Flexible coupler for fixed electrical connector

Abstract

An electrical connector (10) includes a base (14), a coupler (20), a connector body (12) and at least one electrical contact (46). The base (14) includes a backside (22) and a front side (24) facing oppositely to the backside (22), and a mounting feature (26) by which the base (14) is fixed to a structure (16). The coupler (20) has a first end (30) connected to the base (14) at or adjacent to the front side (24) and extends to a second end (32) spaced from the base (14), and the coupler (20) is hollow between the ends (30, 32) and is flexible so that at least part of the coupler (20) including the second end (32) can move relative to the base (14). The connector body (12) is coupled to the second end (32) and is movable with the second end (32). The at least one electrical contact (42, 46) is coupled to a wire (36) extending through the coupler (20) and to or through the base (14).

Description

FLEXIBLE COUPLER FOR FIXED ELECTRICAL CONNECTORTechnical Domain

[0001] The present disclosure relates generally to an electrical connector that is fixed to a structure in use and which includes a flexible coupler to permit changes in the orientation or position of a connector body of the electrical connector.Related Art

[0002] Some electrical connectors are fixed to a structure like a housing, cabinet or bulkhead of a device. Application of disconnection forces at an angle to the fixed connector can damage the connector, and orienting cables associated with the connector in a desirable arrangement or angle can be challenging in certain applications.Short Diclosure of the Invention

[0003] In at least some implementations, a connector includes a base, a coupler, a connector body and at least one electrical contact. The base includes a backside and a front side facing oppositely to the backside, and a mounting feature by which the base is fixed to a structure. The coupler has a first end connected to the base at or adjacent to the front side and extends to a second end spaced from the base, and the coupler is hollow between the ends and is flexible so that at least part of the coupler including the second end can move relative to the base. The connector body is coupled to the second end of the coupler and is movable with the second end. The at least one electrical contact is arranged withinthe connector body and is coupled to a wire extending through the coupler and to or through the base.

[0004] In at least some implementations, the connector body includes a socket and the electrical contact is accessible from within the socket. In at least some implementations, multiple electrical contacts are accessible within the socket. The electrical contacts can be integral with or form a part of the socket.

[0005] In at least some implementations, the coupler is formed from a polymeric material and the coupler flexes to permit movement of the connector body relative to the base. In at least some implementations, the coupler includes corrugations and the connector body is movable through an angle of at least 90 degrees relative to a centerline of the base. The polymeric material, such as but not limited to polyethylene, polypropylene, or polyvinyl chloride, may contain plasticizers to increase the flexibility of the material used. Alternatively, polymeric materials can be used that are inherently more flexible or bendable.

[0006] In at least some implementations, the coupler is cylindrical.

[0007] In at least some implementations, at least part of the coupler is configured to be partially compressed and partially elongated when the connector body moves relative to a centerline of the base. In at least some implementations, at least part of the coupler is extendable and compressible along a centerline of said at least part of the coupler.

[0008] In at least some implementations, the connector body is movable through an angular range in which a centerline of the connector body is at an angle of up to 90 degrees relative to a centerline of the base.

[0009] In at least some implementations, the connector body is movable so that a centerline of the socket is oriented at an angle of up to 90 degrees relative to a centerline of the base.

[0010] In at least some implementations, the coupler includes one or more of one or more of the following: bellows, corrugations, ridges, grooves or accordion folds.

[0011] In at least some implementations, the connector body is configured such that a force needed to flex or bend the coupler or move the connector body relative to the base is less than a disconnection force that is required to disconnect a mating connector from the connector body. In at least some implementations, the connector body is configured such that the force needed to flex or bend the coupler or move the connector body relative to the base is between 10% and 70% of the disconnection force.Short Description of the Drawings

[0012] The following detailed description of preferred implementations and best mode will be set forth with regard to the accompanying drawings, in which:

[0013] FIG. 1 is a perspective view of an electrical connector including a base and a movable connector body coupled to the base by a flexible coupler;

[0014] FIG. 2 is a perspective view illustrating the connector body oriented at a nonzero angle to the base and aligned with a plug of a cable for improved connection or disconnection of the plug from / to the connector body;

[0015] FIG. 3 is a diagrammatic sectional view of the electrical connector with the connector body aligned with the base; and

[0016] FIG. 4 is a view similar to FIG. 3 and showing the connector body angularly moved relative to the base.Example of Embodiments of the present Invention

[0017] The figures may contain simplified schematic representations. Sometimes the same reference signs are used for the same, but possibly not identical, elements. Different views of the same elements may be scaled differently. Directions such as ‘left’, ‘right’, ‘up’ and ‘down’ are to be understood in relation to the respective figure and may vary in the individual representations in relation to the object shown.

[0018] Referring in more detail to the drawings, FIGS. 1-4 illustrate an electrical connector 10 having a connector body 12 connected to a base 14 that is adapted to be connected to a structure 16, like a bulkhead, cabinet, wall or the like. The connector body 12 is adapted for connection with a mating connector 18 (FIGS. 2-4), for example, for example with a plug and socket type connection. Electrical power and data signals may be transmitted through the electrical connector 10, in known manner. To permit flexibility in the connection between the connector body 12 and the mating connector 18, a flexible or bendable coupler 20 is provided between the connector body 12 and the base 14, and permits the connector body 12 to move relative to the base 14 as will be set forth in more detail below.

[0019] Referring to FIGS. 1 and 3, the base 14 has a backside 22 and a front side 24 facing oppositely to the backside 22, and a mounting feature 26 by which the body is fixed to a structure 16. The mounting feature 26 may be, for example, a flange or a bracket and arranged to permit firm connection to the structure 16, such as via fasteners like screws,bolts or clips. In the example shown, the base 14 is or has a flange, and the backside 22 is flat or planar and arranged to be set against a planar surface of the structure 16 to which the base 14 is connected / fixed in use. One or more openings 28 are provided through the flange 26 to receive mounting bolts by which the base 14 is secured to the structure 16. The flange 26 extends outwardly farther than the coupler 20 and the openings 28 may be provided outboard of the coupler 20 for easy access to the bolts / fasteners.

[0020] Bending or flexing of the electrical connector 10 can be prevented by inserting a threaded rod, mounting bolts, or appropriately long screw through the openings 28 of the flange 26 and the openings of the connector body 12 to provide a rigid electrical connector. Alternatively, the flange 26 and the connector body 12 can each be secured through the openings to walls such as a bulkhead, cabinet, wall or the like, whereby the walls can be spaced apart. The openings 28 of the flange 26 and the openings of the connector body 12 are arranged in alignment in an unbent state, such as shown in FIG. 1.

[0021] Referring to FIG. 3, the coupler 20 has a first end 30 connected to the base 14 at or adjacent to the front side 24 and extending to a second end 32 spaced from the base 14. The coupler 20 may be hollow between the ends 30, 32 and is flexible so that at least part of the coupler 20 including the second end 32 can move relative to the base 14 while the first end 30 remains connected to the base 14. The coupler 20 may be connected to the base 14 in any suitable manner, such as by adhesive, weld, fasteners or the like.

[0022] In at least some implementations, the coupler 20 is cylindrical and hollow, and is formed from a polymeric material. The coupler 20 defines a passage 34 in which wires 36 are received, where the wires 36 are connected to the connector body 12 and extend through the base 14 (or may be coupled to the base 14, as desired). The coupler 20 has acenterline 38 or center of mass extending through the passage 34 and between the ends 30, 32.

[0023] To permit movement of the second end 32 relative to the first end 30, the coupler 20 may be formed of a flexible material that can bend or flex a desired amount without plastic deformation. In at least some implementations, the coupler 20 includes one or more flexing features 40 (FIGS. 1 and 2) such as bellows or accordion folds or is corrugated and has axially spaced apart corrugations which may include ridges or grooves or sections, where the spacing between sections / folds / bellows can vary as the coupler 20 is bent or flexed to move the second end 32 so that it is radially offset from the first end 30. When the second end 32 is radially offset from the first end 30, the centerline 38 relative to the center of mass of the coupler 20 is no longer a straight line between the ends 30, 32, as it is when the second end 32 is aligned with the first end 30. Further, in at least some implementations, the coupler 20 may extend respectively elongate to increase its axial length and / or contract to reduce its axial length. When the second end 32 is moved in a radially direction, part of the coupler 20 is in tension any may extend / be lengthened and part of the coupler 20 is in compression and may compress / be reduced in length. In this way, a portion of the second end 32 of the coupler 20 on a side or part of the coupler 20 that is in compression may be axially closer to the base 14 than a portion of the second end 32 of the coupler 20 on a side or part that is in tension. Such movement or bending of the coupler 20 permits the connector body 12 to be oriented at different angles relative to the base 14.

[0024] The connector body 12 is coupled to or located adjacent to the second end 32 of the coupler 20 and is movable with the second end 32 and relative to the base 14. Theconnector body 12 includes, as shown in FIG. 3, one or more conductive contacts called electrical contacts 42 that is / are coupled to a like number of wires 36 extending through the coupler 20 and to or through the base 14. In the implementation shown, the connector body 12 includes a socket 43 having multiple openings 44 in the base or bottom of the socket 43 and in which electrical contacts 42 are received. The electrical contacts 42 may be cylindrical and arranged to receive a separate one of multiple pins / conductive or electrical contacts 46 (FIG. 2) in a plug 47 of the mating connector 18. In this regard, the terms socket and plug are used for mating connection features of the two electrical connectors 10, 18 that are selectively coupled together. Also, the arrangement of electrical contacts 42, 46 may be reversed between the plug 47 and socket 43, or the plug 47 and socket 43 may have complementary ones of the different electrical contact types, or other types of electrical contacts, as desired.

[0025] With the connector body 12 coupled to the coupler 20, the connector body 12 may angularly move relative to the base 14, as shown in FIGS. 2 and 4, such that a centerline 48 of the connector body 12, or the socket cavity (or other connection feature) of the connector body 12, is not coaxial or aligned with a centerline 50 of the base 14. In this way, the socket 43 of the connector body 12 may be aligned at different angles relative to the base 14 and the structure 16 to which the base 14 is connected, to facilitate coupling the connector body 12 with the mating connector 18. As shown in FIGS. 2 and 4, the permitted movement of the connector body 12 may also help to align the connector body 12 relative to a disconnection or breakaway force which may be applied to the mating connector 18 along a line 52 that is not parallel to the centerline 50 of the base 14. This may permit the mating connector 18 to disconnect or breakaway from the connector body12 while aligned with the connector body 12 to limit or prevent damage to the components. In one example, the electrical connector 10 is used with a vehicle charging cable at a vehicle charging station. If the vehicle is inadvertently driven away while the charging cable is still coupled to the connector, the flexible coupler 20 permits the connector body 12 to move to align with or become better aligned with the disconnection force to limit or prevent damage to the connector and the charging cable and the mating connector 18 that is part of the charging cable.

[0026] In at least some implementations, the centerline 48 of the connector body 12 or the socket 43 / connection feature thereof, may move through an angular range of up to 90 degrees relative to the centerline 50 of the base 14, where the angle P (shown in FIGS. 2 and 4) is measured between a centerline 48 of the socket 43 / connection feature of the connector body 12 and the centerline 50 of the base 14 (note that angle P is zero in the orientation of the connector 10 shown in FIGS. 1 and 3). In at least some implementations, the coupler 20 is a single piece body and does not include any joints or openings, and is weather / waterproof and provides protection for the internal wires 36. Of course, the coupler 20 could include a joint / elbow / ball and socket arrangement that permits pivoted or bending movement of the second end 32 of the coupler 20 relative to the first end 30, if desired. In at least some implementations, the coupler 20 has a low resilience and tends to stay in a position in which it is connected, rather than tending to spring back to a position in which the centerline 48 of the connector body 12 is aligned with the centerline 50 of the base 14. In at least some implementations, a low resilience means that the coupler 20 maintains the connector body 12 at or within forty-five degrees of a maximum angle achievable by the coupler 20 / connector body 12. Of course, a coupler 20 having greaterresilience may also be used, including a coupler 20 that returns to or close to a position aligned with the centerline 50 of the base 14, as desired. In at least some implementations, the force needed to flex or bend the coupler 20 or move the connector body 12 relative to the base 14 is less than the force required to disconnect the mating connector 18 from the connector body 12, and may be between 10% and 70% of the force required for disconnection of the mating connector 18 from the connector body 12.

[0027] The connector body 12 can have indentations or projections that interact with corresponding projections or indentations on the mating connector 18 to form a retaining structure (not illustrated). Additionally, or alternatively, the force required to separate the mating connector 18 from the connector body 12 is adjusted by ensuring that the connector body 12 and the mating connector 18 form a corresponding fit when mated. Both parts 12, 18 are designed and dimensioned in relation to each other in such a way that a transition fit is formed.

Claims

Claims1. An electrical connector (10), comprising: a base (14) including a backside (22) and a front side (24) facing oppositely to the backside (22), and a mounting feature (26) by which the base (14) is fixed to a structure (16); a coupler (20) having a first end (30) connected to the base (14) at or adjacent to the front side (24) and extending to a second end (32) spaced from the base (14), wherein the coupler (20) is hollow between the ends (30, 32) and is flexible so that at least part of the coupler (20) including the second end (32) can move relative to the base (14); a connector body (12) coupled to the second end (32) of the coupler (20) and movable with the second end (32); and at least one electrical contact (42) arranged within the connector body (12) and coupled to a wire (36) extending through the coupler (20) and to or through the base (14).

2. The electrical connector (10) of claim 1, wherein the connector body (12) includes a socket (43) and the electrical contact (42) is accessible from within the socket (43).

3. The electrical connector (10) of claim 2, wherein multiple electrical contacts (42) are accessible within the socket (43).

4. The electrical connector (10) of any one of claims 1 to 3, wherein the coupler (20) is formed from a polymeric material and the coupler (20) is configured to flex for permitting movement of the connector body (12) relative to the base (14).

5. The electrical connector (10) of claim 4, wherein the coupler (20) includes corrugations and the connector body (12) is movable through an angle (P) of at least 90 degrees relative to a centerline (50) of the base (14).

6. The electrical connector (10) of any one of claims 1 to 5, wherein the coupler (20) is cylindrical.

7. The electrical connector (10) of any one of claims 1 to 6, wherein at least a part of the coupler (20) is configured to be partially compressed and partially elongated when the connector body (12) moves relative to a centerline (50) of the base (14).

8. The electrical connector (10) of claim 7, wherein at least part of the coupler (20) is extendable and compressible along a centerline (38) of said at least part of the coupler (20).

9. The electrical connector (10) of any one of claims 1 to 8, wherein the connector body (12) is movable through an angular range in which a centerline (48) of the connector body (12) is at an angle (P) of up to 90 degrees relative to a centerline (50) of the base (14).

10. The electrical connector (10) of any one of claims 2 to 9, wherein the connector body (12) is movable so that a centerline (48) of the socket (43) is oriented at an angle (P) of up to 90 degrees relative to a centerline (50) of the base (14).

11. The electrical connector (10) of any one of claims 1 to 10, wherein the coupler (20) includes one or more of the following: bellows, corrugations, ridges, grooves or accordion folds.

12. The electrical connector (10) of any one of claims 1 to 11, wherein the connector body (12) is configured such that a force needed to flex or bend the coupler (20) or move the connector body (12) relative to the base (14) is less than a disconnection force required to disconnect a mating connector (18) from the connector body (12).

13. The electrical connector (10) of claim 12, wherein the connector body (12) is further configured such that the force needed to flex or bend the coupler (20) or move the connector body (12) relative to the base (14) is between 10% and 70% of the disconnection force.

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