Electrical connectors – With contact preventer or retractable cover part – Movably mounted
Reexamination Certificate
1999-03-23
2001-01-09
Nguyen, Khiem (Department: 2839)
Electrical connectors
With contact preventer or retractable cover part
Movably mounted
Reexamination Certificate
active
06171118
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Technical Field
The present invention relates generally to electrically powered accessories for motor vehicles and, more particularly, to a cord set for such electrical powered accessories.
2. Discussion
Various electrically powered devices are designed for use with vehicles including automobiles, light-duty trucks, and heavy-duty vehicles. These devices, including cold weather starting devices such as radiant heaters, engine block heaters, fluid heaters, battery warmers, and the like, are generally fixed to the automobile body and operationally connected to an appropriate component of the vehicle engine. A factor in the sales and use of these devices is the simplicity with which the device can be electrically connected to the power source. To address this ease of use concern, cord sets have been developed that include a receptacle located on the vehicle body for mounting power cords that are connectable to the electrically powered device. The power cords terminate at a male or female plug that is coupled to the receptacle. The other of the male or female plug is selectively disposable in the receptacle to cooperate with the first plug, and electrically connect the device to the power source.
While manufacturers have provided cord sets for selectively connecting electrically powered automotive accessories to an external power source, they have failed to address a variety of operational and assembly concerns particularly with respect to mounting ease and protection of the contacts from the environment. Accordingly, a need still exists for a simple and robust cord set that may be easily installed in a variety of applications. This need manifests itself most specifically in the desire for manufacturing simplicity, cost savings, and operational simplicity.
A further concern with respect to cord sets designed for use with automobiles is the harsh environment to which the cord set is subjected during use. Specifically, it is necessary to maintain the electrical contacts clean and free from environmental elements when the male and female plugs of the cord set are not connected to one another.
In order to prevent dirt, ice, snow, and other environmental elements from negatively impacting the performance of the cord set and, particularly, the electrical connection between the male and female plugs, the prior art commonly provides a receptacle or housing. One of the cords in the set has a first end electrically connected to the electrically powered apparatus and a second end with the male plug. The male plug is received into one end of the housing and securely and sealingly coupled thereto. The housing generally includes a cover for sealing the first end of the housing while the interface between the plug and housing seals the rear side of the housing. As a result, the housing or receptacle requires two sealing interfaces. Each of the interfaces must effectively seal the contacts from environmental elements.
In addition to the multiple sealing interfaces, prior art cord sets required plug and housing configurations different from the standard configuration of electrical extension cords. Commonly, the plugs and receptacles are either circular or rectangular in cross-section to provide interfaces that can be more readily sealed. However, these configurations prevent the use of standard electrical extension cords with the cord sets.
In view of the above, it would be desirable to manufacture a cord set for an electrically powered automotive device that is sufficiently small in size to more readily fit in the extremely tight space constraint within the automotive market, that protects the electrical contacts of the plug automatically upon removal of the mating extension cord, effectively isolates the plug contacts from the surrounding environment, and that can accept standard extension cords.
It is further desirable in view of the above discussion to include a mounting mechanism for connecting the compact plug protector to a fixed point that is on or connectable to the vehicle. Such fixed point mounting plugs are more aesthetically pleasing, eliminate potential for customer misrouting, reduces the strain on the plug/wire interface, are more effectively secured to the vehicles so as to eliminate dangling and associated damage during vehicle motion, simplify power connections, and allow the use of simpler wire harnesses by terminating the plug at the vehicle bumper rather than requiring routing through the vehicle hood.
SUMMARY OF THE INVENTION
In view of the above, it is an object of the present invention to provide a cord set that includes a sealed cavity about the electrical contacts extending from the plug that is mounted to the vehicle body without the need for an additional receptacle or housing within which the plug is disposed.
It is a further object of the present invention to provide a protector cap and contact surface configuration that allows free movement of the protector cap between its open and closed positions while effectively sealing the contact cavity from the surrounding environment when the protector cap is in its closed position.
Still another object of the present invention is to provide a mounting mechanism for connecting the plug to the vehicle body which allows the plug to be mounted within tight space constraints.
Accordingly, the present invention provides a plug assembly and cord set for use with an automobile accessory that is mounted to an automobile body. More particularly, the plug assembly includes a plug body having a contact surface, electrical contacts coupled to the plug body and projecting from the contact surface, and a protector cap that accommodates the contacts and protects the contacts from the surrounding environment when the protector cap is in its closed position. The protector cap includes a contact cavity and a cap seal surface surrounding the contact cavity at an open end thereof. The protector cap is coupled to the plug body for pivotal movement between an open position and a closed position wherein the electrical contacts are disposed within the contact cavity and the cap seal surface engages the contact surface to seal the contact cavity when the protector cap is in its closed position. The present invention further includes a mounting assembly for connecting the plug to the vehicle body wherein the mounting assembly includes a mounting bracket having an aperture to accommodate the plug body and the plug body includes a coupling tab having a first and integral with the plug body and a second end movable between an engaged position and a retractive position. When the coupling tab is in its engaged position the tab engages a mounting bracket to couple the plug body to the mounting bracket.
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Calix brochure dated Apr. 11, 1996 (2 sheets).
Witkowski Ireneusz
Zubin Claudio
Duverne J. F.
Harness & Dickey & Pierce P.L.C.
Nguyen Khiem
Phillips & Temro Industries Ltd.
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