Patent Application
20140073180
The field of the invention relates to electrical connectors and junction blocks, and more particularly to a system of sealed, corrosion resistant and securely mated electrical cables, connectors and junction blocks.
In recent years the number of electric motors and electric devices associated with truck boxes and trailers has increased. All of the motors and other electric devices on a truck box or trailer typically require DC current from a single battery located on the truck cab. Electric cables need to connect each of the motors and devices to the battery or other power source. Making multiple battery-to-motor connections individually requires the use of multiple, lengthy and expensive cables that tend to clog the wiring channels, if multiple cables can even fit in those channels.
In order to reduce the expense and burden of using multiple, lengthy cables between the battery and the electric motors or other devices, junction boxes have been employed. Such boxes used a single cable to create a power source at a more convenient location on the truck box or trailer devices in need of electricity. This reduced the expense of and channel clogging caused by multiple cables traversing the same path, but created other problems.
For example, connecting cables to the junction box is laborious as heavy cables need to be cut to length, stripped of insulation on each conductor and attached to terminals on the box. At the end of the cable attached to an electric motor or device, each conductor needed to be stripped and crimped or soldered onto heavy duty ring terminals. These operations require special tools and extra installation labor, and can be time consuming and expensive to perform.
Electric motors and devices are often added to a truck box or trailer after it is manufactured and delivered, i.e., as a retrofit product or accessory. This increases the difficulty of wiring as the original arrangement may not accommodate the addition of more cables and connections to the junction box. Moreover, retrofit additions of motors or other devices requires that modifications be made by persons (such as equipment operators) in the field who may not be experienced with electrical connectors or wiring, and under challenging circumstances, uncomfortable weather or difficult working conditions.
In addition, in use, truck boxes and trailers experience extreme ambient temperatures combined with moisture, constant high winds, direct sunlight, road salt, and de-icing or other chemicals. As a result, junction boxes, and wiring, ring terminals and other connections on the truck boxes or trailers are subject to corrosion and relatively high failure rates over time. Hence, conventional wiring arrangements on truck boxes and trailers present a number of problems.
It is an object of the invention to provide a corrosion resistant wiring system for truck boxes and trailers.
It is another object of the invention to provide a system of easy to connect cables that will stay securely connected.
It is yet another object of he invention to provide a multi-port junction block for the trailer environment.
It is a further object of the invention to provide a wiring system that can easily accommodate additional electric motors or devices on the truck box or trailer,
It is yet a further object of the invention to provide a wiring system with reduced need for multiple and expensive cables traversing the same channels.
It is yet an additional object of the invention to provide a wiring system accomplishing a combination of two or more of the objects previously mentioned.
Other systems, methods, features and advantages of the invention will become apparent to one with skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description, be within the scope of the invention, and be protected by the accompanying claims.
In order to better appreciate how the advantages and objects of the inventions are obtained, a more particular description of the system, arrangement, connectors and junction block briefly described above will be rendered by reference to specific embodiments thereof and illustrated in the accompanying drawings. It should be noted that the components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. Moreover, in the figures, like reference numerals designate corresponding parts throughout the different views. However, like parts do not always have like reference numerals. Moreover, all illustrations are intended to convey concepts, where relative sizes, shapes and other detailed attributes may be illustrated schematically rather than literally or precisely.
Referring to
Because the male cable connector 20 has two conductor wiring (positive and negative), in order to assist in the correct mating of the male cable connector 20 to a female cable connector 30 (
The generally oblong projecting portion 23 of the male cable connector 20 is fitted on the outside with a gasket or seal 24, preferably fabricated in a resilient sealing material, e.g., silicone, to create a seal between the male cable connector 20 and a female cable connector 30 (
Alternatively, sufficient sealing could be accomplished in other ways. For example, the oblong projecting portion 23 could have one or more grooves that encircle it, in which one or more resilient bands of rubberized material (circular in cross-section) could reside. In this way, any gap between the oblong projecting portion 23 of the male cable connector 20 and the passageway 33 of the female cable connector 30 would be sealed, thereby preventing or at least reducing the risk that dust, dirt, moisture or other impurities or reactants would contact the prongs or other electrical components when they are electrified. This reduces corrosion of the wiring components.
To support high current electricity, the male cable connector 20 has at least two precision, electrically conductive connecting prongs 27, preferably made of brass, capable of carrying 0-200 amps of current. Each prong 27 has an end communicating with the oblong projecting portion 23, and a distal end. The ends of the prongs 27 communicating with the male cable connector 20 are crimped (or soldered or both) on the electric cables 90 during manufacturing. The electric cables 90 are preferably fabricated using 6 American Wire Gauge (AWG) standard copper wires. In order to assist in the correct installation of the male cable connector 20 and the molded cables 90 to an electrical source or equipment, the jacket of the cables 90 are marked such that the positive conductor wire will have a jacket with a red color stripe.
During manufacture, the electrical cables 90 are molded to the male cable connector 30. The jacket of the electrical cables 90 is made of the same electrically insulating material as with the male cable connector 20. As such, the male cable connector 20 fuses together with the jacket of the electrical cables 90. At the distal end of the cables 90, two terminal rings 29a/29b are crimped (or soldered) onto the cables. The crimped ends of the terminal rings 29a/29b are wrapped in color coded electrically insulating jacket 28a/28b. Red color is used for the jacket 28a wrapping the ring 29a that terminates the positive conductor wire. Black color is used for the jacket 28b wrapping the ring 29b that terminates the negative conductor wire. The terminal rings 29a/29b are ready for connecting the cables 90 to electric motors and devices.
Referring to
The U-shaped flange 34 contains bilateral apertures 35a and 35b on opposing sides. The apertures 35a/35b have passages such that a single cylindrical pin with appropriate dimensions can pass through both. The application of the apertures and associated pin is further described below.
Similar to the male cable connector 20, during manufacture, the electrical cables 90 are molded to the female cable connector 30. The jacket of the electrical cables 90 is made of the same electrically insulating material as with the female cable connector 30.
For safety purposes, generally throughout the invention contemplated herein, the male connectors are intended to be connected to hot female connectors. In this way, the exposed prongs of the male connectors are not carrying a charge that could injure a handler and damage equipment. On the other hand, the electrical components of the female connectors are recessed out of the way of inadvertent contact with hands, clothes or equipment. The arrangements described herein, when used, have electrical components well covered at the point where the connections are made, reducing the risk of sparking, shock, injury or property damage during the connection d disconnection operations.
The U-shaped flange 34 on the female connector provides additional shielding against inadvertent contact with hot wires, or ground, or inadvertent sparks at the point of connection. However, the U-shaped flange and corresponding U-shaped space 25 on the male connector could be reversed such that the male connector included a U-shaped flange and the female connector included a U-shaped space. Such as arrangement would continue to provide some of the benefits contemplated herein.
In order o assist in the correct mating of the female cable connector 30 to a male cable connector 20 (
The end of cable 90 opposite of the female cable connector 30 can be either a male cable connector, for example, if needed to be used as an extension between other male and females connections in the system. However, that end could also include a different component. As shown in
Trailer male connector 36 is molded to cable 90 as described above for male connector 20 and female connector 30. It contains a cylindrical passageway 37 exposing prongs 42. A cap 38 is pivotally hinged to the trailer male connector 36, with spring 39 communicating between the two to bias the cap 38 to a position to cover the passageway 37. When the trailer male connector is in use, the cap 38 will rest against the female connector mated with the trailer male connector 36. However, when there is no mated connection, the cap 38 is held by the spring tightly against the passageway 37 entry, creating a moisture and duct proof seal.
The trailer male connector contains two, bilateral flanges 40 with apertures 41. Screws or bolts (not shown) can pass through the apertures to secure the trailer male connector 36 to the sidewall or other structure in the truck box or trailer. The use of the trailer male connector 36 with other components in a trailer electrical system is described in more detail below.
Referring to
Referring to
Each female block connectors 63a/63b/63c are constructed to receive male cable connector 20 (
The center portion 61 of the junction block 60 has a cutout for the male block connector 62. The male block connector 62 of the junction block 60 is constructed to fit into the female cable connector 30. As such, the construction of the male block connector 62 is generally similar to the construction of the male cable connector 20. The male block connector 62 has a front oblong portion 66 that is generally are to the front Oblong portion 23 of the male cable connector 20. The front portion 66 is also fitted with on the outside with a seal or gasket 66a. The male block connector 62 also has an aperture to receive a harness lock pin when the male block connector 62 is orated with a female cable connector 30. The construction of prongs 67 of the male block connector 62 is generally similar to the construction of prongs 27 of the male cable connector 20.
In the past, soft rubber was typically used to provide electric insulation and an adequate seal between two electrical connections. However,soft rubber is expensive to use and has other undesirable characteristics. The presently contemplated connections obtain comparable seals with the use of hard plastic, preferable polyvinylchloride, for the connector and block material, but with a resilient seal or gasket of softer material to seal the space between the male connector's oblong projecting portion and the female connector's passageway.
The junction block 60 has two generally triangular support flanges 68a/68b at the top and bottom. The two flanges 68a/68b are flushed against the back all of the junction block 60 and have apertures so that the junction block 60 can be mounted, using screws (not shown) to a truck box trailer wall or other support or platform.
The junction block 60 has three slots 66a/66b/66c on the front wall. Two outside grooves are extended downward from the apertures 69b and 69d on the flanges 65b and 65c of the female block connectors 63b and 63c to the bottom wall of the junction block 60. One inside slot 66b is extended from the inside aperture 69c, which is aligned with the apertures 69g (
Referring to
The junction block 60 has three female block connectors, providing for connections to three independent electrical motors or devices. The positive input voltage supplied to one of the two pins of the male block connector 62 communicates electrically (through conductive structures within the junction block) with the corresponding positive output sockets on the female block connectors 63a/63b/63c. Similarly, the ground pin of the male block connector 62 communicates electrically with the corresponding ground socket of the female block connectors 63a/63b/63c.
The junction block may be initially installed with one or two unused female block connections, providing the potential easy wiring connection to retrofit electrical devices that are added later. In order to prevent the female block connectors from being exposed to the harsh ambient environment, a male plug 50 is used. In order to provide an efficient seal, it has a shape that generally matches the male cable connector. In particular, the preferred embodiment has two dummy prongs 51, a generally oblong front portion 52, a center portion 53 with a generally U-shaped cutout 54 for receiving the generally U-shaped flange 65a/ 65b/ 65c of the female block connector 63a/63b/63c, and an aperture 55 for receiving a harness lock pin 70. If needed, the male plug 50 could be used to seal the unused, open end of a female cable connector.
As mentioned above, the U-shaped flange associated with the female cable connectors, and U-shaped space associated with the male cable connectors could be reversed. If such an arrangement was used, the junction block could be similarly modified such that a U-shaped flange would be associated with the male block connector 62 and U-shaped spaces would be associated with the female block connectors 63a/63b/63c. This arrangement still allows (1) for female cable connectors to mate with male cable connectors and male block connectors, and (2) for male cable connectors to mate with female cable connectors and female block, connectors. Such junctions can be secured with the use of a lock pin placed in the aligned apertures in the U-shaped flanges and projecting portions.
As generally contemplated herein, a female plug (not shown) having a similar shape as the female cable connector could be utilized to seal the male block connector. The preferred embodiment of the junction block contemplated herein has only a single male block connector that in most cases would be used from the time of initial installation because it functions to bring power into the junction block. However, in the relatively unusual occasion where the single male block connector is unused or a junction block contains an unused second male block connector, a female plug could be utilized. If needed, the female plug could be used to seal the unused, open end of a female cable connector.
Referring to
Persons who build, use and work on truck boxes and trailers will appreciate that there are a variety of possible arrangements of the cables, connectors and junction block described above.
With respect to the embodiment of
The trailer male connector 36 has a cable 90 and female cable connector 30 of the type shown in
The electrical power is then distributed from the junction block 60 to two hopper door motors, a forward hopper door motor 105 and a rearward hopper door motor 107. Forward hopper door motor 105 is connected to a cable 90 by use of terminal rings 29a/29b of the type shown in
Similarly, the rearward hopper door motor 107 is connected to a cable 90 by use of terminal rings 29a/29b of the type shown in
The two male cable connectors 20, along with a female cable connector 30, are no secured in the two female block connectors 63b and 63c, and one male block connector 62 in the junction block 60. This leaves one unused female block connector 63a in the junction block that is available to be connected and bring power to a later-added electrical device on the trailer. This is easily accomplished by merely connecting the new device to terminal rings 29a/29b at one end of a cable 90 and a male cable connector 20 at the other end. However, until that additional device is added, a protective plug 50 is inserted into the unused female block connector 63a to protect it against the ambient environment and reduce any corrosion that could occur at the metal electrical surfaces.
Multiple junction blocks 60 can be utilized on a single trailer to provide the potential to provide power to five or more motors or other devices. This is accomplished by attaching additional junction blocks 60 to the trailer 95.
The two junction blocks are connected by using an extension cable with a male cable connector 20 on one end and a female cable connector on the other end. The male connector 20 is mated with an unused female block connector, for example 63a in
In the foregoing specification, the invention has been described with reference to specific embodiments thereof. It will, however, be evident that various modifications and changes may be made thereto without departing from the broader spirit and scope of the invention. Additionally and obviously, features may be added or subtracted as desired. Accordingly, the invention is not to be restricted except in light of the attached claims and
