Patent Publication Number: US-2023139373-A1

Title: Breakaway electrical connector

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. Application 63/275,573 filed Nov. 4, 2021 the contents of which are incorporated by reference herein. 
    
    
     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. 
     The above-described and other features and advantages of the present disclosure will be appreciated and understood by those skilled in the art from the following detailed description, drawings, and appended claims. 
    
    
     
       DESCRIPTION OF THE DRAWINGS 
         FIG.  1    is a perspective view a breakaway electrical connector according to an exemplary embodiment of the present disclosure in a connected state; 
         FIG.  2    is a perspective view of a load side of the breakaway electrical connector of  FIG.  1   , 
         FIG.  3    is an end view of the load side of  FIG.  2   ; 
         FIG.  4    is a perspective view of a line side of the breakaway electrical connector of  FIG.  1   ; 
         FIG.  5    is an end view of the line side of  FIG.  4   ; 
         FIG.  6    is a first sectional view of the breakaway electrical connector of  FIG.  1    in a normal or disconnected connected state; 
         FIG.  7    is the first sectional view of the breakaway electrical connector of  FIG.  1    in a first partially connected state; 
         FIG.  8    is the first sectional view of the breakaway electrical connector of  FIG.  1    in a second partially connected state; 
         FIG.  9    is a second partial sectional view of the breakaway electrical connector of  FIG.  1    in a connected state; and 
         FIG.  10    illustrates an exemplary embodiment of a set of multipole magnets for use with the breakaway electrical connector of  FIG.  1   . 
     
    
    
     DETAILED DESCRIPTION 
     Referring to the drawings and in particular with simultaneous reference to  FIGS.  1 - 5   , an exemplary embodiment of a breakaway electrical connector according to the present disclosure is shown and is generally referred to by reference numeral  10 . 
     Connector  10  includes a line side  12  and a load side  14  connected to line conductor  16  and a load conductor  18 , respectively. In the illustrated embodiment, sides  12 ,  14  each have a water-tight compression fitting  20  for connection to conductors  16 ,  18 . Fitting  20  allows sides  12 ,  14  to be wired directly to the existing conductors  16 ,  18  on vehicles and stationary power supplies. 
     Of course, it is contemplated by the present disclosure for sides  12 ,  14  to be connected to conductors  16 ,  18  in any desired manner. 
     Connector  10  includes one or more magnets  22  arranged on each of line side  12  and load side  14 . In the illustrated embodiment, sides  12 ,  14  each have four magnets  22 . Of course, it is contemplated by the present disclosure for sides  12 ,  14  to have more or less than four magnets  22  each. 
     Advantageously, connector  10  provides an industrial grade, horsepower rated connector with sides  12 ,  14  that are magnetically secured to one another via magnets  22  with 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 side  12 ,  14 , conductors  16 ,  18 , or fittings  20 . 
     Stated differently, the magnetic connection provided to connector  10  by magnets  22  is sufficient to maintain sides  12 ,  14  connected to one another during normal operation, but this magnetic connection is less than the pull-apart strength of sides  12 ,  14  and of fittings  20 , as well as being less than a tensile strength of conductors  16 ,  18 . As used herein, the term “pull-apart strength” shall mean the strain relief limits of fittings  20 . 
     In the illustrated embodiment, connector  10  is shown as a four-contact connector where line and load sides  12 ,  14  each have a ground contact  24 , a neutral contact  26 , and one or more hot contacts  28 ,  30  (two shown). 
     Of course, it is contemplated by the present disclosure for connector  10  to be configured with any desired configuration of contacts. Moreover, it is contemplated by the present disclosure for connector  10  to be configured for use with one or more different voltages such as, but not limited to, voltages from 12 to 480. 
     Connector  10  can include one or more alignment features. 
     In some embodiments, line side  12  can have a guide opening  32  and load side  14  can have a corresponding guide protrusion  34 . Opening  32  receives protrusion  34  so as to align line side  12  and load side  14  to one another during assembly. In the illustrated embodiment, opening  32  and protrusion  34  are shown centrally arranged in sides  12 ,  14 , respectively and have symmetrical configurations with four sides arranged in a cross-shape. 
     Of course, it is contemplated by the present disclosure for opening  32  and protrusion  34  to have any desired configuration. For example, opening  32  and protrusion  34  can have non-symmetrical shapes and/or can be non-concentrically arranged. In these embodiments, the shapes and/or arrangement of opening  32  and protrusion  34  can ensure proper connection of line side  12  and load side  14  to one another via alignment of contacts  24 ,  26 ,  28 ,  30 . 
     In some embodiments either alone or in combination with opening  32  and protrusion  34 , connector  10  can be configured so that the arrangement of magnets  22  provide, in addition to the aforementioned magnetic connection force, alignment of contacts  24 ,  26 ,  28 ,  30 . 
     The alignment via magnets  22  can be seen with reference to the end views of sides  12 ,  14  shown in  FIGS.  3  and  5   . The polarity of the magnets  22  have been arranged in a manner that sides  12 ,  14  can only be assembled such that contacts  24 ,  26 ,  28 ,  30  of the two sides are properly mated. 
     For example, sides  12 ,  14  can be configured such that magnets  22  having a positive or southern polarity are arranged on the left-hand side of ground and neutral contacts  24 ,  26 , while the magnets having a negative or north polarity are arranged on the right-hand side of ground and neutral contacts  24 ,  26 . 
     Due to this exemplary arrangement of magnets  22  with respect to ground and neutral contacts  24 ,  26 , the magnets  22  would repel sides  12 ,  14  from one another during attempts to assembly connector  10  such that side  12  with ground  24  at the top and neutral  26  at the bottom to side  14  with neutral  26  at the top and ground  24  at the bottom. Further, this exemplary arrangement of magnets  22  with respect to ground and neutral contacts  24 ,  26 , results in the magnets  22  attracting sides  12 ,  14  towards one another during attempts to assembly connector  10  such that sides  12 ,  14  both having ground  24  at the top and neutral  26  at the bottom. 
     Of course, the present disclosure contemplates other arrangements of magnets  22  and contacts  24 - 30  with respect to one another that ensures the desired alignment of the contacts on sides  12 ,  14 . 
     In some embodiments either alone or in combination with the alignment capability provided by opening  32 /protrusion  34  and/or magnets  22 , connector  10  can be configured so that one or more of contacts  24 - 30  can function as alignment features. 
     The alignment via contacts  24 - 30  can be seen with reference to the perspective views of sides  12 ,  14  shown in  FIGS.  2  and  4   . Here, it can be seen that contacts  24 ,  26 ,  28 ,  30  on load side  14  protrude or extend outward, while the contacts on the line side  12  are recessed inward. 
     The recessed contacts  24 - 30  of line side  12  are configured to receive the protruding contacts  24 - 30  of load side  14  so as to align the line and load sides to one another during assembly. 
     In the illustrated embodiment, the recessed and protruding contacts  24 - 30  are shown having a common size and shape. Of course, it is contemplated by the present disclosure for only the contacts on sides  12 ,  14  that are intended to mate with one another to have a common shape to provide further alignment assurance. 
     As shown, connector  10  is configured so that line side  12  includes opening  32  and recessed contacts  24 - 30 —which correspond to an outlet, while load side  14  includes protrusion  34  and protruding contacts  24 - 30 —which correspond to a male plug. In this configuration, connector  10  is configured to provide a familiar look and feel to normal outlets and plugs. 
     Line side  12  is 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 contacts  24 - 30 . Thus, the recessed nature of contacts  24 - 30  on line side  12  can 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 sides  12 ,  14  in any desired manner. 
     In some embodiments, connector  10  can be configured to provide for a specific order of connection among contacts  24 ,  26 ,  28 ,  30 . 
     For example, connector  10  can be configured so that ground contacts  24  on sides  12 ,  14  mate before any of the remaining contacts  26 ,  28 ,  30  mate with one another. Further, connector  10  can be configured so that neutral contacts  26  on sides  12 ,  14  mate after ground contacts  24  are mated, but before hot contacts  28 ,  30  mate. Finally, connector  10  can be configured so that hot contacts  28 ,  30  on sides  12 ,  14  mate after ground and neutral contacts  24 ,  26  are mated with one another, respectively. 
     Connector  10  is 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 sides  12 ,  14 . 
     Accordingly, connector  10  can be configured so that the distance each pair of mating contacts are recessed in and/or protrude from line and load sides  12 ,  14 , respectively, provide the desired ordered mating of contacts  24 - 30 . 
     In some embodiments, connector  10  can be leave one or more of the contacts  24 - 30  on line side  12  unenergized until at least partially mated with load side  14 . In this manner, line side  12  is presented with a dead front end—namely with one or more of contacts  24 - 30  in a de-energized state—until the line side is mated with load side  14 . 
     The specific order of mating of contacts  24 - 30  and the dead front end of line side  12  are described in more detail with simultaneous reference to  FIGS.  6 - 9   . 
     Connector  10  is shown in  FIGS.  6 - 8    via a first cross section that passes through ground contact  24  and neutral contact  26  such that the order of mating and dead front end of connector  10  are discussed with respect to contacts  24 ,  26 . Connector  10  is shown in  FIG.  9    via a second cross section, taken ninety degrees from the first cross section of  FIGS.  6 - 8   , that passes through hot contacts  28 ,  30 . 
       FIG.  6    illustrates connector  10  in a normal or disconnected state. Here, guide protrusion  34  of load side  14  is being received in guide opening  32  into line side  12  so as to start the mating of the line and load sides—while none of the contacts  24 ,  26 ,  28 ,  30  have yet mated with one another. 
     Ground contact  24  has a front portion  24   a , a rear portion  24   b , and a biasing member  24   c . Front portion  24   a  is positioned for connection with the corresponding ground contact  24  of load side. Front portion  24   a  is movable along an axis of the mating movement of connector  10  and is normally biased by biasing member  24   c  away from rear portion  24   b . Rear portion  24   b  is operatively connected to supply conductor (not shown) and, thus, is energized by the supply conductor. 
     In the normal position shown in  FIG.  6   , biasing member  24   c  forms an air gap  24   d  between front and rear portions  24   a ,  24   b  of ground contact  24 . Biasing member  24   c  is electrically isolated from at least one—and preferably both—front and rear portions  24   a ,  24   b  of ground contact  24 . In this manner, ground contact  24  is configured so that electrical energy cannot be conducted from rear portion  24   b  to front portion  24   a  in the normal position. 
     Neutral contact  26  is similarly constructed and, thus, also has a front portion  26   a , a rear portion  26   b , and a biasing member  26   c  that result in an air gap  26   d  between the front and rear portions in the normal position of  FIG.  6   . 
     Although not shown, hot contacts  28 ,  30  are also similarly constructed and, thus, have an air gap between the front and rear portions in the normal position of  FIG.  6   . 
     As shown, the front portions  24   a ,  26   a  of contacts  24  and  26  (as well as the unshown contacts  28 ,  30 ) on line side  12 , although connected to the supply conductor, are not energized—providing the line side of connector  10  with a “dead front end”. 
       FIG.  7    illustrates connector  10  in a partially connected state. 
     Here, ground contact  24  of line side  12  and ground contact  24  of load side  14  have contacted with one another. It can be seen that the force of contacts  24  of line and load sides  12 ,  14  on one another has compressed biasing member  24   c  to the point where air gap  24   d  has been closed with front and rear portions  24   a ,  24   b  of ground contact  24  of the line side in electrical contact with one another. This position places the front portion  24   a  in electrical communication with the supply conductor through rear portion  24   b  and places front portion  24   a  in electrical communication with the corresponding ground contact  24  on load side  14 . 
     It can also be seen that air gap  26   d  of neutral conductor  26  remains—with front and rear portions  26   a ,  26   b  of the neutral contact  26  electrically isolated from one another, such that the front portion  26   a  is electrically isolated from supply conductor. 
     Air gap  26   d  remains due to one or more dimensions of connector  10 . 
     In one embodiment, line side  12  can be configured such that neutral contact  26  is recessed more as compared to ground contact  24 . In other embodiments, load side  14  can be configured such that ground contact  24  protrudes more as compared to neutral contact  26 . In still other embodiments, line side  12  can be configured such that air gap  24   d  of ground contact  24  is smaller than air gap  26   d  of neutral contact  26 . 
     Of course, it is contemplated by the present disclosure for connector  10  include one or more of these or other dimensional constraints sufficient to ensure that during mating of line and load sides  12 ,  14  the front and rear portions  24   a ,  24   b  mate prior to the front and rear portions  26   a ,  26   b.    
     Although not shown, it can be appreciated that since hot contacts  28 ,  30  are also similarly constructed, these hot contacts also still have an air gap between the front and rear portions in the partially connected state of  FIG.  7   . 
       FIG.  8    illustrates connector  10  in a second partially connected state, namely after mating of ground contacts  24  and neutral contacts  26 . 
     Here, it can be seen that biasing member  26   c  has also been compressed to a point where air gap  26   d  has been closed with front and rear portions  26   a ,  26   b  of neutral contact  26  in electrical contact with one another. This position places the front portions  24   a ,  26   a  in electrical communication with the supply conductor through rear portions  24   b ,  26   b  and places front portions  24   a ,  26   a  in electrical communication with the corresponding ground and neutral contacts  24 ,  26  on load side  14 . 
       FIG.  9    illustrates connector  10  in a connected state, namely after mating of ground contacts  24 , neutral contacts  26 , and hot contacts  28 ,  30 . 
     Biasing members  28   c ,  30   c  have also been compressed to a point where the respective air gaps have been closed with front and rear portions hot contacts  28 ,  30  in electrical contact with one another, respectively. To provide the aforementioned front dead end, connector  10  is configured so that the air gaps of hot contacts  28 ,  30  are closed after air gap  26   d  of neutral contact  26 . 
     Disconnection of line and load sides  12 ,  14  is the reversal of the above-described process, where hot contacts  28 ,  30  reform the respective air gaps prior to neutral contact  26 , which in turn reforms its air gap prior to ground contact  24 . 
     In some embodiments, one or more of contacts  24 ,  26 ,  28 ,  30  are 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 connector  10  is illustrated by way of example only as having multiple magnets  22  on each of line and load sides  12 ,  14 . However, it is contemplated by the present disclosure for connector  10  to include embodiments having a single magnet  122  on each side  12 ,  14 . Magnet  122  is described in more detail with reference to  FIG.  10   . 
     Magnet  122  is illustrated as a two-pole magnet—namely having both a positive or southern polarity and a negative or northern polarity. Connector  10  can be configured to have one magnet  122  on line side  12  and one magnet  122  on load side  14 . The magnets  122  are positioned on sides  12 ,  14  with the polarity arranged in a manner that the sides can only be assembled with contacts  24 ,  26 ,  28 ,  30  of the two sides properly mated. As shown, one magnet  122  (left hand side of  FIG.  10   ) can have the southern polarity at the top and the other magnet  122  (right hand side of  FIG.  10   ) can have the southern polarity at the bottom. 
     Of course, it is contemplated by the present disclosure for sides  12 ,  14  to have the single magnets  122  with other arrangements that ensure contacts  24 ,  26 ,  28 ,  30  of the two sides are properly mated. Moreover, it is contemplated by the present disclosure for connector  10  to have more that one magnet  122  on each side  12 ,  14  and/or to include a combination of single pole magnets  22  and multipole magnets  122 . 
     Connector  10  provides the advantage of eliminating of costly and untimely repairs of damaged electrical wiring systems due to accidental drive off while sides  12 ,  14  are connected. Connector  10  further 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. 
     It should also be noted that the terms “first”, “second”, “third”, “upper”, “lower”, and the like may be used herein to modify various elements. These modifiers do not imply a spatial, sequential, or hierarchical order to the modified elements unless specifically stated. 
     While the present disclosure has been described with reference to one or more exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the present disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the disclosure without departing from the scope thereof. Therefore, it is intended that the present disclosure not be limited to the particular embodiment(s) disclosed as the best mode contemplated, but that the disclosure will include all embodiments falling within the scope of the appended claims. 
     
       
         
           
               
             
               
                   
               
               
                 PARTS LIST 
               
               
                   
               
             
            
               
                   
               
            
           
           
               
               
               
            
               
                   
                 breakaway electrical connector 10 
                 front portion 24a 
               
               
                   
                 line side 12 
                 rear portion 24b 
               
               
                   
                 load side 14 
                 biasing member 24c 
               
               
                   
                 line conductor 16 
                 air gap 24d 
               
               
                   
                 load conductor 18 
                 front portion 26a 
               
               
                   
                 fitting 20 
                 rear portion 26b 
               
               
                   
                 magnets 22 
                 biasing member 26c 
               
               
                   
                 ground contact 24 
                 air gap 26d 
               
               
                   
                 neutral contact 26 
                 front portion 28a 
               
               
                   
                 hot contacts 28, 30 
                 rear portion 28b 
               
               
                   
                 guide opening 32 
                 biasing member 28c 
               
               
                   
                 guide protrusion 34 
                 front portion 30a 
               
               
                   
                   
                 rear portion 30b 
               
               
                   
                   
                 biasing member 30c 
               
               
                   
                   
                 magnet 122