Patent Publication Number: US-6217340-B1

Title: Electrical connector assembly

Description:
TECHNICAL FIELD 
     The present invention relates to a connector assembly for an electric light bulb, and more specifically, to a connector assembly for mounting a taillight to a vehicle. 
     BACKGROUND OF THE INVENTION 
     A conventional connector assembly mounts a light bulb to a vehicle taillight lens. The vehicle taillight lens and the connector assembly are designed to withstand environmental conditions. The taillight lens is handled significantly during assembly to the vehicle, and the taillight lens must withstand moisture and contaminants to maintain the light bulb in operating condition once the taillight lens is installed in the vehicle. 
     Known assemblies do not adequately meet the above requirements. In known assemblies a wire harness, exterior to the taillight lens, provides power to the connector assembly and the light bulb. The use of the harness results in some mechanical failures during handling and exposure to moisture and contaminants. The present invention provides an inexpensive connector assembly which can be easily handled and provide a reliable barrier to these external factors such as moisture and contaminants. 
     SUMMARY OF THE INVENTION 
     The present invention relates to a connector assembly for mounting a light bulb to a fixture. The fixture has an interior surface, an exterior surface, and an opening. The opening defines a peripheral surface interconnecting the interior and exterior surfaces. 
     The connector assembly includes a housing for supporting the light bulb, at least one tab, and a flange. The housing has an axis, a first portion, and a second portion spaced axially from the first portion. The tab extends radially from the first portion of the housing and includes at least a first pair of electrical contacts for engaging at least a second corresponding pair of electrical contacts on the interior surface of the fixture when the first portion of the housing is axially inserted through the opening in the fixture and rotated about the axis of the housing. The flange extends radially from the second portion of the housing and has a seal for axially engaging the exterior surface of the fixture as the first portion of the housing is inserted through the opening in the fixture. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The foregoing and other features of the invention will become more apparent to one skilled in the art upon consideration of the following description of the invention and the accompanying drawings wherein: 
     FIG. 1 is a schematic view of a connector assembly embodying the present invention; 
     FIG. 2 is a view taken along line  2 — 2  of FIG. 1; 
     FIG. 3 is a view taken along line  3 — 3  of FIG. 1; and 
     FIG. 4 is a schematic view of the assembly of FIG. 1 mounting a light bulb to a fixture. 
    
    
     DESCRIPTION OF PREFERRED EMBODIMENTS 
     According to the present invention, as seen in FIGS. 1-4, a connector assembly  40  mounts, both mechanically and electrically, a wedge base lamp (light bulb)  20  to a taillight lens (fixture)  22  of a vehicle. 
     As viewed in FIG. 4, the fixture  22  has an interior surface  24 , an exterior surface  26 , and an opening  28 . The opening  28  defines a peripheral surface interconnecting the interior and exterior surfaces  24 ,  26 . 
     The connector assembly  40  includes a cylindrical housing  42 , a first arc-like tab  44 , a second smaller arc-like tab  46 , and a circular flange  48 . The housing  42  supports the light bulb  20  on the fixture  22 . The housing  42  has an axis  50 , a first portion  52 , and a second portion  54  spaced axially from the first portion  52 . The first and second portions  52 ,  54  are centered on the axis  50 . The housing  42  further includes a socket  56  and a base, or knob  58 . The socket  56  receives the light bulb  20 . The knob  58  provides a handle for the connector assembly  40  which handle is manipulated during installation onto the fixture  22 . 
     The first and second tabs  44 ,  46  extend radially from the first portion  52  of the housing  42  and circumferentially around the housing  52 . The tab  46  extends a shorter distance circumferentially around the housing  42  than the tab  44 . The tabs  44 ,  46  are spaced apart at diametrically opposed positions around the axis  50  of the housing  42 . Each of the first and second tabs  44 ,  46  is associated with one of a first pair of metal electrical contacts  60 ,  62  for engaging a second corresponding pair of metal electrical contacts  30 ,  32  molded into the interior surface  24  of the fixture  22  (FIG.  4 ). The contacts  60 ,  62  are located beneath the tabs  44 ,  46 , respectively, as shown in FIG.  4 . 
     The connector assembly  40  is installed on the fixture  22  by axially inserting the first portion  52  of the housing  42  through the opening  28  in the fixture  22  and rotating the connector assembly  40  about the axis  50  of the housing  42 . The knob  58  on the housing  42  is manually gripped to manipulate the connector assembly  40  during this operation. 
     The first pair of electrical contacts  60 ,  62  electrically connect with contacts  71 ,  72  within the socket  56  of the connector assembly  40  and transfer power from the first pair of contacts  60 ,  62  to the contacts  71 ,  72  and corresponding contacts (not shown) on the light bulb  20 . The second pair of electrical contacts  30 ,  32  on the fixture  22  engage power conduits  36 ,  38  embedded within the fixture  22 . The power conduits  36 ,  38  are connected to a power source, such as a vehicle battery or a vehicle alternator. Through these connections, power is transferred to the light bulb  20 . 
     Each of the first pair of the electrical contacts  60 ,  62  associated with the first and second tabs  44 ,  46  is received in first and second recessed portions  64 ,  66  on the first and second tabs  44 ,  46 , respectively. A projection  70  is located adjacent the second tab  46 . This projection  70  limits the rotation of the housing  42  about the axis  50  after the first portion  52  of the housing  42  is inserted through the opening  28  of the fixture  22 . The projection  70  determines a stopping point for rotation of the housing  42  by abutting a portion of the fixture  22 . 
     The flange  48  extends radially from the second portion  54  of the housing  42  and supports a seal ring  80  which is concentric about the axis  50  of the housing  42 . The seal ring  80  engages the exterior surface  26  of the fixture  22  and is compressed as the first portion  52  of the housing  42  is inserted through the opening  28  in the fixture  22 . Together, the tabs  44 ,  46  and the flange  48  secure the contacts  30 ,  32 ,  60 ,  62 , the fixture  22 , and the seal ring  80  between them, as seen in FIG.  4 . The seal ring  80  blocks moisture and contaminants from reaching any of the electrical contacts  30 ,  32 ,  60 ,  62  and the interior of the fixture  22 . 
     The opening  28  of the fixture  22  includes a circular portion through which the housing  42  is inserted and two arcuate slots (not shown) which communicate with the circular portion. The slots correspond in size and shape to the first and second tabs  44 ,  46  (i.e., one slot sized to receive the first tab  44  and one slot sized to receive the smaller second tab  46 ). As the housing  42  is inserted through the opening  28 , each tab  44 ,  46  travels axially through its corresponding slot. As the housing  42  is then rotated about its axis  50 , the tabs  44 ,  46  move angularly about the axis  50  of the housing  42 , slide along the interior surface  24  of the fixture  22 , and block axial movement of the housing  42  back through the opening  28 . The projection  70  blocks rotation farther than the edge of the second tab  46  by abutting a side of the smaller of the two slots of the opening  28 . 
     The first pair of electrical contacts  60 ,  62  of the tabs  44 ,  46  and the seal ring  80  face in parallel opposite directions toward each other. The engagement of the flange  48  with the exterior surface  26  of the fixture  22  secures the first pair of electrical contacts  60 ,  62  of the tabs  44 ,  46  against the second pair of electrical contacts  30 ,  32  of the interior surface  24  of the fixture  22 . The engagement of the tabs  44 ,  46  with the interior surface  24  of the fixture  22  secures the seal ring  80  of the flange  48  against the exterior surface  26  of the fixture  22 . 
     The resilience of the seal ring  80  typically maintains a tight axial pressure fit between the tabs  44 ,  46 , the first pair of electrical contacts  60 ,  62 , the second pair of electrical contacts  30 ,  32 , the fixture  22 , the seal ring  80 , and the flange  48  because the flange  48  depresses the seal ring  80  against the exterior surface  26  of the fixture  22 . If the assembly is made of a flexible material, such as a polymer, the tabs  44 ,  46  and flange  28  may be fitted such that the tabs  44 ,  46  form flexure springs which are deflected axially when the tabs  44 ,  46  engage the fixture  22  and utilize friction between the tabs  44 ,  46  and the fixture  22  to further maintain the tight fit. 
     The housing  42  further includes two axially projecting support arms  141 ,  142 . The support arms  141 ,  142  are flexible cantilevers extending upward away from the base of the socket  56  (as viewed in FIG.  2 ). The support arms  141 ,  142  spring apart when the light bulb  20  is inserted into the socket  56  and spring back when the light bulb  20  is in its installed position, thereby securing the light bulb  20  in the socket  56 . 
     The housing  42  may be constructed of several parts which are assembled in order to enclose the connections of the electrical contacts  60 ,  62 ,  70 ,  72 . Mechanical snap construction or sonic welding are typical assembly methods if several parts are assembled together. 
     From the above description of the invention, those skilled in the art will perceive improvements, changes and modifications. For example, for a dual filament light bulb  20  three electrical contacts and three tabs would be required instead of the two electrical contacts  60 ,  62  and two tabs as disclosed in the drawings. Such improvements, changes and modifications within the normal skill of the art are intended to be included within the scope of the appended claims.