 8 , terminal  16  will be described in greater detail. Terminal  16  is formed of an electrically conductive material such as a metal and is provided with spring flanges  46 , which are captured within flange receivers  44  of connector body  14 . Terminal  16  also is provided with terminal retention tabs  42  which, upon installation of terminal  16  within connector body  14 , become inserted into grooves  40  to prevent pull out of terminal  16  within terminal apertures  18  of connector body  14 . As previously described, the function of spring flanges  46  is to provide a positive capture of spring flanges  46  within flange receivers  44  and to thereby prevent the withdrawal of terminals  16  from terminal apertures  18  of connector body  14 . In  FIG. 8 , the embodiment of terminal  16  is shown with a crimp connection  54  which has first and second legs  54 A and  54 B which receive conductor  22  therebetween upon which legs  54 A can be pressed against conductor  22  to capture conductor  22  therebetween for positive electrical connection. 
         [0031]    Once the connector system is securely attached to the trailer, a power cord can be connected to a forward mounted J560 connector to provide trailer power from the tractor power. Alternatively a power cord can be attached to a rear mounted J560 connector to provide power to tandem trailer or converter dolly. 
         [0032]    In the foregoing description, certain terms have been used for brevity, clearness and understanding; but no unnecessary limitations are to be implied therefrom beyond the requirements of the prior art, because such terms are used for descriptive purposes and are intended to be broadly construed. Moreover, the description and illustration of the invention is by way of example, and the scope of the invention is not limited to the exact details shown or described. 
         [0033]    Certain changes may be made in embodying the above invention, and in the construction thereof, without departing from the spirit and scope of the invention. It is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not meant in a limiting sense. 
         [0034]    Having now described the features, discoveries and principles of the invention, the manner in which the inventive electrical connector is constructed and used, the characteristics of the construction, and advantageous, new and useful results obtained; the new and useful structures, devices, elements, arrangements, parts and combinations, are set forth in the appended claims. 
         [0035]    It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.