Self docking electrical connector

Information

  • Patent Grant
  • 6244884
  • Patent Number
    6,244,884
  • Date Filed
    Wednesday, February 16, 2000
    24 years ago
  • Date Issued
    Tuesday, June 12, 2001
    23 years ago
Abstract
A self-docking connector includes first and third fixed contacts and an intermediate fixed contact. The first and third contacts are mounted on male and female connectors, respectively, and the intermediate contacts are mounted on a slideable plate. The plate is mounted on an upper tray surface of the female connector and is capable of sliding movement between a connected and a disconnected position. In the disconnected position, the intermediate contacts are resiliently biased by a biasing member away from contacting the third contacts, therefore creating an open circuit between the intermediate and third contacts. However, in the connected position, the intermediate contacts are forced into positive contact with the third contacts, thereby creating a readily disconnectable electrical connection therebetween.
Description




FIELD OF THE INVENTION




The present invention relates to automotive electrical connections and more particularly to self-guiding electrical connections for connecting peripheral devices within an automobile.




BACKGROUND OF THE INVENTION




For economic reasons, automobile manufacture has become increasingly modularized and subdivided among various original equipment manufacturers and aftermarket parts suppliers. Accordingly, OEM electrical appliances within an automobile may originate from different sources. As a result, extensive efforts have been made to standardize electrical connections within the vehicle to accommodate multiple suppliers. Additionally, aftermarket appliances are increasingly made available directly to consumers. Often, installation of the aftermarket appliances requires that any electrical connection to the vehicle be made after first removing an existing component and then substituting the aftermarket appliance in its place.




For example, aftermarket vehicle console units are being made available to automobile purchasers that include various electronic and/or entertainment devices, such as sound and audio-visual entertainment systems. To replace an original equipment center console unit with an aftermarket one, the original unit first must be physically disconnected from the automobile before removal therefrom. Second, the original unit must be electrically disconnected from the vehicle before removal and before installation of the new aftermarket unit. Finally, once the new console is installed, it is not readily removable.




In existing automotive electrical system designs, disconnection of an existing appliance requires actual disconnection of wiring from the appliance, generally using a standardized plug and socket arrangement. Plug and socket connections are advantageous because they eliminate bare or open contact leads that may lead to inadvertent shorting of the automotive electrical system. However, modification of plug and socket connections once an automobile leaves a factory is extremely difficult. Also, exposed portions of plug and socket connections are always electrically charged. And plug and socket electrical connections are not conducive to repeated disconnection and removal of installed appliances, for example, as a method to prevent theft.




Additionally, often the location of an existing plug is incompatible with or remote from the socket on aftermarket appliances, or else the wire lead length is insufficient to easily interconnect to the new device. Moreover, in existing electrical system designs, electrically connecting a new device requires manually locating and physically reconnecting the socket and plug, either before or after physical installation of the new device, thereby adding to installation time and effort. Finally, in those systems where an existing appliance is not replaced, but is instead simply added, extensive time and effort are required to install the new unit, either because additional wiring must be added or because new electrical connections must be made to interface the new appliance with the automobile electrical system.




Accordingly, an easily connectable and disconnectable electrical connection is needed to provide simple and safe connection and disconnection of electrical appliances to an automobile electrical system without threatening the integrity of the electrical system.




SUMMARY OF THE INVENTION




The above-described disadvantages of current electrical connection systems are overcome by the self docking electrical connector of the present invention. The connector of the present invention includes first and third fixed contacts and an intermediate fixed sliding contact. The first and third contacts are mounted on male and female connectors, respectively, and the intermediate contacts are mounted on a slideable plate.




In the preferred embodiment, the plate is slideably mounted on an upper tray surface of the female connector and is capable of sliding movement between a connected and a disconnected position. In the disconnected position, the intermediate contacts are resiliently biased by a biasing member away from contacting the third contacts, therefore creating an open circuit between the intermediate and third contacts. However, in the connected position, the intermediate contacts are forced into positive contact with the third contacts, thereby creating an electrical connection therebetween.




The male member includes at least one actuator post extending outwardly from a main body of the male member. A distal end of an actuator post projection includes a first cam surface designed to interact with a second cam surface located on an upper surface of the plate. Most preferably, the actuator post extends normal to the male body such that the angle of incidence of the actuator post onto the upper surface of the plate is approximately normal to the upper surface of the plate.




In operation, the male body is brought into facing contact with the female body such that the first cam surface on the actuator post projection contacts the second cam surface on the upper surface of the slideable plate. As the first and second cam surfaces interact, a lateral force is exerted on the plate sufficient to overcome the resilient biasing force of the biasing member, forcing the plate to slidably move from the disconnected to the connected position. When the actuator post is fully inserted into the female member, the slideable plate will have completely moved to the connected position, thereby causing an electrical connection between the intermediate and the third contacts. Moreover, when the actuator post is fully inserted, the first contacts mounted on the male connector are forced into positive electrical contact with the intermediate contacts, thereby forming a complete circuit between the first, intermediate and third contacts, and therefore between the male and the female connectors. Importantly, the resilient member is not itself used as an electrical conductor. Instead, opposed cam surfaces on respective male and female connectors slide a fixed intermediate contact mounted on the female connector into electrical engagement with first and third contacts rigidly retained on the male and female member, respectively. Therefore, the resiliently biased slideable plate is actuated as a cam follower by the male connector actuator post inserted at an angle normal to the sliding plate. Additionally, the actuator post may be sufficiently large to provide structural support to any device attached to the male connectors. To save space, the plate is mounted to the female connector. However, the slidable plate may be mounted in any convenient place to accomplish sliding motion between an engaged and disengaged positions. For instance, the slidable plate may be mounted to the male connector if desired, but if mounted to the male connector, which is inserted into the female connector, then the male extension would have to be made longer.




Using the self docking electrical connector of the present invention, an automotive peripheral electrical device may be quickly and easily attached and detached from the automotive electrical system. The connector is flexible, because the terminals may transmit any type of information, including electrical current or control information (including fiberoptic data transmission).




Because the slideable plate is resiliently biased to a disconnected position, the connector is preferentially uncharged. Thus, the intermediate terminals pose no danger to the automotive electrical system (through shorts or grounds) when the male connector is not attached to the female connector, and may therefore be exposed and easily accessible. The connector therefore provides a simple yet inherently stable electrical connection mechanism that may be utilized with both original equipment and aftermarket appliances such as seats, instrument clusters, switches, restraint systems or any other device requiring electrical coupling within the vehicle.











BRIEF DESCRIPTION OF THE DRAWINGS




The features and advantages of the present invention will be apparent to one of ordinary skill and art from the detailed description of the invention that follows and from the accompanying drawings, wherein:





FIG. 1

is an exploded view of a first embodiment of the male and female electrical connectors of the present invention, including a mounting point for the female connector.





FIG. 2

is a second perspective view of the connectors of

FIG. 1

includes a mounting surface for the male connector.





FIG. 3

is a third perspective view of the first embodiment of the present invention.





FIG. 4

is a perspective view showing a second embodiment of the self docking electrical connector of the present invention.





FIG. 5A

is a first cross-sectional view of an assembled second embodiment connector showing the terminals in the disconnected position.





FIG. 5B

is a second cross-sectional view of an assembled second embodiment showing the terminals in the connected position.











DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS




A first embodiment of a self-docking electrical connection system


10


is shown in

FIGS. 1

,


2


and


3


, including a male connector


12


and a female connector


14


. Male connector


12


includes a body


16


and at least one actuator post


18


extending in a direction normal to the body. As seen in

FIGS. 1 and 3

, actuator post


18


may be a single continuous post having a width identical to body


16


, or the actuator post may be of any convenient shape. Both body


16


and actuation post


18


are made of nonconductive material such as injection molded nylon or similar material that provides both electrically insulative and structural properties. Actuator post


18


includes at least one projection


20


extending distally beyond post


18


. The tip of each projection


20


includes a first cam surface


22


to help ease the coupling between the male and female members, as described more fully below.




Male connector


12


also includes terminal connection areas


24


, and may include mounting apertures


26


positioned in any convenient place. Preferably, mounting apertures


26


receive fasteners (not shown) that are used to secure male connector


12


adjacent an outer surface of an appliance


27


(see

FIG. 2

) that is to be installed in a vehicle. Additionally, connection areas


24


provide locations for interfacing electrical connections between the connector and the appliance. A first set of fixed contacts


28


are mounted on male connector


12


, and preferably include at least a portion mounted on actuator post


18


in electrical communication with connection areas


24


. The number of contacts


28


(and connection areas


24


) may be adjusted to accommodate the amount of power or information that must be transmitted to the peripheral electrical device.




Female member


14


includes a tray-shaped base


30


that includes an upper surface


32


. A plate


34


is slidably mounted relative to surface


32


. Plate


34


includes second cam surfaces


36


designed to receive and mate with the first cam surfaces


22


on actuator post


18


.




Plate


34


also includes a second or intermediate set of contacts


40


that correspond in number and align with the first contacts


28


when the actuator post


18


is properly inserted into the female member


14


. Additionally, base


30


includes a third set of fixed contacts


42


that correspond in number and align with second set


40


. At least one biasing member


37


is mounted on surface


32


and interacts with plate


34


at an edge


38


. Biasing member


37


may take the form of a leaf spring, as shown in

FIGS. 1

,


2


and


3


, or more preferably, may be one or more coil springs


137


(seen in FIG.


4


). Under the influence of biasing member


37


and absent any external force being applied, plate


34


is forced to slide along axis S in a direction away from biasing member


37


to a first, or disconnected, position. In the disconnected position, intermediate and third contacts


40


,


42


are not in electrical contact with each other because biasing member


37


forces plate


34


, including intermediate contacts


40


, away from third contacts


42


. However, if lateral force is applied to plate


34


sufficient to overcome the force applied by the biasing member, plate


34


may slide along axis S to a second, or connected position, where intermediate and third contacts


40


,


42


are forced into positive engagement with each other, thereby completing an electrical circuit.




Female member further includes at least one set of terminal connection areas


44


that allow female member


14


to interface with the existing automotive electrical system to transfer power and/or information through the connector


10


. In

FIGS. 1

,


2


and


3


, connection areas


44


are housed within a molded socket


46


that may be easily attached to a pre-existing plug


47


when female connector


14


is installed during vehicle manufacture. However, any convenient type of connection between female connector


14


and the wires


49


within a vehicle electrical system may be utilized.




Finally, female member


14


may include mounting apertures


48


that receive fasteners for mounting member


14


to corresponding apertures


50


in a vehicle tray


52


(see FIG.


1


). Optionally, tray


52


may include a cutout


54


sized to expose only a portion of plate


34


upper surface


56


, including cam surfaces


36


. Of course, a portion of second terminal set


40


may be exposed as well. However, since plate


34


is biased to the disconnected position when male connector


12


is not installed, no electrical potential is applied to second terminal set


40


when exposed, so the exposed terminals pose no danger to the vehicle electrical system.




A second and preferred embodiment of an electrical connector


110


is illustrated in

FIGS. 4 and 5

. Connector


110


has a structure similar to the connector


10


shown in

FIGS. 1

,


2


and


3


and accordingly, similar reference numbers will indicate similar structure. In particular, a male body


112


is shown having a base


116


with at least one actuator post


118


extending generally normal to base


116


. Post


118


includes distal projections


120


having first cam surfaces


122


at each projection tip. Wire leads


123


interconnect with terminal connections


124


, thereby providing an electrical interface between the male connector


112


and any peripheral electrical device. Terminal connections


124


are also electrically connected to first fixed terminals


128


mounted on actuator posts


118


.




Male body


112


includes mounting apertures


126


conveniently positioned at each of four corners of base


112


, though the mounting configuration may vary. Preferably, mounting apertures


126


receive fasteners (not shown) that are used to secure body


12


to a peripheral electrical device that is to be installed in a vehicle.




Male body


112


is adopted to engage and mate with female body


114


. Female body


114


includes a base


130


that includes a tray-shaped upper surface


132


. A plate


134


is slidably mounted on surface


132


adapted to slide along an axis S′. Plate


134


further includes second cam surfaces


136


designed to receive and mate with the first cam surfaces


122


on projections


120


. Either or both of surfaces


122


,


136


are formed so that when the surfaces mate with each other, the plate


134


is forced to move laterally.




Plate


134


also includes an intermediate set of contacts


140


that correspond in number and align with the first contacts


128


when the actuator post


118


is properly inserted into the female member


114


. Additionally, base


130


includes a third set of fixed contacts


142


that correspond in number and align with second set


140


. At least one coil spring


137


is mounted on surface


132


and interacts with plate


134


at an edge


138


. Under the influence of spring


137


, plate


134


is forced to slide along axis S′ in a direction away from spring


137


to a first, or disconnected, positions shown in

FIGS. 4 and 5A

. Therefore, in the disconnected position, intermediate and third contacts


140


,


142


are not in electrical contact with each other because spring


137


forces plate


134


, including intermediate contacts


140


, away from third contacts


142


. However, if force is applied to plate


134


sufficient to overcome the force applied by the biasing member, plate


134


may slide along axis S′ toward springs


137


to a second, or connected position (shown in FIG.


5


B), where intermediate and third contacts


140


,


142


are forced into positive engagement with each other.




Female member


114


also includes at least one set of terminal connections


144


that allow female member


114


to interface with the existing automotive electrical system to transfer power and/or information through the connector


110


. As above, connection areas


144


are housed within a molded socket


146


that may be easily attached to a pre-existing plug (not shown). Finally, female member


114


may include mounting apertures


148


that receive fasteners for mounting member


114


to the vehicle.




Proper operation of the inventive connector


110


will be described with reference to

FIGS. 5A and 5B

. It should be understood that the connector


10


of

FIGS. 1

,


2


and


3


operates in substantially the same manner. To utilize the inventive connector, male connector


112


, and any peripheral electrical component attached thereto, is aligned so that actuator post


118


is oriented above the exposed portion of plate


134


. In particular, first and second cam surfaces


122


,


136


are aligned into mating contact with each other. Under normal circumstances, plate


134


is biased in away from spring


137


to an electrically disconnected position such that second contacts


140


are biased away from contacting third contacts


142


, thus preventing an electrical interconnection between the second and third terminal sets. Accordingly, when at rest, plate


134


is biased into the disconnected position.




However, as additional force is exerted through actuator post


118


normal to the sliding axis S′ of plate


134


, the cam surfaces interact and force plate


134


to slide laterally along axis S′ toward spring


137


and away from the disconnected position. As plate


134


slides laterally, an opening sized to receive actuator post


118


is revealed in the female body member below plate


134


so that post


118


may be fully inserted into female body member


130


.




As plate


134


slides laterally, intermediate contacts


140


move with the plate along axis S′ towards the third contacts


142


. When actuator post


118


is fully inserted and plate


134


has moved a predetermined distance along axis S′ away from springs


137


, intermediate and third contacts


140


,


142


are forced into positive engagement with each other, creating an electrical contact therebetween. Additionally, when post


118


is fully inserted, first contacts


128


are forced into positive engagement with intermediate contacts


140


, thereby completing a circuit between first and third contacts


128


,


142


through intermediate contacts


140


. In this way, easy electrical interconnection may be accomplished between connection areas


144


and wires


123


(

FIG. 4

) through movement of plate


134


from a disconnected to a connected position, and therefore between a peripheral electrical device and the vehicle electrical system. Moreover, the size and length of actuator post


118


may be adjusted to provide sufficient structural support to the peripheral electrical device, if desired. Thus, the connector


110


may provide both electrical and structural interconnection between the vehicle and any peripheral electrical device.




Importantly, the resilient member


37


or


137


does not itself create an electrical connection. Instead, the slideable plate


34


,


134


is actuated as a cam follower to mechanically place three fixed electrical contacts into positive electrical communication with each other. Additionally, mounting the plate


34


,


134


to the female connector


14


,


114


saves space and minimizes the risk of inadvertent damage to any projections extending from the male connector


12


,


112


.




The self-docking and readily disconnectable nature of the inventive connector makes it ideal for removable and portable appliances. In one application, the connector of the present invention may be used in conjunction with existing socket and plug arrangements in vehicles when installing new aftermarket appliances. In another application, the connector, and especially the female portion of the connector, may be pre-installed at various locations in new vehicles to enable modification and upgrading of vehicle appliances by the manufacturer, the dealer or even the consumer, requiring only that new appliances include the male portion for proper fit and placement.




Thus, the present invention allows fast and easy mechanical and electrical coupling between any peripheral electrical component and a vehicle electrical or control system. The connector may be easily modified to couple with any type of component, and may transfer any type of electrical impulse, including power. Since both male and female connectors are fixed in place, installation of peripheral components is rapid, eliminating time consuming wiring requirements. Additionally, since the connector is dormant (i.e. not charged with electricity) until both the male and female connectors are mated, the integrity of the vehicle electrical system is not challenged by leaving a portion of the connection exposed and readily accessible.




The disclosed embodiments and examples are given to illustrate the present invention. However, they are not meant to limit the scope and spirit of the present invention. Therefore, the present invention should be limited only by the appended claims.



Claims
  • 1. A self-docking electrical connector, comprising:first and third fixed contacts respectively mounted on male and female bodies, said female body including a recess for receiving at least a portion of said male body; and a slidable plate including intermediate contacts fixed thereto, said plate sliding in response to insertion of said male body into said female body from a disconnected position, wherein said third and intermediate contacts are spaced apart in said disconnected position, and wherein said third and intermediate contacts positively engage each other in a connected position.
  • 2. The connector of claim 1, wherein said plate is resiliently biased to said disconnected position when said male body is not inserted into said female body.
  • 3. The connector of claim 1, wherein said plate is mounted on an upper surface of said female body.
  • 4. A self-docking electrical connector, comprising:first and third fixed contacts respectively mounted on male and female bodies, said female body including a recess for receiving at least a portion of said male body; and a slidable plate mounted on an upper surface of said female body, said plate including intermediate contacts fixed thereto, said plate sliding in response to insertion of said male body into said female body from a disconnected position, wherein said third and intermediate contacts are spaced apart in said disconnected position, and wherein said third and intermediate contacts positively engage each other in a connected position.
  • 5. The connector of claim 4, wherein said male body includes at least one actuator post for insertion into said recess, said at least one actuator post including at least one projection, a distal end of said projection including a first cam surface for interacting with an upper surface of said plate to force said plate to slide from said disconnected to said connected position.
  • 6. The connector of claim 5, wherein said plate upper surface includes a second cam surface adapted to mate with said first cam surface to exert a lateral force on said plate.
  • 7. The connector of claim 5, wherein said post extends generally normal to said male body such that the angle of incidence of said post onto said plate upper surface is approximately normal to the upper surface of the plate.
  • 8. The connector of claim 7, wherein said plate is resiliently biased to said disconnected position when said post is not inserted into said female body.
  • 9. The connector of claim 4, wherein said female body further includes a socket for coupling said third contacts to an electrical system.
  • 10. A self-docking electrical connector, comprising:first and third fixed contacts respectively mounted on male and female bodies, said female body including a recess for receiving at least a portion of said male body; a slidable plate mounted on an upper surface of said female body, said plate including intermediate contacts fixed thereto, said plate sliding in response to insertion of said male body into said female body from a disconnected position, wherein said third and intermediate contacts are spaced apart in said disconnected position, wherein said third and intermediate contacts positively engage each other in a connected position; and a spring attached between a side edge of said plate and said female body upper surface wherein said spring resiliently biases said plate to said disconnected position when said post is not inserted into said female body.
  • 11. The connector of claim 10, wherein said spring is a leaf spring.
  • 12. The connector of claim 10, wherein said spring is a coil spring.
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4859199 Komatsu Aug 1989
4881901 Mendenhall et al. Nov 1989
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5993232 Iguchi Nov 1999