Patent Abstract:
A connector, comprises a connector assembly; a main housing having an internal chamber for receiving therein the connector assembly; and a housing cover which mates with the main housing to cover the internal chamber. The main housing includes an opening at one end of the main housing with a removable and retractable cover permitting access to the internal chamber. A mating connector is connected to the connector assembly, the mating connector including a fastening tab; and the fastening tab including a main tab that is interlocked with the removable cover to prevent the mating connector from unintentionally disconnecting from the connector assembly. A protective housing assembly is also disclosed.

Full Description:
RELATED APPLICATIONS 
     The present application is related to applicant&#39;s Australian patent application No. AU2009201426 published on Oct. 28, 2010 and applicant&#39;s U.S. Design Pat. No. D640,639, issued on Jun. 28, 2011, the disclosures of which are hereby incorporated by reference. 
     FIELD OF THE INVENTION 
     The present invention relates to a protective housing assembly for electrical connectors and in particular a protective housing assembly which encases an electrical connector for physical protection and secures a connected mating connector from inadvertent disconnection. 
     The invention has been developed primarily as a protective housing assembly for electrical connectors and will be described hereinafter with reference to this application. However, it will be appreciated that the invention is not limited to this particular field of use. 
     BACKGROUND OF THE INVENTION 
     Any discussion of the prior art throughout the specification should in no way be considered as an admission that such prior art is widely known or forms part of the common general knowledge in the field. 
     There are many types of electrical connector&#39;s available with the main purpose to connect and supply electrical current to a mating connector. There are many electrical connectors that are used in applications which they were physically not designed for or certain connectors may be designed for the application however lack essential physical protective features to operate correctly and prolong their operational life. An example of this is using a heavy duty connector assembly made for fixed interior use in or on the exterior of a motor vehicle. In such circumstances the connector is vulnerable to the intake of dust and moisture as well as exposed to extreme vibration. Furthermore the mounting of the connector may not be sufficient to make it securely attached to the vehicle. Any mating connector would suffer the same problems. The mating connection between the two connectors could also prove to make a poor electrical connection and possibly even be disconnected due to vibration because of incorrect mounting and mating retaining setups. 
     Attempts have been made to protect electrical connectors in the form of molded housings. Conventional housings of this nature include those found in WO/2005/069444 and WO/2009/043862. 
     WO/2005/069444 discloses a housing for a connector module in which the housing has a frame for which the connector module can be inserted to. A stirrup device which is movable about the housing serves the purpose of aiding the coupling of an additional connector as well as providing a locking means for the initial connector module in the frame. 
     This device while providing a housing has a main objective of locking the connector module to the housing by way of stirrup device. The connector module is not fixable to the main housing with out the stirrup device engaged. Furthermore the device does not include a complete barrier to protect the connector module from environmental conditions. 
     WO/2009/043862 discloses connector cover with first and second connecting members which are able to be connected together to cover a connector. At least one of the parts has a protruding locking pin to engage and lock the connector cover to a separate housing. 
     The connector cover does not have a fixing means to the actual connector itself however; instead the assembly relies on the connecting of the first and second connecting members together to hold the housing, total stability is only achieved when the connector cover is engaged into the separate housing. This device also lacks a complete barrier to protect the housed connector inside the cover assembly. 
     It has now been found by the present inventors that a connector cover assembly can be economically constructed to form a complete barrier to physically protect an electrical connector without affecting its operation or versatility. It has also been found by the present inventors that such an assembly can be used with different connector types. 
     OBJECTS OF THE INVENTION 
     It is an object of the present invention to overcome or ameliorate at least one of the disadvantages of the prior art, or to provide a useful alternative. 
     It is yet another object of the present invention to provide a connector housing assembly which provides a securing means for fastening a connector into a main housing of the connector cover assembly to ensure stability. 
     A further object of the invention provides a sealed physical protective barrier for a connector seated into the connector cover assembly, in which the barrier also allows access when a mating connector is needed to make a connection to the connector. 
     Another object of the invention is to provide solid points for mounting the connector housing assembly to a surface. 
     It is yet a further object of the invention to provide a connector housing assembly which has means to secure the physical connection of a mating connector to the connector housed within the connector housing assembly. 
     SUMMARY OF THE INVENTION 
     The present invention provides a protective housing assembly for a connector, comprising a main housing having an internal chamber for receiving therein a connector assembly, the internal chamber having a first dowel for insertion into an aperture in the connector assembly, thereby to position the connector assembly within the chamber; a housing cover including a second dowel for insertion into the aperture of the connector assembly, thereby to interlock the housing cover with the connector assembly and the main housing, the housing cover being attached to the main housing to cover the internal chamber; an opening at one end of the main housing with a removable and retractable cover to permit access to the internal chamber; another opening at another end of the main housing to permit access to the internal chamber; and the main housing and the housing cover including flanges for attachment to a surface. 
     The present invention also provides a connector comprising a connector assembly; a main housing having an internal chamber for receiving therein the connector assembly; and a housing cover which mates with the main housing to cover the internal chamber. The main housing includes an opening at one end of the main housing with a removable and retractable cover permitting access to the internal chamber. A mating connector is connected to the connector assembly, the mating connector including a fastening tab; and the fastening tab including a main tab that is interlocked with the removable cover to prevent the mating connector from unintentionally disconnecting from the connector assembly. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       In order that the invention may be better understood and put into practical effect, reference will now be made to the accompanying drawings in which:— 
         FIG. 1  is a front perspective view of a protective housing assembly in a fully assembled condition with a removable cover in the open position; 
         FIG. 2  is a side plan view the protective housing assembly with the removable cover closed; 
         FIG. 3  is a bottom plan view of the protective housing assembly; 
         FIG. 4  is a top plan view of the protective housing assembly; 
         FIG. 5  is a front elevational view of the protective housing assembly with the removable cover closed; 
         FIG. 6  is an end elevational of the protective housing assembly showing a rear sealing device; 
         FIG. 7  is a front perspective view of a connector assembly; 
         FIG. 8  is a top plan view of the connector assembly; 
         FIG. 9  is a top plan view of the main body showing the elements of the internal section; 
         FIG. 10  is a bottom plan view of the top cover showing underside elements; 
         FIG. 11  is an exploded end view of the protective housing assembly showing a second form of sealing means; 
         FIG. 12  is a partially assembled end view showing the assembly and second form of sealing means; 
         FIG. 13  is an end view of a first form of sealing means; 
         FIG. 14  is an exploded front perspective view of the protective housing assembly showing how the connector assembly is fitted to the protective housing cover; 
         FIG. 15  is an exploded side view of the protective housing assembly in unassembled condition showing exterior components; 
         FIG. 16  is a side plan view of the protective housing assembly showing securing means for a mating connector before it is connected to the connector assembly inside the protective housing assembly; 
         FIG. 17  is a side plan view of the protective housing assembly showing securing means for a mating connector after it is connected to the connector assembly inside the protective housing assembly; 
         FIG. 18  is a top plan view of the internal section of the main body showing how the first form and second form sealing means can be used together and applied to a cable; 
         FIG. 19  is an exploded front perspective view showing a twelve pin trailer connector to be disposed inside the protective housing assembly; 
         FIG. 20  is an exploded front perspective view showing a dual seven pin trailer connector to be disposed inside the protective housing assembly; 
         FIG. 21  is a perspective top side and rear end of the protective housing assembly; 
         FIG. 22  is a perspective bottom side and front end view of the protective housing assembly; 
         FIG. 23  is a perspective view of the internal structure of housing cover; and 
         FIG. 24  is a perspective view of the internal structure of the main housing. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring to the drawings, the fully assembled protective housing assembly  10  is shown in  FIG. 1 . A housing cover  12  is attached to and interlocks with a main housing  14 . At the front end of the protective housing assembly  10  there is an opening  15  to an internal chamber  17  which is molded into the interior of the main housing  14 . The opening  15  is defined by means of a removable cover  18 . The cover includes a weather proof seal  20 , which when retracted against the main body  14  closes and seals the opening  15 . The removable cover  18  is attached to the main body by a pin  22  which is inserted into a hole  24  in the removable cover  18 . The pin  22  also is inserted into pin dowels  16  which are attached to the main body  14 . This setup attaches the removable cover  18  to the main body. The removable cover  18  is automatically closed by a spring  26  which applies pressure to the removable cover  18  in the closed position, thus requiring a force to open. 
       FIG. 2  shows the removable cover  18  in the closed position, the housing cover  12  and main housing  14  are defined by the lines  3 - 3 . A first form rear sealing device  28  is shown attached to the rear end of the protective housing assembly  10 . The first form rear sealing device  28  acts as a cable entry and sealing point into the main housing  14 . A gland nut  30  is attached to the rear sealing device  28 . An insert  32  is molded into the bottom of the main housing  14 . The insert provides means of attaching the housing cover  12  to the main housing  14 . 
     As shown in  FIG. 3  the main body  14  has bracket flanges  34 ,  36  attached at each side. Each bracket flange  34 ,  36  include a plurality of holes  38 - 48 . A main housing aperture  50  is shown placed into the molded insert  32 . 
       FIG. 4  shows the housing cover  12  which has bracket flanges  52 ,  54  attached at each side. Each bracket flange  52 - 54  includes a plurality of holes  56 - 66 . An housing cover aperture  72  is embedded into the housing cover  12  which aligns with the main housing aperture  50  when the housing cover  12  is interlocked with the main body  14 . Finger grips  68  and  70  protrude from the retractable cover as shown in  FIG. 4 . When the housing cover  12  and the main body  14  are interlocked the bracket flanges  34 ,  36  of the main body  14  align with the bracket flanges  52 ,  54  of the housing cover  12  to form completed brackets  74 ,  76  of the protective housing assembly  10 . 
     The rear end sealing device  28  is shown in its complete form in  FIG. 6 . The gland nut  30  compresses a constrictive gland  78  which seals around a cable when tightened. 
     A connector assembly  80  is illustrated in  FIGS. 7 and 8  in its complete form, commonly known to a person skilled in the art as an “Anderson Connector” although many look alike alternatives exist. The connector assembly  80  has a bottom wall  81  and at least one electrical connector  83  housed within it. A plurality of protrusions  82 ,  84  on each side wall  88 ,  86  as shown in  FIG. 8 . The connector assembly  80  also has a front wall  90 , a top wall  91 , and end wall  92 . Two connector assembly apertures  94 ,  96  extend from the top wall  91  to the bottom wall  81 . 
       FIGS. 9 and 24  show in detail the internal chamber  17  of the main housing  14 . The internal chamber is shaped to receive the contours of the connector assembly  80 . When the connector assembly  80  is inserted into the internal chamber  17 , the internal chamber front wall  98  aligns with the front wall  90  of the connector assembly  80 . The internal chamber bottom wall  100  mates with bottom wall  81 , internal chamber side walls  102  and  104  also align with side walls  88  and  86  of the connector assembly  80 . A plurality of opposing protrusions  108 ,  106  on each side of the internal chamber  17  are shaped to mate with the protrusions  82 ,  84  of the connector assembly  80  when inserted into the internal chamber  17 . The internal chamber end wall  110  also aligns with the bottom end wall  81 . An internal chamber aperture  112  extends to main housing aperture  50  and aligns with connector assembly aperture  94  on the connector assembly  80 . An internal chamber locating dowel  114  is also situated on the internal chamber bottom wall  100  and aligns and interlocks with connector assembly aperture  96  on the connector assembly  80 . An internal groove  116  is molded into one end of the main body  14  which receives the sealing device  28 . 
     The underside of the housing cover  12  is shown in  FIGS. 10 and 23 . The housing cover internal wall  118  aligns with the top wall  91  of the connector assembly  80 . An internal housing cover aperture  120  extend to housing cover aperture  72  and aligns with connector assembly aperture  94  of the connector assembly  80 . A rectangular housing cover locating dowel  122  has an outer end  123  that engages against the top wall  91  of the connector assembly  80  to keep the connector assembly  80  from moving up and down within the housing assembly. A round housing cover locating dowel  124  aligns and interlocks with aperture  96  of the connector assembly. An internal groove  126  is molded into one end of the housing cover which aligns with the internal groove  116 . The setup of the aperture alignment and dowel alignment provide a fastening mechanism for the connector assembly  80  into the protective cover housing  10 . 
     As illustrated in  FIGS. 11 and 12 , top seal  128  and bottom seal  130  are inserted into top groove  126  and bottom groove  116 . Each seal being made of a flexible sealing material. Cable cut outs  134  and  132  exist on each top seal  128  and bottom seal  130 .  FIG. 12  shows how when the protective housing assembly  10  is assembled, top seal  128  and bottom seal  130  align and compress to form a second form sealing device  136  for a cable. 
       FIG. 13  shows a first form sealing device  28  with gland nut  30  and constrictive cable gland  70  which seals and grips the cable. The second form sealing device  136  can be used independently of the sealing device  28  and vice versa. Each sealing device  136  and  28  can also be used together within the protective housing assembly  10 . 
       FIG. 14  Illustrates how the connector assembly  80  is aligned to housing cover  12  and main housing  14  in preparation to assemble the protective housing assembly  10 . The connector assembly  80  is inserted into the main housing  14  and aligned with the main housing side walls  106  and  108 . The protrusions on the side wall  94  align and mate with protrusions  108  of the internal chamber. Locating dowels  122 ,  124  and  114  all assist in aligning and securing the connector assembly into the completed protective housing assembly  10 . 
       FIG. 15  shows an external exploded view of protective housing assembly and in particular a fastener  138  in the form of a bolt is shown which extends through apertures  72 ,  94  and  50  and can be tightened to an opposing fastener  144  in the form of a nut which is secured into the molded insert  32 . The fastener  138  acts as means for attaching and securing the connector assembly  80  to the main housing and also the housing cover  12  to the main housing. A gripping finger gland  140  and constrictive seal form the constrictive gland  72  and are part of the first form sealing device  28 . 
     A fastening device  146  is illustrated in  FIG. 16  which is inserted into a mating connector  158 . The fastening device  146  has a tab  148  extending downwards. Pins  150  and  152  are attached to the fastening device and extend upwards. The pins  150  and  152  have locking heads  154 ,  156 . The fastening tab  146  is inserted into the mating connector  158  by way of pins  150  and  152  being inserted into mating connector apertures  160 ,  162  respectively. Once fully inserted, locking heads  154  and  156  securely lock the fastening tab  146  to the mating connector  158 . Shown in  FIG. 17  when the mating connector  158  is inserted into the protective housing assembly,  10  and mated to the connector assembly  80  housed inside, a front wall  164  of the removable cover  18  engages with the main tab  148  of the fastening device, thereby securing the mating connector  158  to the protective housing assembly  10 . 
       FIG. 18  shows how both first and second form sealing devices  28  and  136  respectively are used together in the protective housing assembly  10 . The cable from the connector assembly  80  is first sealed by the top seal haled  128  and bottom seal half which are comprised around cable entry holes  132  and  134  respectively. The cable is then placed through the sealing device  28  for which the gland nut  30  tightens around the constrictive gland  72  forming a secure cable seal. 
       FIG. 19  illustrates how different forms of connectors or connector assemblies can be used with the protective housing assembly. A twelve pin flat trailer connector assembly  168  has a plurality of protrusions  170  in the same form as those protrusions  82  on the connector assembly  80 . The twelve pin flat trailer connector assembly  168  is aligned to housing cover  12  and main housing  14  in preparation to assemble the protective housing assembly  10 . The twelve pin flat trailer connector assembly  168  is inserted into the main housing  14  and aligned with the main housing side walls. The protrusions on the side wall  170  align and mate with protrusions  108  of the internal chamber. Locating dowels  122 ,  124  and  114  all assist in aligning and securing the twelve pin flat trailer connector assembly  168  into the completed protective housing assembly  10 . 
       FIG. 20  shows another form of connector assembly that can be used in the housing in the form of a dual seven pin round trailer connector assembly  172  which has a plurality of protrusions  174  in the same form as those protrusions  82  on the connector assembly  80 . The dual seven pin round trailer connector assembly  172  is aligned to top cover  12  and main housing  14  in preparation to assemble the protective housing assembly  10 . The dual seven pin round trailer connector assembly  172  is inserted into the main housing  14  and aligned with the main housing side walls. The protrusions on the side wall  174  align and mate with protrusions  108  of the internal chamber. Locating dowels  122 ,  124  and  114  all assist in aligning and securing the dual seven pin round trailer connector assembly  172  into the completed protective housing assembly  10 . 
       FIGS. 21 and 22  show the various exterior features of the protective housing assembly  10 . 
     Although the invention has been herein shown and described in what is conceived to be the most practical and preferred embodiment, it is recognized that departures can be made within the scope of the invention, which is not to be limited to the details described herein but is to be accorded the full scope of the appended claims so as to embrace and any all equivalent devices and apparatus.

Technology Classification (CPC): 7