Electrical connector and light assembly

Abstract

An electrical connector comprising a female terminal on a first end thereof and a male terminal on a second end thereof; and a wire electrically connected to the female and male terminals. The electrical connector is adapted to connect in series.

Description

Atorney Docket No.: 2021P.002WO (9113840)ELECTRICAL CONNECTOR AND LIGHT ASSEMBLYCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] None.FIELD

[0002] The present teachings generally relate to an electrical connector, such as a bullet-type connector, and a light assembly comprising the electrical connector.BACKGROUND

[0003] Some conventional vehicle light assemblies include male or female terminals that engage with a complementary terminal in the vehicle's power circuit. Often, these include one-to-one connection points, that is. one terminal in the native vehicle circuit for every terminal of a light. In this regard, there are many connection points that decrease efficiency of installation, are susceptible to being points of failure, are susceptible to debris and / or fluid ingress, and can be difficult to manage with respect to wire organization. These challenges can be more pronounced with groupings of multiple light assemblies within a region of a vehicle, such as strings of lights extending across a body component of a vehicle.

[0004] These challenges are conventionally realized in semi-trucks, and lights such as watennelon lights that are typically installed in plurality on various body components (e.g.. in series) to aid in visibility during night-time driving. Installation challenges are particularly felt by consumers as semi-truck exterior lighting is often customized by the owner. Reliable electrical connections are important, as fully operational lights arc required by transportation laws and regulations.

[0005] There is a need for a light assembly that connects to a power circuit and / or one or more additional light assemblies with fewer wire harnesses or terminals relative to conventional light assemblies.

[0006] There is a need for an electrical connector that can connect to one or more additional electrical connectors in a series.SUMMARY

[0007] The present disclosure relates to an electrical connector, which may address at least some of the needs identified above.

[0008] The electrical connector may comprise a female terminal on a first end thereof and a male terminal on a second end thereof. The electrical connector may comprise a wire electrically connected to the femaleAtorney Docket No.: 2021P.002WO (9113840) and male terminals. The electrical connector may be adapted to connect in series with one or more other electrical connectors. The female and male tenninals may be contained within a common housing.

[0009] The female and male terminals may be respectively defined by connection orientations that are in different directions.

[0010] The connection orientations may be in opposing orientation.

[0011] Tire connection orientations may be arranged on a common axis.

[0012] Tire female terminal may be in the form of a hollow tube and the male terminal may be in the fomr of a pin that interference fits within the hollow tube.

[0013] The electrical connector may be a bullet-type connector.

[0014] The female terminal and the male terminal may be complementary.

[0015] The electrical connector may further comprise a housing containing the female and male terminals.

[0016] Tire housing may comprise a shoulder extending from tire housing, from which the wire extends.

[0017] Tire shoulder may be defined by an angle of about 15° to 45° relative to a longitudinal axis of the electrical connector.

[0018] The electrical connector may further comprise a plug adapted for being received into the female terminal: optionally the plug being secured to the wire.

[0019] The electrical connector may be a single conductor.

[0020] Tire male and female terminals may each comprise one or more crimp members that receive the wire. The wire may electrically communicate with both of the male and female tenninals.

[0021] The male and female terminals may engage together, such as in an interference fit.

[0022] The male and female terminals may be monolithically fonned together.

[0023] The housing may be generally tube-shaped.

[0024] The present disclosure relates to a light assembly, which may address at least some of the needs identified above. Tire light assembly may comprise one or more of the electrical connectors described above.

[0025] The light assembly may comprise one or more LEDs.

[0026] The light assembly may be in the form of a watermelon light.

[0027] The light assembly may be adapted to connect in series, via the one or more electrical connectors, with one or more additional light assemblies.

[0028] Tire light assembly, together with one or more additional light assemblies, may be adapted to connect one-to-one with terminals in a native vehicle circuit.

[0029] The light assembly may comprise three of the electrical connectors, including a negative, a positive, and a ground.Atorney Docket No.: 2021P.002WO (9113840)BRIEF DESCRIPTIONS OF THE DRAWINGS

[0030] FIG. 1 illustrates light assemblies according to the present teachings.

[0031] FIG. 2A is a plan view of an electrical connector according to the present teachings.

[0032] FIG. 2B is a perspective view of the electrical connector.

[0033] FIG. 3 illustrates two electrical connectors arranged in a series.

[0034] FIG. 4 is an exploded view of an electrical connector.

[0035] FIG. 5 is a sectional view of an electrical connector.DETAILED DESCRIPTION

[0036] The present teachings describe an improved electrical connector and a light assembly comprising one or more of the electrical connector. The electrical connector may comprise a female terminal on a first end thereof and a male terminal on a second end thereof. In this regard, two or more of the electrical connectors may connect in a series.

[0037] The electrical connector of the present teachings may be advantageous for connecting light assemblies to a power circuit in a vehicle, although other applications for tire electrical connector described herein are also contemplated.

[0038] The female terminal and the male terminal may each be defined by connection orientations. That is, an orientation along or relative to an axis, with directionality, according to which the female or male tenninals couple with complementary female or male terminals of another electrical connector. Hie connection orientations may be in different directions. Tire connection orientations may be in opposing directions. The connection orientations may be along a common axis.

[0039] The connection orientations may be generally in the same direction, and oriented about at an angle relative to each other. The angle may be about 5° or more, 25° or more, 45° or more, 65° or more, or even 85° or more. The angle may be about 175° or less, 150° or less, 130° or less, or even 110° or less. For example, the connection orientations may be such that the terminals form a Y-shape.

[0040] The electrical connector may be a snap-plug-type connector, such as a bullet-type connector or otherwise referred to in the art as a barrel connector. In this regard, the female terminal may be in the form of a tube and the male terminal may be in the form of a pin. The pin may be adapted to fit within the tube. The tube may be hollow. The pin may have a rounded end to aid with insertion into the tube. These configurations are merely exemplary and the present teachings contemplate other variations, such as geometries other than tubular. The female terminal may be electrically insulated on an exterior surface thereof such that, when joined, the female and male tenninals are both located within said insulation and thus, are electrically insulated.Atorney Docket No.: 2021P.002WO (9113840)

[0041] The female and male tcnninals of the electrical connector may be complementary. That is, they may be of the same type, length, diameter, wire gauge of attached wire, or any combination thereof, such that they would fit together if not physically constrained (e.g., in opposing directions) upon the same electrical connector.

[0042] The electrical connector may comprise a wire. The wire may electrically couple the electrical connector to a light. The wire may be electrically coupled to both of the female terminal and the male terminal. A single wire may extend between the electrical connector and the light.

[0043] The electrical connector and the wire may be single conductors. A single electrical connector and associated wire may function as positive, negative, or ground. Tire light assembly may comprise a positive wire and a negative wire, with associated electrical connectors; or a positive wire, a negative wire, and a neutral wire, with associated connectors.

[0044] Tire female and male terminals may each comprise one or more crimp members. The crimp member may function to receive the wire and crimp upon the wire to secure the wire. The wire may be received by at least one crimp member of the female terminal and / or at least one crimp member of the male terminal.

[0045] The female and male terminals may be structurally discrete from each other. The female and male terminals may engage together, such as in an interference fit, soldering, clipping, the like, or any combination thereof.

[0046] Tire female and male terminals may be monolithically fomred together, such as being cast, machined, or tire like as a monolithic structure.

[0047] The electrical connector may comprise a housing. The housing may function to electrically insulate the female and male terminals, receive one or more wires electrically communicating with the female and male terminals, or both. The housing may extend at least partially over the male terminal. The housing may extend at least the length of the female terminal, but preferably the housing may extend beyond the length of the female terminal (e.g., about 1 mm or more, about 2 mm or more, 3 mm or more, or even about 4 mm or more; about 10 mm or less, about 9 mm or less, about 8 mm or less, or even about 7 mm or less). In this regard, the portion of the housing associated with the female terminal may accommodate a plug, as described herein.

[0048] The housing may comprise a shoulder. The shoulder may function to receive one or more wires electrically communicating with the female and male terminals. Tire shoulder may extend from a perimeter of the housing. The shoulder may be defined by an angle of about 15° or more, 20° or more, or even 25° or more. The shoulder may be defined by an angle of about 45° or less, about 40° or less, about 35° or less, or even about 30° or less. The angle may be of a surface of the shoulder and / or an angle at which the wire enters the shoulder. The shoulder may be defined by an axis that is skewed from an axis of the femaleAttorney Docket No.: 2021P.002WO (9113840) terminal and / or the male terminal. For example, the female and male terminals may be oriented along the same axis, and an axis defining the shoulder may be skewed from said axis.

[0049] The electrical connector may further comprise a plug. The plug may function to mitigate or substantially prevent ingress of debris and / or fluid into the female terminal. The plug may fit into the female terminal and / or a portion of the housing proximate to the female terminal. The plug may be engaged with the housing when a female terminal is left unoccupied by a male terminal (e.g., when an electrical connector is last-in-series).

[0050] The plug may comprise a tab. The tab may extend from the plug and secure the plug to the wire. The tab may comprise a loop through which the wire extends. In this regard, the plug may remain secured to the wire when not engaged with the female terminal.

[0051] A light assembly may comprise one or more of the electrical connectors described herein. For example, the light assembly may comprise two or three electrical connectors. The electrical connectors may include a negative, a positive, a ground, or any combination thereof.

[0052] The light assembly may comprise one or more lighting elements. Tire one or more lighting elements may include LEDs, such as LED strips; incandescent lights; fluorescent lights; halogen lights; or any combination thereof. The foregoing is not intended to be limiting of the present teachings and are provided for example. The light assembly may be in the form of a watermelon light.

[0053] Tire light assembly may be adapted to connect in series, via the one or more electrical connectors, with one or more additional light assemblies.

[0054] FIG. 1 shows three different and non-limiting versions of light assemblies 10. The light assemblies 10 each comprise a light 12 (e.g., as shown, watermelon lights) that electrically connects to a power source via wires 14, 14', 14", which are respectively positive, negative, and neutral. Each wire 14, 14', 14" terminates to an electrical connector 16, 16', 16".

[0055] FIG. 2A and FIG. 2B depict an electrical connector 18. Tire electrical connector 18 comprises a female terminal 20 and male terminal 22 that are oriented in opposing directions. In this regard, the electrical connector 18 can couple with another electrical connector via the female terminal 20 and / or the male terminal 22. When not in use, the female terminal 20 may be sealed-off by a plug 24.

[0056] The electrical connector 18 has a housing 26 that contains the female terminal 20 and male terminal 22. The housing 26 includes a shoulder 28 into which a wire 30 (e.g., such as one of the wires 14, 14', 14" shown in FIG. 1) extends to provide for an electrical connection to the female terminal 20 and the male tenninal 22. As will be seen, tire plug 24 is fit into the portion of the housing 26 that contains the female terminal 20.

[0057] FIG. 3 show a first electrical connector 32 and a second electrical connector 34 arranged in series. The male terminal of the first electrical connector 32 is engaged with the female terminal of the secondAtorney Docket No.: 2021P.002WO (9113840) electrical connector 34. A plug 36 scals-off the female terminal of the first electrical connector 32. The male tenninal 38 of the second electrical connector 34 remains available to tie into a power circuit. Although, the present teachings contemplate that the female terminal of the first electrical connector 32 may tie into the power circuit.

[0058] FIG. 4 is an exploded view of an electrical connector 40 and FIG. 5 is a sectional view of the electrical connector 40. The electrical connector 40 comprises a male terminal 42 and a female terminal 44, which are contained within a housing 46. The male tenninal 42 and the female terminal 44 engage together, such as in an interference-fit fashion, although the present teachings contemplate the male terminal 42 and female tenninal 44 being integrally formed together (e.g., cast, machined, or otherwise as a monolithic structure). The male terminal 42 and the female terminal 44 each include crimp members 48, 50, as shown, in the form of discontinuous loops with an end connected, respectively, to tire male terminal 42 and the female terminal 44, and a free end. In total, there are eight crimp members 48, 50 shown. The electrical connector 40 comprises a wire 52, which is received within the crimp members 48, 50 to provide for an electrical connection with the male terminal 42 and the female terminal 44. A plug 54 locates within the housing 46 to seal -off the female terminal 44.

[0059] It is understood that the above description is intended to be illustrative and not restrictive. The explanations and illustrations presented herein are intended to acquaint others skilled in the art with the invention, its principles, and its practical application.

[0060] Those skilled in the art may adapt and apply the invention in its numerous fomis, as may be best suited to the requirements of a particular use. Many embodiments as well as many applications besides the examples provided herein will be apparent to those of skill in the art upon reading the above description.

[0061] Accordingly, the specific embodiments of the invention set forth herein are not intended as being exhaustive or limiting of the teachings. The scope of the invention should, therefore, be determined not with reference to the above description, but should instead be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.

[0062] The omission in the following claims of any aspect of subject mater that is disclosed herein is not a disclaimer of such subject mater, nor should it be regarded that the inventors did not consider such subject mater to be part of the disclosed inventive subject mater.

[0063] The disclosures of all articles and references, including patent applications and publications, are incorporated by reference for all purposes.

[0064] Plural elements or steps can be provided by a single integrated element or step. Alternatively, a single element or step might be divided into separate plural elements or steps.

[0065] The disclosure of “a7’ or “one” to describe an element or step is not intended to foreclose additional elements or steps.Atorney Docket No.: 2021P.002WO (9113840)

[0066] The use of “about” or “approximately” in connection with a range applies to both ends of the range. Thus, “about 20 to 30” is intended to cover “about 20 to about 30”, inclusive of at least the specified endpoints.

[0067] Unless otherwise stated, all ranges include both endpoints and all numbers between the endpoints in increments of one unit provided that there is a separation of at least 2 units between any lower endpoint and any higher endpoint. As an example, if it is stated that the amount of a component, a property, or the like is, e.g., from 1 to 90, from 20 to 80, or from 30 to 70, it is intended that intermediate range values such as. e.g., 15 to 85, 22 to 68, 43 to 51, 30 to 32, etc., are within the teachings of this specification. Likewise, individual intermediate values are also within the present teachings.

[0068] For values which are less than one, one unit is considered to be 0.0001, 0.001, 0.01, or 0.1 as appropriate. These are only examples of what is specifically intended and all possible combinations of numerical values between the lowest endpoint and the highest endpoint enumerated are to be considered to be expressly stated in this application in a similar manner.

[0069] The term “consisting essentially of’ to describe a combination shall include the elements or components identified, and such other elements or components that do not materially affect the basic and novel characteristics of the combination. The use of the terms “comprising” or “including” to describe combinations of elements or components herein also contemplates embodiments that consist essentially of the elements or components.

[0070] While the terms first, second, third, etc., may be used herein to describe various elements, components, regions, layers, and / or sections, these elements, components, regions, layers, and / or sections should not be limited by these terms. These terms may be used to distinguish one element, component, region, layer, and / or section from another region, layer, and / or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Tirus, a first element, component, region, layer, and / or section discussed below could be termed a second element, component, region, layer, and / or section without departing from the teachings.

[0071] Spatially relative terms, such as “inner,” “outer.” “beneath,” “below,” “lower,” “above.” “upper,” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the drawings. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the drawings. For example, if the device in the draw ings is turned over, elements described as “below ” or “beneath” other elements or features would then be oriented “above” the other elements or features. Tims, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.Attorney Docket No.: 2021P.002WO (9113840)

[0072] Tire terms “generally” or “substantially” to describe angular measurements may mean about + / - 10° or less, about + / - 5° or less, or even about + / - 1° or less. Hie tenns “generally” or “substantially” to describe angular measurements may mean about + / - 0.01° or greater, about + / - 0. 1° or greater, or even about + / - 0.5° or greater.

[0073] The terms “generally” or “substantially” to describe linear measurements, percentages, or ratios may mean about + / - 10% or less, about + / - 5% or less, or even about + / - 1% or less. The terms “generally” or “substantially” to describe linear measurements, percentages, or ratios may mean about + / - 0.01% or greater, about + / - 0.1% or greater, or even about + / - 0.5% or greater.REFERENCE NUMERALS

[0074] 10 Light assembly

[0075] 12 Light

[0076] 14 Wire

[0077] 14' Wire

[0078] 14" Wire

[0079] 16 Electrical connector

[0080] 16' Electrical connector

[0081] 16" Electrical connector

[0082] 18 Electrical connector

[0083] 20 Female terminal

[0084] 22 Male terminal

[0085] 24 Plug

[0086] 26 Housing

[0087] 28 Shoulder

[0088] 30 Wire

[0089] 32 First electrical connector

[0090] 34 Second electrical connector

[0091] 36 Plug

[0092] 38 Male terminal

[0093] 40 Electrical connector

[0094] 42 Male tenninal

[0095] 44 Female terminal

[0096] 46 Housing

[0097] 48 Crimp memberAtorney Docket No.: 2021P.002WO (9113840)

[0098] 50 Crimp member

[0099] 52 Wire

[0100] 54 Plug

Claims

Attorney Docket No.: 2021P.002WO (9113840)CLAIMSWhat is claimed is:Claim 1: An electrical connector comprising: a female terminal on a first end thereof and a male terminal on a second end thereof; and a wire electrically connected to the female and male terminals, the electrical connector adapted to connect in series with one or more other electrical connectors; and wherein the female and male terminals are contained within a common housing.Claim 2: The electrical connector according to Claim 1, wherein the female and male terminals are respectively defined by connection orientations that are in different directions.Claim 3 : The electrical connector according to Claim 1 or Claim 2, wherein the connection orientations are in opposing orientation.Claim 4: The electrical connector according to any one of the preceding claims, wherein the connection orientations are arranged on a common axis.Claim 5 : The electrical connector according to any one of the preceding claims, wherein the female terminal is in the form of a hollow tube and the male terminal is in the form of a pin that interference fits within the hollow tube.Claim 6: The electrical connector according to any one of the preceding claims, wherein the electrical connector is a bullet-type connector.Claim 7 : The electrical connector according to any one of the preceding claims, wherein the female terminal and the male terminal are complementary with respect to terminal type and size.Claim 8 : The electrical connector according to any one of the preceding claims, wherein the housing comprises a shoulder extending from the housing, from which the wire extends.Claim 9 : The electrical connector according to any one of the preceding claims, wherein the shoulder is defined by an angle of about 15° to 45° relative to a longitudinal axis of the electrical connector.Atorney Docket No.: 2021P.002WO (9113840)Claim 10: The electrical connector according to any one of the preceding claims, further comprising a plug adapted for being received into the female tenninal; optionally the plug being secured to the wire.Claim 11: The electrical connector according to any one of the preceding claims, wherein the electrical connector is a single conductor.Claim 12: Tire electrical connector according to any one of the preceding claims, wherein the male and female terminals each comprise one or more crimp members that receive the wire; and wherein the wire electrically communicates with both of the male and female terminals.Claim 13: Tire electrical connector according to any one of the preceding claims, wherein the male and female terminals engage together, such as in an interference fit.Claim 14: The electrical connector according to any one of Claims 1 through 13. wherein the male and female terminals are monolithically formed together.Claim 15 : Tire electrical connector according to any one of the preceding claims, wherein the housing is generally tube-shaped.Claim 16: A light assembly comprising one or more of the electrical connectors according to any one of the preceding claims.Claim 17: Tire light assembly according to Claim 16, wherein the light assembly comprises one or more LEDs.Claim 18: The light assembly according to Claim 16 or Claim 17, wherein the light assembly is in the form of a watermelon light.Claim 19: Tire light assembly according to any one of Claims 16 through 18, wherein the light assembly is adapted to connect in series, via the one or more electrical connectors, with one or more additional light assemblies; and wherein the light assembly, together with the one or more additional light assemblies, is adapted to connect one-to-one with terminals in a native vehicle circuit.Atorney Docket No.: 2021P.002WO (9113840)Claim 20: The light assembly according to any one of Claims 16 through 19, wherein the light assembly comprises three of the electrical connectors, including a negative, a positive, and a ground.

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