Trailer Socket Spring-Loaded Cover and Modular Harness
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Solution Overview
Problem
Existing trailer socket connectors for towing vehicles, particularly those following the SAE J1239 standard, lack effective water tightness and require manual closure of covers, leading to exposure of contact terminals to the elements and laborious replacement processes that involve cutting and splicing electrical wires.
Innovation Solution
A socket design with a spring-loaded, hinge-connected cover and a modular harness connector system featuring lamella and single wire seals, along with a drainage mechanism to ensure water tightness from the socket interface to the wire harness side, allowing for independent sealing and easy replacement of components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a rubber cover is provided to protect the contact system, then water protection is improved, but the closing operation becomes manual and not secured by system component
Solution Approach 1:
The cover is spring-loaded to automatically close and seal the socket after the plug is removed, eliminating the need for manual closing operations. The spring mechanism self-activates when the plug is withdrawn, pushing the cover into the closed position where it seals against the socket housing.
Solution Approach 2:
The cover transitions from a static manual-closure design to a dynamic spring-loaded system that automatically responds to plug insertion and removal. The spring provides continuous force to maintain the cover in the closed position, creating an active sealing system rather than a passive one.
2Object-affected harmful factors
If over molded contact wires are used to improve water protection, then water tightness is improved, but serviceability deteriorates as complete harness exchange is required
Solution Approach 1:
The electrical connection system is divided into separate modular components: the socket housing with integrated contact terminals, and individual wire connectors that can be independently attached or removed. This segmentation allows the wire connectors to be replaced without replacing the entire harness or socket assembly.
Solution Approach 2:
The wire connectors are extracted as separate replaceable components from the overall harness assembly. Each wire connector can be individually removed and replaced at the socket interface, eliminating the need to exchange the complete harness when servicing is required.
3Object-affected harmful factors
If the socket is sealed to prevent water entry, then water protection is improved, but trapped water cannot escape
Solution Approach 1:
The sealing system is designed with spatially differentiated functions: the main body is sealed to prevent water entry, while a specific localized region includes a drainage path. The drainage hole or channel provides a controlled exit point for trapped water, while the rest of the socket remains hermetically sealed.
4Reliability
If the cover is spring-loaded in the closing direction, then automatic sealing is improved, but the structure becomes more complex
Solution Approach 1:
The spring mechanism is integrated directly into the cover structure itself, rather than being a separate assembly. The spring is molded or mounted as part of the cover component, combining the sealing function and the actuating mechanism into a single integrated part, which reduces overall structural complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides reliable water tightness and easy maintenance by ensuring water can drain from the socket even when the trailer plug is inserted, and allows for modular replacement of the harness connector, preventing premature corrosion and simplifying service processes.
Implementation Method 1
a cover sealing off the first plug receiving opening in its closed position and being spring-loaded in the closing direction
Implementation Method 2
the single wire seal surrounding the single wire connected to the harness contact terminal, the single wire seal abutting and sealing against an inside wall of the terminal opening
Data Source
AI summary
A socket for connecting a trailer plug connector in the outside area of a towing vehicle has a socket housing, a first plug receiving opening, a cover, a harness connector, and a second plug receiving opening. Electrical socket contacts are supported in the socket housing extending into the first receiving opening for mating with a trailer plug connector and into the second plug receiving opening for mating with a harness connector. The harness connector has an outer perimeter lamella seal. The harness connector has terminal openings. A contact terminal connects with one single wire and has a single wire seal surrounding the single wire. The single wire seal abuts and seals an inside wall of the terminal opening. The socket housing includes a drainage opening from the inside of the first plug receiving opening to the outside of the socket housing. A shielding plate with a channel is located below the drainage opening to block water flow from outside into the plug receiving opening.