Abstract:
A wiring arrangement for interconnecting an alternating current power source to a receptacle within a motor vehicle includes a first wire harness having a current rating and a second wire harness having a similar current rating. A coupling mechanism electrically interconnects the first and second wire harnesses of similar current ratings. The coupling mechanism restricts interconnection of wire harnesses having dissimilar current ratings.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of U.S. Provisional Application No. 60/919,319, filed Mar. 21, 2007. The disclosure of the above application is incorporated herein by reference. 
     
    
     BACKGROUND 
       [0002]    The present invention relates generally to electrical connectors and, more particularly, to connectors for use with alternating current surface mounted receptacles within motor vehicles. 
         [0003]    Operators of cargo carrying vehicles such as Class 7 and Class 8 tractor-trailers may find themselves far away from home a large portion of the time. As such, many of these vehicles are equipped with sleeper cabs to allow the operator to rest within the vehicle during a stationary period. Accordingly, it may be desirable to equip such vehicles with wiring systems to allow use of common household electrical devices such as lap top computers, microwaves, televisions and the like. 
         [0004]    Based on the wide variety of electrical appliances that may be used within the vehicle, it may be desirable to provide designated circuits having maximum amperage ratings that vary from one another. For example, many homes are equipped with 15 amp circuits as well as 20 amp circuits to meet the demand of the particular appliance or appliances to be electrically energized. It may also be desirable to equip a vehicle with electrical hardware configured to provide different amperage circuits. As such, a need may exist to assure that the various components used to create the different amperage circuits are not interchanged with one another. Additionally, it may be desirable to assure that a receptacle sized to transfer a certain maximum amperage is not inadvertently connected to components rated to carry a lesser current load. 
       SUMMARY 
       [0005]    A wiring arrangement for interconnecting an alternating current power source to a receptacle within a motor vehicle includes a first wire harness having a current rating and a second wire harness having a similar current rating. A coupling mechanism electrically interconnects the first and second wire harnesses of similar current ratings. The coupling mechanism restricts interconnection of wire harnesses having dissimilar current ratings. 
         [0006]    In addition, a cord set for electrically connecting a receptacle within a vehicle to an alternating current power source includes a first wire harness having a first end and a second end. The first end has a first connector adapted to be electrically connected to the power source. The cord set also includes a second wire harness having a first end and a second end. The first end has a second connector adapted to be selectively connected to the receptacle within the vehicle. A coupling mechanism electrically couples the first wire harness to the second wire harness. The coupling mechanism includes a first housing fixedly attached to the second end of the first wire harness. The first housing includes a projection radially outwardly extending therefrom, a radially inwardly protruding and axially extending rib and a circumferentially extending recess positioned radially between the rib and the projection. A second housing is fixedly attached to the second end of the second wire harness. The second housing includes a flexible finger having an aperture for receiving the projection, an axially extending groove for receiving the rib and a cylindrical wall for insertion within the recess. 
         [0007]    In addition, the present disclosure provides cord sets for connecting electrical receptacles mounted within a vehicle to a power source. A first cord set has a first wire harness having a first current rating, a second wire harness having the first current rating and a first coupling mechanism electrically interconnecting the first and second wire harnesses. A second cord set has a third wire harness having a second current rating greater than the first current rating, a fourth wire harness having the second current rating and a second coupling mechanism electrically interconnecting the third and fourth wire harnesses. The first and second coupling mechanisms prevent electrical connection of wire harnesses having dissimilar current ratings. 
         [0008]    Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. 
     
    
     
       DRAWINGS 
         [0009]    The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way. 
           [0010]      FIG. 1  is a fragmentary exploded perspective view of a first electrical connector assembly; 
           [0011]      FIG. 2  is a fragmentary exploded perspective view of the electrical connector assembly shown in  FIG. 1  including an elastomeric gasket; 
           [0012]      FIG. 3  is a fragmentary perspective view of a wire harness having an overmolded sheath; and 
           [0013]      FIG. 4  is a fragmentary exploded perspective of another electrical connector assembly. 
       
    
    
     DETAILED DESCRIPTION 
       [0014]    The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features. 
         [0015]    The present disclosure provides a first electrical connector assembly  10  and a second electrical connector assembly  12 . Each of the connector assemblies  10 ,  12  perform substantially similar functions providing a connection/disconnection between two wire harnesses. It is contemplated that each of connector assemblies  10 ,  12  may be used in conjunction with systems providing  120  volt alternating current from a power source to a receptacle within a motor vehicle. One such system is described in commonly owned U.S. Pat. No. 6,644,987 which is herein incorporated by reference. 
         [0016]      FIGS. 1-3  depict first connector assembly  10  or a portion thereof. First connector assembly  10  is designed for use with one of a 15 amp supply circuit or a 20 amp circuit. For purposes of clarity of description, connector assembly  10  will be described in relation to the 15 amp circuit but may be utilized to provide other current levels. 
         [0017]    Connector assembly  10  includes a first wire harness  14  and a second wire harness  16 . First wire harness  14  includes a first end  18  adapted to be coupled to a power source. First end  18  is not shown in detail but may include terminals and/or a plug to electrically connect first wire harness  14  to the power source. First wire harness  14  also includes a second end  20  having a housing  22 . A plurality of male current-carrying pins or electrical terminals  24   a,    24   b,    24   c  are mounted to housing  22  and positioned within a cavity  26  formed within housing  22 . Terminals  24   a,    24   b,    24   c  are in electrical communication with wires  28   a,    28   b,    28   c,  respectively, extending through housing  22 . Housing  22  includes an end face  30  having a circular groove  32  formed therein. As such, an inner wall  34  and an outer wall  36  are formed bounding groove  32 . Groove  32  terminates at a back wall  38  extending between inner wall  34  and outer wall  36 .  FIG. 2  shows an elastomeric gasket  40  positioned within groove  32 . Housing  22  includes a radially inwardly protruding and axially extending rib  42 . Rib  42  is integrally formed with and extends from inner wall  34 . 
         [0018]    Second wire harness  16  includes a first end  50  adapted to be connected to a receptacle (not shown) mounted within a vehicle. A second end  52  of second wire harness  16  is configured to be mechanically and electrically coupled to second end  20  of first wire harness  14 . Second end  52  includes a housing  54  in receipt of female electrical terminals  53   a,    53   b  and  53   c  as shown in  FIG. 3 . The female electrical terminals are electrically coupled to wires  56   a,    56   b,    56   c  that extend through housing  54 . More particularly, terminal  53   a  is fixed in electrical communication with wire  56   a.  Terminal  53   b  is fixed in electrical communication with wire  56   b.  Terminal  53   c  is fixed in electrical communication with wire  56   c.  Housing  54  includes a central protruding boss  60  having an end face  58  formed thereon. Each female electrical terminal  53   a,    53   b,    53   c  is positioned within one of pockets  57   a,    57   b,    57   c  inwardly extending from end face  58  of housing  54 . 
         [0019]    Boss  60  further includes an axially extending groove  62  sized to receive rib  42  during insertion of boss  60  within cavity  26 . While male current-carrying pins  24   a,    24   b,    24   c  and female electrical terminals  53   a,    53   b,    53   c  function to rotationally orient housing  54  with housing  22 , rib  42  and groove  62  provide another rotational alignment feature to assure that certain male terminals  24  are coupled to the appropriate female electrical terminals  53  of second wire harness  16 . 
         [0020]    Housing  54  also includes a cylindrical wall  64  encompassing a portion of boss  60 . An end face  66  of wall  64  is axially offset and substantially parallel to end face  58 . Cylindrical wall  64  is sized and positioned to engage gasket  40  and become at least partially positioned within groove  32  between inner wall  34  and outer wall  36  when second end  52  is coupled to second end  20 . In particular, end face  66  of wall  64  engages an outer surface  68  of gasket  40 . 
         [0021]    An axially extending flexible finger  70  is integrally formed with housing  54  and axially extends parallel to boss  60 . A radially outwardly extending protrusion or peg  74  is integrally formed with housing  22 . Once rib  42  and groove  62  are rotationally aligned with one another, housing  54  may be moved toward housing  22  to couple second end  52  to second end  20 . During relative translation toward one another, a lead chamfer  72  of finger  70  engages a sloped surface  73  of peg  74 . Finger  70  is deflected radially outwardly at this time. Once peg  74  enters a slot  76  formed in finger  70 , the catch returns toward its undeformed state and captures peg  74 . Finger  70  and peg  74  engage one another in a snap-fit arrangement to resist forces tending to separate first wire harness  14  from second wire harness  16 . At this time, each male electrical terminal  24   a,    24   b,    24   c  is positioned in electrical communication with its associated female electrical terminal  53   a,    53   b,    53   c.  It should be appreciated that flexible finger  70  and peg  74  act to rotationally align housing  22  and housing  54  as well. 
         [0022]    To aid in possibly mounting housing  22  or housing  54  to a rigid structure, housing  22  includes a radially extending flange  80  and a reduced diameter tubular portion  82  axially extending therefrom. An external thread  84  is formed on tubular portion  82 . A threaded nut (not shown) may be threadingly engaged with thread  84  to mount housing  22  to a desired structure. In similar fashion, housing  54  includes a radially extending flange  90 . A reduced diameter tubular portion  92  axially extends from flange  90 . An external thread  94  is formed on tubular portion  92 . 
         [0023]      FIG. 3  depicts an optional sheath  96  coupled to housing  54 . Sheath  96  may be fixed to housing  54  in a pressed fit manner or a threaded engagement. Sheath  96  may alternatively be overmolded about housing  54 . In the latter arrangement, housing  54 , terminals  53   a,    53   b,    53   c  and wires  56  are placed into a cavity of an injection mold. Molten polymer is injected within the cavity to surround tubular portion  92  and a portion of wires  56 . The overmolding process produces a robust, sealed second end  52 . It should be appreciated that another sheath (not shown) may be coupled to tubular portion  82  of housing  22 . 
         [0024]      FIG. 4  depicts second connector assembly  12 . Second connector assembly  12  is designed for use with circuits of different current ratings than first connector assembly  10 . For example, second connector assembly  12  is configured for use with 20 amp circuits. It should be appreciated that second electrical connector assembly  12  is substantially similar to the first electrical connector assembly  10 . As such, like elements will be identified with similar reference numerals increased by 100. One skilled in the art will appreciate that different regulatory standards exist regarding circuits carrying various current levels. For example, a 20 amp circuit may be required to include wires having a heavier gauge than the wires used for 15 amp circuits. Terminal designs may also differ. Accordingly, it may be desirable to provide unique connectors for different current-carrying sets of wire harnesses that allow interconnection of like amperage rated wire harnesses but do not allow interconnection of unlike current rated wire harnesses. In particular, it may be desirable to assure that second wire harness  16  associated with a 15 amp circuit may not be coupled to a third wire harness  114  associated with a 20 amp circuit. 
         [0025]    Third wire harness  114  includes a boss  160  having a first groove  200  and a second groove  202 . The grooves are spaced apart from one another and axially extend along boss  160 . To provide a properly mated interconnection, a fourth wire harness  116  includes a second end  120  having a housing  122 . Housing  122  includes an inner wall  134  and an outer wall  136  bounding a groove  132 . A first radially inwardly protruding and axially extending rib  204  is integrally formed with inner wall  134 . A second radially inwardly protruding and axially extending rib  206  is also integrally formed with inner wall  134 . Ribs  204  and  206  are spaced apart from one another and positioned substantially parallel to each other. Ribs  204 ,  206  are spaced apart and sized to be received within grooves  200 ,  202  formed on boss  160 . 
         [0026]    It should be appreciated that groove  132  is sized for receipt of a gasket (not shown) and that the interconnection between second end  120  and second end  152  is substantially similar to the sealing arrangement and catch retention design previously described in relation to first electrical connector assembly  10 . As such, the description will not be repeated. The dual rib feature of housing  122  and the dual groove feature of boss  160  assure electrical connection of only 20 amp circuit wire harnesses with one another. Similarly, the position of the single rib  42  of housing  22  as well as the single groove  62  of boss  60  restrict the interconnection of a 15 amp harness with a 20 amp harness but allow the electrical coupling of like amperage wire harnesses. 
         [0027]    Furthermore, the foregoing discussion discloses and describes merely exemplary embodiments of the present disclosure. One skilled in the art will readily recognize from such discussion, and from the accompanying drawings and claims, that various changes, modifications and variations may be made therein without departing from the spirit and scope of the disclosure as defined in the following claims.