Patent Publication Number: US-6902441-B2

Title: Modular layered stackable connector system

Description:
FIELD OF THE INVENTION 
     The present invention relates generally to wire harness connector systems, most notably those associated with commercial vehicle installations. More particularly, the present invention relates to a modularized connector system, such as in which either or both of male and female connector sub-assemblies include the ability to stack or interengage any plurality of individual terminal retention layers. The purpose behind the ease of modularity is to provide the ability to adapt the capabilities of the connector system to allow for unique wire harness subsystems to be quickly assembled, either in the field or factory, thus reducing assembly labor, eliminating assembly/wiring errors, and reducing the need for unique wire harness levels. 
     BACKGROUND OF THE INVENTION 
     The prior art is well documented with various types of connector assemblies, and which are typically in use with vehicle wire harnesses. It is common to require a uniquely designed wire harness for each combination of options associated with a given installation, these including such as automotive, telecommunications, aircraft, commercial and other consumer applications. The shortcoming of the prior art has been the inability to allow for modularity of wire harnesses, employing a standardized connector housing, and in order to satisfy a range of load and output requirements. 
     SUMMARY OF THE INVENTION 
     The present invention is a connector system for use with wire harness assemblies. In particular, the system provides for the ability to modularize the capacity of the connector through the provision of any plurality of individual and stackable terminal retention layers, on either or both of interconnecting male and female sub-assembly portions, and in order to quickly adapt the capabilities of the connector system to allow for the assembly of unique wire harness subsystems. 
     Each of the male and female sub-assemblies includes a three dimensional and interengaging housing which, in combination, defines an open interior. First and second pluralities of inter-engageable terminal pins are associated with each of the male and female sub-assemblies and each of the sub-assemblies further includes a plurality of individual and stackable retaining layers to which individual sub-pluralities of the pins are secured. 
     The exposed ends of the housing sub-assemblies are each enclosed by a slit matt seal and a two-piece seal retainer. It is also contemplated that each of the plurality of succeeding and stackable retainer layers includes a given array of apertures to both facilitate mounting of selected pins, as well as to permit passage therethrough of differently lengthened pins associated with preceding layers and wire passage. Conductive inserts may also be secured between succeeding terminal pin retaining layers, to effectively short out electrical connections between pins associated with the succeeding layers or prior layers, and it is also contemplated that active or passive electronic, electro-mechanical, or mechanical components, such as fuses, relays and the like, can be incorporated into any of the layers. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Reference will now be made to the attached drawings, when read in combination with the following detailed description, wherein like reference numerals refer to like parts throughout the several views, and in which: 
         FIG. 1  is a perspective view of the modular layered connector system according to the present invention and further illustrating wire harnesses extending from both of assembled male and female subassembly portions; 
         FIG. 2  is an exploded view of a subset male assembly according to the present invention; 
         FIG. 3  is an exploded view of a subset female assembly according to the present invention; 
         FIG. 4  is a cutaway view in perspective and illustrating the modularized/stackable nature of the terminal pin retention layers and associated/interengageable pins of the male and female subassembly portions; 
         FIG. 5A  is a frontal perspective view of the male housing subassembly according to the present invention; 
         FIG. 5B  is a rear perspective view of the male housing subassembly illustrated in  FIG. 5 ; 
         FIG. 6A  is a rear perspective view of the female housing subassembly according to the present invention; 
         FIG. 6B  is a frontal perspective view of the female housing subassembly illustrated in  FIG. 6A ; 
         FIG. 7  is an exploded view of a selected array of module terminal layers according to the present invention; 
         FIG. 8  is a sectional perspective view of a further selected terminal retention layer and which includes the provision of conductive inserts for shorting of pin terminals associated with succeeding layers; 
         FIG. 9  is a sectional perspective view of a yet further selected terminal retention layer and illustrating a selected electrical component secured thereto; 
         FIG. 10  is an exploded perspective view of an assembleable male/female module layered connector system and incorporating a conventionally designed housing retrofitted with the terminal retaining layers according to a further preferred embodiment of the present invention; 
         FIG. 11  is a side cutaway view, taken along line  11 — 11  of  FIG. 10 , and illustrating the stackable and spatial arrangement of a plurality of three terminal retention layers according to the present invention; and 
         FIG. 12  is an exploded and planar view of the further selected array of module terminal layers also illustrated in  FIG. 11 . 
     
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
     Referring now to  FIG. 1 , a perspective view is shown at  10  of a modular layered connector system according to a preferred embodiment of the present invention and which further illustrates individual wire harnesses  12  and  14  extending, respectively from each of assembled male  16  and female  18  sub-assembly portions. As previously explained, either or both of male and female connector sub-assemblies include the ability to stack or interengage any plurality of individual terminal retention layers. The purpose behind the modularity of construction is further to adapt the capabilities of the connector system to allow for unique wire harness subsystems to be quickly assembled, thus minimizing wasteful and unwanted “giveaway” of excess/unneeded connector capacity, reducing assembly labor, eliminating assembly/wiring errors, and reducing the need for unique wire harness levels. 
     Referring again to  FIG. 1 , as well as to  FIGS. 2 and 3  in succession, the connector system  10  is constructed of two individual and inter-connectible subassemblies, including a first or male sub-assembly  16  ( FIG. 2 ) and a second or female sub-assembly  18  ( FIG. 3 ). Referring also to front are rear perspective looking views of  FIGS. 5A and 5B , the male sub-assembly  16  includes a three dimensional shaped housing, generally rectangular in configuration and with first  20 , second  22 , third  24  and fourth  26  interconnecting sides. 
     The interconnecting sides,  20 ,  22 ,  24  and  26  defining the male sub-assembly further exhibit both outwardly and inwardly facing surfaces, thus defining a substantially open interior. Additional features associated with the male sub-assembly housing include a pair of inwardly recessed grooves  28  extending in depth-wise extending fashion along a bottom inner surface (see side  24 ), as well as additional depth-wise extending recesses  30  ( FIG. 5B and 32 ) ( FIG. 5A ) positioned along inner facing surfaces of sides  22  and  26 , respectively, the significance of which will be shortly discussed. Also configured, on selected exterior facing surfaces of the main housing sub-assembly, is a substantially rectangular shaped and interiorly open receiving portion  34  (see exterior facing surface of upper-most side  20 ). Additionally, first  36  and second  38  pairs of exteriorly projecting window portions are positioned proximate to both rearward and forward facing ends of the main housing sub-assembly. 
     Referring again to the exploded view of  FIG. 2 , additional features of the male sub-assembly  16  include the provision of a plurality of stackable and sandwiching components, these including individual terminal pin retaining layers  40 ,  42  and  44 , a slit matt seal  46  and a two piece seal retainer (see substantially “L” shaped and assembleable components  48  and  50 ). Each of the terminal pin retaining layers  40 ,  42 , and  44  are, in a preferred embodiment, rectangular in shape and are capable of being constructed of an insulating or conductive material, depending upon the electrical needs of the connector assembly. 
     Furthermore, in the preferred embodiment, each includes exteriorly projecting keys, or tabs, see such as at  47  and  49  for layer  40 , at  51  and  52  for layer  42 , and at  54  and  56  for layer  44 . The uniquely configured and projecting tabs are intended to mate with the likewise uniquely/inwardly keyed recesses  30  and  32 , these further being positioned and individually dimensioned in length to receive each of the succeeding pin retainer layers  40 ,  42  and  44  in a predetermined spaced and stacking arrangement. 
     As is also best illustrated in  FIG. 2 , each of the layers  40 ,  42  and  44  includes a plurality of configured apertures formed therethrough, these being selected from such as smaller circular shaped apertures (see at  58  for layer  40 ), as well as slot shaped  60 , oval shaped  62  and larger sized circular shaped  64  apertures (see in particular layer  42 ). Individual pluralities of male terminal pins,  66  for layer  40 ,  68  for layer  42  and  70  for layer  44 , are provided. Each sub-plurality of pins is dimensioned to a different length (such as the forward most layer  40  and pins  66  being the shortest and the rearward most layer  44  and pins  70  being the longest) and so that, upon assembly of the pins into specified circular shaped apertures (see again at  58 ) of each terminal layer  40 ,  42  and  44  of the male sub-assembly  16 , the extending ends of the pins  66 ,  68  and  70  are all evenly arranged. 
     The arrangement and configuration of the variously shaped apertures (e.g. at  58 ,  60 ,  62  and  64 ) is further such that the longest pins (see again  70  associated with rearward most layer  44 ) are able to pass through the preceding and forwardly located layers  40  and  42  in the assembled stacking arrangement of the male sub-assembly  16 . As will also be discussed in further detail, and referenced in the alternate sectional view of  FIG. 11 , individual wire strands composing the first wire harness  12  are connected to associated rearward ends of likewise individual ones of the male terminal insertion pins  66 ,  68  and  70 . The configuration of the oval slots and channels in particular facilitates the clearance for previous layer terminal pins and wires (for example slots  60  in layers  42  and  44  allow for attached wire strands to clear existing attached wire strands in preceding layers) and it is also contemplated and understood that any suitable plurality of retaining layers and associated terminal pins can be installed into the male sub-assembly, the same only being limited by practical space considerations. 
     Referencing further the rearwardly positioned slit matt seal  46  (again  FIG. 2 ), the same is shaped similarly to each of the succeeding pin retainer layers  40 ,  42  and  44 , and includes keyed or tabbed portions, see at  72  and  74  and for positioning the matt seal  46  in a rearward most location, as well as smaller sized slits  76  for allowing clearance of the harness wires  12  associated with the pins  66 ,  68  and  70 . Finally, the two piece seal retainer, see again at  48  and  50 , is by necessity constructed in this fashion and so that it can be assembled around the wire harness extending from the male sub-assembly  16 . End extending and keyed portions  78  (for retainer portion  48 ) and  80  (for retainer portion  50 ) are configured to engaged specified and associated window portions  36  and  38  of the male housing and in order to secure the male assembly together in the manner substantially illustrated in  FIG. 1 . 
     Referring again to  FIG. 1 , as well as to the exploded view of  FIG. 3  and the individual front and rear perspective illustrations of  FIGS. 6A and 6B , a similar explanation of the components associated with the female housing sub-assembly  18  will now be made. In providing this explanation, duplicate explanation of common elements discussed in reference to the male sub-assembly  16  will be, to the extent possible, avoided and in the interests of clarity and non-repetition. 
     The above said, and referring again to front are rear perspective looking views of  FIGS. 6A and 6B , the female sub-assembly  18  also includes a three dimensional shaped housing, generally rectangular in configuration and with first  82 , second  84 , third  86  and fourth  88  interconnecting sides, these defining the female sub-assembly and further exhibiting both outwardly and inwardly facing surfaces, thus again defining a substantially open interior. The configuration and dimension of the interconnecting sides  82 ,  84 ,  86  and  88  is such that the female housing sub-assembly is slidably inserted between the interiorly facing surfaces of the male housing sub-assembly. The female sub-assembly housing further includes a forward and projecting frame  90  (defining a stop location for insertion in the male sub-assembly) and a rearwardly extending and keyed portion  92 , secured to a top surface of the frame  90  and, as will be further explained, is engageable with the interiorly open receiving portion  34 . 
     Additional features associated with the female sub-assembly housing  18  include a pair of bottom projecting rails  94 , these extending in depth-wise extending fashion along a bottom outer surface (see side  86 ) and which are received within the depthwise recesses  28  of the male sub-assembly upon engagement. Yet additional features include additional depth-wise extending recesses  96  and  98  positioned along inner facing surfaces of sides  84  and  88 , as are additional recesses  97  and  99  in association with the outer facing frame  90  (this further being to seat the extending key portions of the two piece seal retainer to be discussed). Additionally, first  100  and second  102  pairs of exteriorly projecting window portions are positioned proximate to both rearward and forward facing ends of the female housing sub-assembly  18  and similar to those previously referenced at  36  and  38  in  FIGS. 5A and 5B . 
     Referring again to the exploded view of  FIG. 3 , additional features of the female sub-assembly  18  include the provision of another plurality of stackable and sandwiching components, these including individual terminal pin retaining layers  104 ,  106  and  108 , a slit matt seal  110  and a two piece seal retainer (see substantially “L” shaped and assembleable components  112  and  114 ). Each of the terminal pin retaining layers  104 ,  106 , and  108  are likewise, in a preferred embodiment, rectangular in shape and are capable of being constructed of an insulating or conductive material, depending upon the electrical needs of the connector assembly. 
     Again, and according to the preferred embodiment, each layer  104 ,  106  and  108  includes exteriorly projecting keys, or tabs, see such as at  116  and  118  for layer  104 , at  120  and  122  for layer  106 , and at  124  and  126  for layer  108 . As with the tabs associated with male assembly retainer layers  40 ,  42  and  44 , the uniquely configured and projecting tabs are intended to mate with the likewise uniquely/inwardly keyed recesses  96  and  98  of the female sub-assembly, these again further being positioned and individually dimensioned in length to receive each of the succeeding pin retainer layers  104 ,  106  and  108  in a likewise desired and predetermined spaced and stacking arrangement. 
     As is also again best illustrated in  FIG. 3 , each of the layers  104 ,  106  and  108  includes a plurality of configured apertures formed therethrough, these being selected from such as smaller circular shaped apertures (see at  128  for layer  104 ), as well as slot shaped  130 , and oval/slot shaped apertures  132  and  134  (layers  106  and  108 ). Individual pluralities of female terminal pins,  136  for layer  104 ,  138  for layer  106  and  140  for layer  108 , are provided. 
     As discussed in reference to the male sub-assembly, each sub-plurality of pins  136 ,  138  and  140  is dimensioned to a different length (such as the forward most layer  104  and pins  136  being the shortest and the rearward most layer  108  and pins  140  being the longest) and so that, upon assembly of the pins into specified circular shaped apertures (see again at  128 ) of each terminal layer  104 ,  106  and  108  of the female sub-assembly  18 , the extending ends of the pins  136 ,  138  and  140  are all evenly arranged. As further illustrated, the extending ends of the female pins further exhibit open interiors which facilitate seating insertion and engagement by the opposingly extending and male terminal pins  66 ,  68  and  70 . 
     The arrangement and configuration of the variously shaped apertures (e.g. at  128 ,  130 ,  132  and  134 ) is further such that the longest pins (see again  140  associated with rearward most layer  108 ) are able to pass through the preceding and forwardly located layers  104  and  106  in the assembled stacking arrangement of the female sub-assembly  18 . As discussed in reference to the male sub-assembly, individual wire strands composing the second wire harness  14  are connected to associated rearward ends of likewise individual ones of the female terminal insertion pins  136 ,  138  and  140 . As with the description of  FIG. 2 , the configuration of the slots and channels facilitates the clearance for previous layer terminal pins and wires and it is also contemplated and understood that any suitable plurality of retaining layers and associated terminal pins can also be installed into the female sub-assembly, the same likewise only being limited by practical space considerations. 
     Referencing further the rearwardly positioned slit matt seal  110  (again  FIG. 3 ), the same is shaped similarly to each of the succeeding pin retainer layers  104 ,  106  and  108 , and includes keyed or tabbed portions, see at  142  and  144  and for positioning the matt seal  110  in a rearward most location, as well as smaller sized slits  146  for allowing clearance of the harness wires  14  associated with the pins  136 ,  138  and  140 . Finally, the two piece seal retainer, see again at  112  and  114 , is also by necessity constructed in this fashion and so that it can be assembled around the wire harness extending from the female sub-assembly  18 . Keyed portions  148  (for retainer portion  112 ) and  150  (for retainer portion  114 ) are configured (see arrow shaped pointed ends  152  in  FIGS. 1 ,  2  and  4 ) to engage specified and associated window portions  100  and  102  and in order to secure the female assembly together in the manner again substantially illustrated in  FIG. 1 . Along with the seal retainer associated with the male sub-assembly, each of male and female seal retainers can be quickly disassembled to allow for easy addition (such as in the field) of extra module layers and in order to add new feature content to the connector assembly. 
     Referring further to  FIG. 7 , an exploded view is illustrated of a further selected array of module terminal layers  154 ,  156  and  158  and which is intended only to build upon the disclosure of the sub-pluralities of various terminal retainer layers previously illustrated and discussed in reference to  FIGS. 2 and 3 . In particular, the reference of  FIG. 7  is intended to illustrate that the infinite possibilities in the design and configuration of the pin retainer layers, each being keyed (see at  160  and  162  for layer  154 , at  164  and  166  for layer  156 , and at  168  and  170  for layer  158 ) for proper fit and assembly order, including again the necessary apertures (circular  172 , slotted  174 , etc.) providing the needed clearances for previous layer terminal pins and wires. As again previously described, the individual layers can be constructed of insulating or conductive materials, depending upon the electrical requirements of the connector assembly. 
     Referring now to  FIG. 8 , a sectional perspective view of a further selected terminal retention layer  176  is shown and which includes the provision of conductive inserts  178  and  180  secured to a selected face of the layer  176 . In use, terminal pins associated with the layer  176  are inserted and which, as desired, are shorted (electrically conducted) to selected associated and succeeding pin retainer layers (such as through the holes associated therewith and which are not shown) and in order to adapt the capabilities of the connector system. In this fashion, the shorting feature can be combined with all other features of the connector system. 
     Referring now to  FIG. 9 , a sectional perspective view is illustrated at  182  of a yet further selected terminal retention layer and which illustrates a selected electrical component, such as shown at  184 , secured thereto. The electrical component  184  can be drawn from any of a number of known components, including active or passive electronic, electromechanical or mechanical components, such as fuses, relays, and the like, it being understood that the present invention contemplates the ability to add components to a given module layer. 
     Referring finally to  FIGS. 10–12 , a series of views are shown of a slightly modified connector system  186  ( FIG. 10 ) according to the present invention and which includes a conventionally designed male housing sub-assembly  188  and a corresponding conventionally designed female housing sub-assembly  190 . The body sub-assemblies  188  and  190  further include integral connector pin supports and optional perimeter sealing structure (further not shown). 
     Referenced generally by oval circles  192  and  194  are further the general interior locations of layered stackable terminal retainer layers, and such as is further illustrated by layers  196 ,  198  and  200  associated with female sub-assembly  190  (circle  194 ) and further shown in  FIGS. 11 and 12 . As is again referenced by the side cutaway view of  FIG. 11 , an illustration is best shown of the stackable and spatial arrangement of the plurality of three terminal retention layers  196 ,  198  and  200  and best showing the manner in which extending ends of associated pins  202 ,  204  and  206 , respectively for layers  196 ,  198  and  200 , are aligned equally. 
     Additional components, such as conductive inserts  208 ,  210  and  212  may be provided for electrically shorting pin receiving apertures between succeeding layers and trailing harness wires  214  are further illustrated. Referring finally again to  FIG. 12 , the exploded and planar view of the further selected array of module terminal layers  196 ,  198  and  200  again references components, including edge extending tabs or projections, apertures, channels and slots, such as have been previously described, such that further and repetitive description herein is unnecessary. 
     The present invention therefore discloses a connector system exhibiting modular upgrade capabilities in either or both the male and female sub-assembly housings. It is further contemplated that, according to specific retrofit applications, a conventionally known male or female connector sub-assembly can be utilized in combination with a corresponding male or female sub-assembly as constructed according to the present disclosure. 
     Furthermore, and as has again been previously explained, any number of terminal retention layers can be incorporated into the present invention, and beyond the three layers illustrated for each sub-assembly. Along these lines, further examples include, without limitation, a five layer, twelve pin version of a male sub-assembly and a three layer twelve pin version of a female sub-assembly. 
     Having described my invention, other and additional preferred embodiments will become apparent to those skilled in the art to which it pertains, and without deviating from the scope of the appended claims.