CA2129873A1 - Electrical connector inlet assembly with break-away mechanism for electric vehicle - Google Patents

Abstract

ELECTRICAL CONNECTOR INLET ASSEMBLY WITH
BREAK-AWAY MECHANISM FOR ELECTRIC VEHICLE

ABSTRACT OF THE DISCLOSURE

An electrical connector inlet assembly with a break-away mechanism coupled to an electric vehicle for receiving electrical energy. The break-away mechanism disconnects the contacts of the inlet assembly or receptacle from the contacts of the plug to prevent damage of the electrical connector assembly, upon application of a highly excessive force pulling the plug away from the receptacle prior to disengagement of the contacts. The electrical connector inlet assembly receives an electrical connector or plug with electrical contacts for mating with the electrical contacts of the electrical inlet assembly or receptacle.
The plug has a cover for selectively covering and uncovering its electrical contacts to prevent inadvertent contact with the electrical contacts and to protect the electrical contacts from the environment. Likewise, the receptacle has a cover for selectively covering and uncovering its electrical contacts to prevent inadvertent contact with the electrical contacts and to protect the electrical contacts from the environment. In the preferred embodiment, the covers of the plug and receptacle are either automatically or manually uncovered only after full insertion of the plug into the receptacle. The plug can be inserted into the receptacle with little or no force by the user since the contacts of the plug and receptacle are not electrically coupled together until after full insertion of the plug into the receptacle.

Description

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.s ",:'", ' ELECTRICAL CONNECq~OR INLET ASSEMBLY WITH ~ ;
. 1~,BREAR--AWAY MECHANISM FOR ELE:CTRIC VEHICIE

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Field o the Invention .
.~This invention relates to an electrical connector .
inlet assembly with a break-away mechanism for receiving a plug or male eleckrical connector. The electrical ~:1 connector inlet assembly or receptacle mates with the plug .-~
;! or male electrical connector for electrically coupling a . : first ~et of contacts in the plug with a second set of - : :
`:3~ 10contacts in the receptacle. In the event an excessive :
1 force occurs between the inlet assembly and plug, the :~
.~j break-away mechanism retracts the contacts of the inlet assembly from the plug to release the plug from the inlet ~, caviky.

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BackgE~ound of the Invention The number of automobiles being operated in the world is continuing to increa~e. This increase in automobiles ha~ significantly increased t]he worldwide air pollution ~ 5 problem. In order to control this air pollution problem ,`-~ from automobileF, many countries have begun to regulate ~he ;~
., exhauit ~missions from au~omobile~. In fact, the exhaust , emissions standards are constantly becoming ~tricter each year. For example, California regulators have recently passed a law requiring 2% of all vehiclQs sold in California to be ~zero-emissions" or electric powered by 1998. Failure tv meet the new emission ~tandard would ";
result in ~ignificant fines to au~omobile manufacturers selling automobiles in California. A~cordingly, automobile ~q 15 manufacturer~' abllity to sell automobile~ in California will be hurt if they do not produce an automobile with ~;;i zero-emissions.
~, In view of these increasingly stricter emi~sion - -~
;i!,l requ~rement , automobile manufacturers are beginning to ~ 20 develop electric powered vehicles. Accordingly, it will be ,~ nece~sary to provide the owners of the electric vehicles with a safe and easy way of recharging their batteries.
Moreover, electric vehicles have a limited range of travel before requiring their batteries to be recharged. Thus, recharging stations will be needed which are conveniently located and ea~y to operate in substantially the same manner in which gas ~tations are currently available for ga~ powered vehicles. ~`
One example of an electric vehicle and a recharging station for recharging the batteries of electric vehicles i8 disclosed in U.S. Patent No. 4,158,802 to Rose, II. The electric vehicle and the racharging station disclosed in i~ the patent i~sued to Rose, II have many drawbacks. For instance, the contact surface of the vehicle i8 exposed to .
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,t,'~ the environment which can cause the electrical contact ;t ; surfaces of the vehicle to corrode. Also, the electrical contact surfaces of the vehicle and the recharging ~tation are exposed to the driver such that the driver of the vehicle could sccidentally touch one of the electric '>`jl! contacts and receive an electrical shock. Furthermore, this recharging station would require all electric vehicles to be manufactured within a c~rtain range of ~izes and ,~, shapes. .
r-!JJ 10 Accordingly, many att2mpts have been made to use inductive power coupling~ to rechargQ the batteries of an electric vehicle. Inductive power coupling~ transfer p~wer ~rom a power source to the vehicle by mean~ of a magnetic ~ield that extends through an air gap. ~owever~ these inductive po~er couplings have certain disadvantages. For example, research is currantly being conducted on the harmful effects on humans of magnetic fields, ciuch as -~
created ~y inductive couplings. Moreover, existing inductive power couplings are not capable of transferring high amperage which is necessary to provide a fast charge ~ ~
~j to the vehicle~ 8 battery. ~ ;
~xample of inductive ~ower coupling~ are disclosed in the following patents: U.S. patent 4,347,472 to Lemelson;
U.S. Patent ~,800,328 to Bolger et al; U.S. Patent 5,157,319 to Rlonte et al; Japanese patent application 53-287607 to Matsuoka; German patent 23 30 255; and Japanese patent application 58-69404 to Yamsda.
In view of the above, it i8 apparent that there exists a need for an electrical connector assembly for ~i 30 transferring energy by conduction to electric vehicles from i¦ electrical recharging stations which will overcome the ;;~ above probl~ns of the prior art, and which are safe and co~venient to operate. This invention addresses this need in the art along with other needs which will become ';

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~` apparent to those 6killed in ~he art once given this disclosure.
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Summary of the Invention -~j 5Accordingly, a primary ob~ect of the present invention i8 to provide an electri~al connector a~6embly, especially for electric vehicles, which is safe and convenient to ~ ;
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operate.
1 An ob~ect of the present invention i8 to provide an `~ 10~lectrical connector assembly having one electrical connector ~oupled to a recharging station and ano~her electrical connector coupled to an electric car in which the plug and the receptacle will disengage ~rom each other `~without damage thereto when an exces~ively high force is -~ -1 15applied to the cable of the plug.
Another ob~ect of ths present invention i8 to provide -~
an electrical connector having its contacts covered or concealed from the u~er to avoid accidental contact by the ~ ; ;
user.
20Another object of the present invention is to provide ~;~
an electrical connector a~sembly having a plug which can be inserted into a receptacle with little or no force. ;~Another ob~ect of the present invention is to provide an electrical connector ass~mhly having a plug with a fir~t 25set of contact~i and a receptacle with a second set of contacts in which both sets of contacts remain covered ;~ ~ until after full in,3ertion of the plug into the receptacle.
~r Still another ob~ect of the present in~ention is to -provido a weather-tight electrical connector assembly.
Another ob~ect of the present invention is to provide an electrical inlet a#~embly having a weathershield or hood ., for covering the mating connector during recharging of the '.';!~ vehicle.

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Pi~ -Yet another object of the present invention is to provide an electrical connector a~embly in which the contact~ of the plug and the contacts of the receptacle move in a direction transverse to the direction of s insertion of the plug into the receptacle~
iX, Another ob~ect i8 to provide electrical connectors for ~-~ electric vehicles or electric recharging stativns which are relatively inexpensive and sim~le to manufacture.
The foregoing ob~ect~ are basically attained by providing, an electrical connector inlet assembly for "~ recharging a battery of an electric vehicle, comprisings a first housing with a mounting member for ri~idly coupling the first housing to a structure of the veh~cle; a second housing with an inlet cavity for receiving a mating lS alectrical connector with a first ~et of electrical contacts therein; a ~oint assembly movably coupling the ~i first housing to the second housing for limited relative movement therebetween; a second set of electrical contac~s movably coupled to the second hou3ing for movement between a retracted position remote from the inlet cavity and an extended position located within the inlet cavity for electrically engaging the first set of electrical contacts of the mating electrical connector; an actuation mechanism op~ratively coupled to the second set of electrical contact~ for moving the second set of electrical contacts between the retracted position and the extended position;
~ and a break-away mechanism for disengaging the first ~et of v electrical contacts of tha mating elactrical connector from the second 8et of electrical contacts when coupled together . 30 and after application of an excessively high force .l therebetween, the break-away mechanism including a relea~e ~i mechanism for moving the second set of contacts from the .. extended position to the retracted po~ition upon a predetermined amount of relative movement between the fir~t ", ~`s ` ""';"

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~, 6 -i`~ and second housings, and a trigger mechanism operatively :: coupled between the first and second housings for sensing relative movement between the first and second hou~ings and operatively coupled to the release mechanism for activating ~i 5 the release mechani~m.
~' Other ob~ects, advantages and ~ali~nt features of the ~-' invention will become apparent from the following detailed ., description, which, taken in con~unction with the annexed ill drawing~, discloseæ four preferred embodiments of the invention.
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Brief Dsscription of the Drawin~s Referring to the drawings which form a part of this original disclosure~
Figure 1 i8 a partial per~pective view of an electrical connector assembly in accordance with a first embodiment of the present invention and illustrated in connection with an electric vehicle and an electric ~'; recharging ~tation;
Figure 2 i8 an anlarged, partial perspective view of the electrical connector a~sembly illustrated in Figure 1 with certain parts broken away for clarity;
Figure 3 is a partial elevational view of an electrical connector or plug just prior to full insertion into an electrical connector inlet assembly or receptacle which is shown in partial cro~s-section and with certain parts removed for clarity;
~'`1 Figure 4 i~ a partial elevational view of the electrical connector ~ust after full insertion into the electrical connector inlet assembly which i8 shown in partial crosl3-section and with certain parts removed for clarity;
Figure 5 i~ z partial elevational view of the electrical connector after full insertion into the ,~ Y ;~

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electrical connector inlet a~;~embly, which is shown in partial cross-~ection with certain parts removed for .~! clarity and with the handle moved to the grab position;
:~; Figure 6 i8 a partial ele~ational view of the eleckrical connector electri~ally coupled to the electrical :~ connector inlet assembly, which i8 shown in partisl cross-section with certain parts r~moved for clarity, and with the weathershield or hood fully extended;
Figure 7 is an exploded perspective view of the electrical connector or plug illustrated in Figures 1-6 in ~1 accordance with the present invention;
`~ Figure 8 is a schematic 8~ de elevational view of the electrical connector or plug illustrated in Figures 1-7 ;~ with a portion broken away to schematically ~how one of the .~ 15 contacts;
F~gure 9 i8 a right side elevational view of the upper half of the contact retainer body of the electrical connector or plug illustrated in Figures 1-9;
Figure 10 i8 a rear elevational view of the upper half :J 20 of the contact retainer body illu~trated in Figure 9;
'b~ Pigure 11 i~ a bottom plan view of the upper half of the contact retainer body illustrated in Figures 9 and 10;
Figure 12 i~ a front elevational view of the upper half of the co~tact retainer body illustrated in Figures 9-Figure 13 i8 a front elevational view of the lower half of the contact retainer body of the electrical connector illustrated in Figures 1-8;
Figure :L4 i8 a top plan view of the lower half of the contact reta:Lner body illustrated in Figure 13;
; Figure 15 i~ a rear elevational view of the lower half ~'`t of the contact retainer body illustrated in Figures 13-14;
Figure :L6 is a bottom plan view of the lower half of the contact retainex body illustrated in Figures 13-15;

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~,; ; , if~re 17 i8 a cross-~ect~lfLonal view of the lower half i of the contact retainer body illustrated in Fig~res 13-16 taken along line 17-17 of Figuxe 13; ;~
Fif~ure 18 is a cross-sectional view of the contact ~:
cover of the electrical connec:tor or plug illu~trated in ~j Figures 1-8;
Figure 19 i~ a front elevational view of the electrical connector inlet assf2mbfly or receptacle in acfrordancfe with the present invention with cerSain parts ~ 10 removed ffofr clari.y; . ~.
~ Figure 20 i~ an exploded perspective view of selected ~ pf~ 8 of the electrif~ffal connfefctor lnlet asfse~fly or ~ ~
,i, receptacle illustxat2d in Fif~rfef 19; ;~.
Figure 21 iB a front elevational view of the ou~er `~
inlet housing of thf2 electrical co~ector inlet asse~f illustrated in ~igures 19 and 20;
f~ Fif~re 22 i~ a ref~ elfevational view of the outer .;~
~fl inlet houf3ing of the electrical connector inlet assf~fly ~ illustrated in Fif~res 19-21; ~::
f;f; 20 fffif~re 23 is a longitudinal cross-sectional view of the outer inlet housing of the electrical inlet assembly f~(f illustrated in F~ f~res 19-22; -~ ;
'~¦ Figure 24 i8 a front eleva~ftional ~iew of the inner inlet housing of the electrical connector inlet assfembfly `~
~i 1 25 illustratef-~f in Flgure~ 19 and 20;
~1 Figure 25 i8 a top plan view of the inner inlet ~ -if -~
housing of the elefctrical connector inlet assemkffly fl illustrated in Figures 19, 20 and 24; ~;
Figure 26 i8 a longitudinal cros~-~ectional view of ~ .
the inner in:Let housing of the electrical connector inlet ,"`~ assfembly shown in Fifgures 19, 20, 24 and 25; .
.f Figure ;2~ff i~ a lfefft side per~pective view of the cam plate unit ~Df the electrical connector inlet asse~Dly illustrated i.n Figures l9 and 20;
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- Figure 28 i8 a left side perspective view of the drive ,.. plate unit of the electrica:L connector inlet as~embly i~ illustrated in Figures 19 and 20;
.. , Figure 29 is a left sicle perspective view of the ~i 5 actuation unit of the electrical connector inlet assembly -'' illustrated in Fi~ures 19 and 20;
~-~ Figure 30 i8 a l~ft side perspecti~e view o~ the upper `~ latch of the electrical connector inlet assembly illustrated in Figures 19 and 20;
Figure 31 i8 a left side perspective vi~w of the lower i~ latch of the electrical conne~tor inlet a~sembly illustrated in Figures 19 and 20, Figure 32 i8 a left side pexspe~tive view of the release latch of the electrical connector inlet assembly illustrated in Figures 19 and 20;
Figure 33 i8 a left side perBpective view of the inlet contact cover of the electrical connector inlet a~sembly ~ illustrated in Figure 19;
P.j - Figure 34 iæ a left side elevational view of the .~ zo contact bail of the contact assembly for the electrical L~', connector inlet assembly;
. ~ Figure 35 i8 a rear elevational view of the contact bail illustrated i~ Figure 34;
Figure 3b is a top plan ~iew of the contact bail ~i 1 2s illustrated in Figures 34 and 35;
Figure 37 i~ a left side elevational view of the trigger support of the break-away assembly for the electrical connector inlet assembly;
Figure 38 i8 a rear elevational view of the trigger support of the breaX-away assembly illustrated in Figure 37 i.~. with a portion broken away for clarity;
Figure 39 i8 a top plan view of the trigger support of the break-away assembly illustrated in Figures 37 and 38;

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., Figure 40 LS a partial, exploded perspective view of selected parts of the actuation assembly for the electrical . ,. ; .
;:~ connector inlet assembly or receptacle;
<.~ Fi~ure 41 i~ a cross-sectional view taken along a - 5 vertical plane extending thu~ough the center of the ~:
:. electrical connector inlet a88embly illu~trating the inlet :, :
. ..~, contact assembly and break-away assembly; ~ :
Figure 42 i8 a cross-sectional Vi8W of the electrical - .
connector inlet as~mbly taken along a vertical plane illustrating the release latch in the retracted po~ition;
Figure 43 i~ a cross-sectional view of the electrical :l connector inlet as~embly taken along a vertical plane ; . :
illustrating the cam plate in the retracted position;
Figure 44 i8 a cro~s-sectional view of the electrical ..
, 15 connector inlet as~embly taken along a ver~ical plane ~-illustrating the ~riVQ plate in the retracted position;
Figure 45 i8 a cro~s-~ectional view of the electrical ~ connector inlet assembly taken along a vertical plane j illustrating the actuation plats in the retracted position;
.`1 20 Figure 46 i8 cros~-sectional view of the electric21 3 connector inlet ass~mbly taken along a vertical plane illustrating the actuation plate ~n a ~rab position;
Figure 47 i8 a cross-~ectional view of the electrical ;, connector inlet assembly taken along a vertical plane :~
illustrating the cam plate in an extended position; - ..
Figure 4B is a cross-sectional view of the electrical i;~
connector inlet assembly taken along a vertical plane illustrating the drive pl~te in the extended position;
Figure 43 i8 a cross-sectional view of the electr~cal 3 30 connector inlet a~sembly taken along a vertical plane illu~trating the actuation plate in the extended position;
~ Figure 50 i8 a cross-sectional view of the electrical ,J connector inlet assembly taken along a vartical plane illustrating the cam plate and release latch in their ; : ~ ' . '` ' ':

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; break-away positions after a break-away force has been ~`~ applied to the electrical co~lector inlet a6sembly, but prior to retrac~ion of the cam plate;
Figure 51 is a cross-sectional view of the electrical ~, 5 connector inlet assembly taken along a vertical plane illustrating the cam plate in the retracted position after i a break-away force ha~ been applied to the electrical ~I connector inlet assembly;
.~,, Figure 52 i~ a ~chematic view of the electrical connector or plug shown in partial elevation and ,~:i illustrating the engagement with the upper latch prior to ;' movement of the upper latch by the electrical connector or plug;
~-~ Figure 53 i8 a schematic view of the electrical connector or plug shown in partial elevation and illustra~ing the engagement of the upper latch with the j'i lower latch after movement of the upper latch by the electrical connector or plug;
Figure 54 i8 a ~chematic view of the electrical ~:~ 20 connector or plug ~hown in partial elevation and illustrating the movement of uppex and lower latches after full in~ertion of the electrical connector into the inlet cavity and the actuation plate moved to a grab ~o~ition;
Figure 55 i8 a schematic view of the electrical connector or plug shown in partial elevation~ and illustrating the mo~ement of upper and lower latches upon partial removal of the electrical connector or plug.from the inlet cavity;
Figure 56 i8 a side per~pective view of an automatic version of ~m elactric 1 connector inlet a~sembly in accordance with a second embodiment of the present invention;
Figure 57 i8 a partial side elevational view of the automatic version of the electrical connector inlet `' ~,' ,~.
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,l " assembly illu~trated in Figure 56 with a portion of the outer inle~ hou~ing broken away for clarity;
igure 58 is a perspecti~e view of the drive arm for ,;j the automatic version of the electrical connector inlet assembly illustrated in Figures 56 and 57;
Figure 59 is an exploded perspective view o~ selected parts of modified electrical connector inlet assembly illustrated in Figures 1-55 in accordance with a third .' embodiment of the present invention;
Figure 60 i8 a schematic cross-sectional ~iew of an ;~i electrical connector inlet as~embly in ~ccordance with the b,'`'~ third embodiment of the prese~t inven$ion illustrated in Figure 59;
, Figure 61 is a partial front ele~ational view of a ~ 15 vehicle with the slectrical connector inlet assembly of .~ Fic3ures 59 and 60 mounted therein; and Fic~ure 62 i8 a partial cross-~ectio~al view of an automatic version of an electrical connector inlet as~embly in accordance with a fourth embodLment o~ the present invention taken along a ~ertical plane.

Detailed Description of ~he Drawinc~s Referring initially to Figure~ 1 and 2, an electrical ~: connector assembly 10 especially desic3ned for use with an eIectric car or vehicle 12 i8 illustrated in accordance with the present invention, and includes a power source or charging station 14 for dispensing electrical energy, a plug or male electrical connector 16 electrically coupled to power æousc:e 14 by an electrical and data/communicationæ
3V cable 18, a receptacle or ~emale electrical connector inlet a883mbly 20 mounted in electric vehicle 12 for receiving ~ electrical energy from electrical connector 16, a battery i 22 located i.n vehicle 12 and electrically coupled to ~ electrical co~nector inlet asæembly 20 for receiving r~

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`.`~.~ electrical energy therefrom, ancl an on-board microproce~or or computer 24 located ln vehicle 12 for transmitting and ,:~, receiving relevant data to and from power source 14 and to and from electrical connector inlet a88embly 20 to control :;5 the operation thereof.
While electrical connector 16 and electrical connector ~;~ inlet assembly 20 are illustrated in conjunction with an ~`- electric vehicle 12, it ~ill become apparen~ from this disclo3ure that electrical connector 16 and electrical connector inlet as~embly 20 can be u~ed in many other electrical systems and applications. ~oreover, it will be apparent to tho~e skilled in the art from this di~closure that electrical co~nector 16 can be electrically coupled to ~æ~l battery 22 and on-board microprocessor 24 by cable 18, and that electrical connector inlet a88embly 20 can be electrically coupled to the recharging station 14.
t.J Po~er source or charging station 14 is preferably connected to the local electrical utility company~ 8 power line or to any other conventional source of electrical energy. Charging station 14 can be mounted in practically any location, including residential hou~es, apartment buildings, gas ~tat~ons; parking garages, or even at the ~ide of a curb ~o that power can be readily available to vehicls 12.
. 25 ' In residential applications, charging station 14 can be electrically con~ected in a conventional maDner to a cirauit braaker panel or power meter in a residential home or apartment. ~lectrical connection~, breaker panels, and~or power meter are all conventional and well known, and thus they will not be discussed or illustrated in detail herein.
,'1 In comme:rcial applications, charging station 14 can be constructed to u8e ~imilar electronics as used in today~s , automated gas station~. For example, charg~ng station 14 .~
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can be provided with a conventional power meter for determining the amount of electrical energy disp2nsed, a credit or debit card ~lot for payment of the dispen~ed ~' electrical en~rgy, and any other of the similar type of ~ 5 conveniences provided at automated ga~ ~tations. ~he `~ electronics and circuit~ which can be used for operating .~`i3~1 charging station 14 in commercial applications are conventional and well known, i.e., ~imilar electrical circuits are currently used to operate gas stat:Lon pumps, and thus ~he electronics and circuit~ for charging station 14 will not be discu~sed or illustrated in detail herein.
~j hikewi~e, electric vehicle 12 with ba~tery 22 and ,'~,~.'','!~1 microproceæ~or 24 are all conventional and well known, andthu~ they will not be discussed or illustrated in detail.
As seen in Figure 7, cable 18 preferably includes four elec~rical power conductors 26 and a comm~mications wire 28. Power conductors 26 are all 8ub8tantially identical ~o each other, except that one of the conductors 26 is a ground, and the other three conductors 26 are current car~ying-conductors.
Each conductor 26 i~ a conventional conductor with a conductive core and an insulating sheath covering the core.
Accordingly, conductors, such as conductor~ 26, are well known, and thus will not be di~cu~sed or illustrated in ~ I 25 detail herein.

:~ Electrical Connector 16 .'~'.; A~ ~een in Figure 7, electrical coDnector 16 includes ~i (1) four terminal blocks 30 with cylindrical bores 32 and cylindrical brush contscts 34, (2) a communications connector or ~ata plug 36 with one or more communications contacts 38, land (3~ an insulated housing 40 coupled to one end of cable 18 for housing contacts 34 and 38.
,., Specifically, a terminal block 30 is fixedly coupled to one 'I,c ~1~
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end of each of the conductor~ .26l while the oth2r end of i' each of conductors 26 is electrically eoupled to power ~ource 14. Each terminal block: 30 has a cylindrical bore 32 with a metallic, cylindrical, tubular brush Gontact 34 fixedly mounted within bore 32 and electrically coupled conductive to the core of the associated conductor 26.
;;;~ Communications wira 28 i8 a conventional :-! communication~ wire, and thus will not be discussed or ~l illustrated in detail herein. ~hile communications wire 28 0 i8 illustrated a~ a ~ingle conductor, it will be apparent 3 from thi~ disclosure tha~ ~ommunications wire 28 is i~ preferably a data plug with a plurality of insulated '~`!;,~ conductors which are each connected at one end to the electronic circuitry of power source 14 and at the other end to a plurality of contacts 38 contained in a communications connector 36. Communic~tions connector or data plug 36 i8 a conventional connector wi~h conventional ;~ electrical contact~ 38 electrically connected to the in~ulated communications conductor~. For exampla, ~; 20 communications wire 28 and communications connector 36 can ~'~.i, be similar to a conv~ntional telephone wire and telephone ~acket which has a plurality of conductors and contact~
Accordingly, communications connector 36 as well as its contacts 38 will not be illustrated or discus~ed in detail herein.
,~ A~ seen in Figur~s 7 and 8, electrical connector 16 is coupled to the end of cable 18 for housing the contacts 34 and 38 of c2~b1e 18, and for seleGtively covering and exposing the contact~ 34 and 38 of cable 18.
A3 particularly seen in Figure 7, insulated housing 40 of electrical connector 16 is coupled to one end of cable ~; 18 in a water-tight manner, and includes a handle portion 42, a cable clamp 44 removably coupled to handle portion 42 ~,. by two screws 46 for securing cable 18 thereto, a contact . . !' ~ S~
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retainer body 48 for housing terminal blocks 30 and ~, communications connector 36, a contact cover 50 pivotally coupled to contact retainer body 48 for selectively concealing and exposing the contacts 34 and 38 of cable 18, ~i~; 5 a torsion spring 52 coupled between contact retainer body 48 and contact cover 50 for bialsing contact cover 50 to a closed position covering contacts 34 and 38, and three gaskets 54, 56 and 58 for protectin~ contactfi 34 and 38 from the weather or other contaminant6.
Handle portion 42 ha~ a mounting portion 60 with three screw holes 62 for receiving ~crews 64 therethrough for attachin~ the handle portion 42 to the contact retainer body 48. The handle portion 42 al~o has a handle 66 extending rearwardly from mounting portion 60 and a cable receiving cavity 68 for receiving conductors 26 and `~ communications wire 28 therein. Preferably, handle portion 42 i8 molded as an integral, one-piecer unitary me~er from a hard, rigid, non-conductive material ~uch as plastic.
Cable recei~ing c~vity 68 of electrical connector 16 2~ has a cable ~lamping ~urface 70 with a pair of threaded holes ~not shown) for threadedly receiving screws 46 to secure cable clamp 44 thereto. Specifically, conductors 26 and communications wire 28 are cl~mped between cable clamp 44 and cable clamping surface 70 for securing cable 18 to electrical connector 16. Preferably, cable clamping ;~ sur~ac2 70 and ci~ble cli~mp 44 are both contoured with five complementary rec~sses for individually sgueezing each of the power conductors 26 and communication~ wire 28 therebetween iEor securely clamping ci~ble 18 to electrical connector 16.
A~ ~een :in Figures 7-17, contact retainex body 48 of ~; electrical cor~ector 16 i~cludes an upper half or member 80 and a lower half or member 82 relea~i~bly coupled together ! ~ by four screw~ or fa~teners 84. Preferi~bly, both the upper " ~ :
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half 80 and the lower half 82 are molded as integral, one-~ piece, unitary members from hard, rigid non-conductive ,-' material~ such as plaatic.
Referring to Figures 9-12, upper half 80 includes a top wall 86, a front wall 87 extending from top wall 86, a '~ pair of substantially identical side walls 88 extending irom wall~ 86 and 87, a rear wall 89 extending between l walls 86 and 88, and a hook 90 extending outwardly from the -~ intersection o$ top wall 86 and front wall 87 for removably coupling electrical connector 16 to electrical connèctor inlet assembly 20 as discu~sed below.
Top wall 86 of upper half 80 ha~ four holes 91 with ;l one of the holes 91 being located at each of the corner~
for receiving ~cr~wa B4 therethrough. Extending downwardly from top wall 86 are five positioning flanges 92 for engaging terminal blocks 30 and communications connector 36. In other words, positioning flanges 92 maintain power terminals 30 and communLcations connector 36 within lower half 82 to prevent movement therein.
The rear wall 89 of upper half 80 has four power conductor hole~ 93 for receiving power conductors 26 therethrough and one communicat:Lons wire hole 94 for receiving communication~ wire 28 therethrough. ~ear wall 89 also include~ a threaded hole 95 for receiving one of the screws 64 to rel2asably couple contact retainer body 48 to handle portion 42.
Referring to Figures 7 and 13-17, lower half 82 of ;~ contact retainer body 48 has a pair of substantially identical side walls 100, a front wall 102, a rear wall 104 "h"~ 30 and a bottom wall 106. The ~ide walls 100 are each ~1 provided with a circular hole 108 for receiving a pivot pin `~ 110 therethrough. The side walls 100 have upper portions 112 and lower portions 114 which form a part of a ledge 116 therebetween 130 that the upper portions 112 of the side 1.`'l ~ .
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~, ,, i ,, - 18 -.,~, i ;~ walls 100 are sized to be received between side wall~ 88 of upper half 80~ In other w~rdst lower portions 114 are spaced inwardly from upper portions 112 80 that side walls 88 of upper half 80 ~it on the ledge 116 of the lower half S 82 when coupled together. The :lower portions 114 of side ~`, walls 100 are each provided with a notch 118 which engages a portion of the electrical connector inlet assembly 20 as discussed below. One or both of the lower portions 114 of side walls 100 have a magnet 119 mounted therein for ~, 10 actlvating microprocessor 24 as discussed below in more detail.
~i Front wall 102 of lower half 82 has a upper portion 120 and a lower portion 122 with a large front opening 124 communicating with the interior space of lower half 82.
Upper portion 120 is spaced inwardly from lower portion 122 :~ for forming a part of ledge 116. Opening 124 is sized to ,~ frictionally receive gasket 54 therein.
'; Rear wall 104 of lower half 82 has a pair of threaded ~`: openings 126 for receiving two of screws 64 therein. Rear wall 104 also has five cutouts 127-131 for allowing conductors 26 and communications wire 28 to e~ter the îi interior ~pace of lower half 82 of contact retainer body 48.
Bottom wall 106 of lower ~alf 82 is recessed from the bottom edges of side walls 100 80 as to form a cavi~y 132 i for receiving contact co~er 50 therein. Specifically, bottom wall ln6 i8 substantially U-shaped 80 that cavity } 132 i8 substantially U-shaped. ~ccordingly, contact cover 5 0 i8 received completely recessed within cavity 132.
Bottom wall 106 has a no~ch 133 for engaging torsion spring 52 for biasing contact cover 50 to a clo~ed position as ~,, discussed below.
1`.i' The lower half 82 of contact retainer body 48 further ~ includes four substantially identical dividers 134 which 1~." ~
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'`, divide the interior of the lower half 82 of contact retainer body 48 into five contact receiving cavities 135-,~ 139. In particular~ dividers 134 are substantially parallel with side walls 100 for maintaining terminal blocks 30 and communications c:onnector 36 substantially parallel and aligned with one another. The middle three ~ cavitie~ 136, 137 and 138 are subs~antially identical in r~; size and ~hape, while end cA~ity 135 i8 slightly smaller than middle cavitie~ 136, 137 and 138. End cavity 139 i~
even smaller than the remaining cavities for receiving the communications connector 36 therein.
hedge 116 has ~our threaded bores 140 for threadedly receiving screws 84 to ~ecure to upper half 80 of contact retainer body 48 to lower half 82 of contact retainer body 48. Of cour~e, upper and lower halves 80 and 82 could be permanently fastened together by an adhesive or other fastening device.
As seen in Figures 7 and 18, contact cover 50 includes a pair of substanti~lly identical side walls 172 with a ~ 20 curved cover plate 176 extending therebetween and a divider ;.. ,.~ plate 178 extending between side walls 172 so as to form a pair of recesses 180 and 182.
Each of the side walls 172 has a pivot hole 184 for ~: receiving pivot pin liO therethrough for pivotally coupling ~ l 25 contact cover S0 to lower half 82 of contact retainer body .;; 48. Pivot holes 184 are po~itioned to communicate with : recess 180 80 that pivot pin 110 passe~ through recess 180.
~: Accordi~gly, :recess 180 of contact cover 50 is sized to recei~e tor~ion spring 52 thereon. In particular, torsion spring 52 is wrapped around pivot pin 110 for engaging both contact co~er 50 and lower half 82 of contact retainer body 48 for biasing contact cover 50 to its closed position ~:~ ayainst retainer body 48.

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~, Cover 50 al80 has a pair of spaced notches 188 in the front portion of curved cover plate 176 for pivoting ~, contact cover 50 between its open and closed positions by electrical connector inlet asse~ly 20 as di~cussed below.
~, 5 A locking reces~ 189 is fo~med in the botto~ surface of I cul~ed cover plate 176 for engag.ing a portion of electrical ,~i connector inlet as~2mbly 20 to retain electrical connector ~',;,~ 16 xelative to electrical connector inlet assembly 20.
~, Rece~ 182 of contact cover 50 i~ ~ized to encompass the lower por~ions of cavities 135-139. Accordingly, ~:~3 contact cover 50 completely conceal~ the contact~ 34 and 38 `~ when in he clo~ed position.
As seen i~ Figur~P 7, torsion spring 52 is a onventional torsion spring constructed of resilient wire ,-1 15 which ls helically wrapped. Tor~ion ~pring 52 has a first ~ -end 190~ an intermedlate tab 192 and a second end 194.
; First and second ends 190 and 194 engage divider plate 178 1 of contact covar 50, while the tab portion 192 engage~
!,'~`~.' notch 133 ormed in bottom wall 108 of lower half 82 of contact retainer body 48.
A~ seen in Figure 7, gaskets 54, 56 and 58 are co~ventional gaskets made of resilient material such as foam or rubber. ~asket 54 i8 curved and has five circular openings (not shown) therethrough for xeceiving the --contacts of the ele~trical connector inlet as~embly 20 therethrough a~ diseussed below.
~' Gasket 56 is substantially circular in cross-section and form~ a rectangular ring which i8 frictionally retained ';',.~r~
around bottom wall 106 within cavity 132 of lower half 82 ~`1 30 of retainer body 48 ~o that the upper e~ges of side walls 172 as well a~ the upper edge of the curve cover plate 176 engages ga~ket 56 to ensure that the contact remained sealed when the cover 50 i~ in the closed position.
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! . - 21 Gasket 58 is positioned between handle portion 42 and contact retainer body 48 for sPaling the interface therebetween. In par~icular, gasket 58 i8 ~ubstantially rectangular with five circular openlng~ 198 for receiving conductor~ 26 and communicationR wire 28 thersthrough.
Preferably, the holes 198 are sized to cause a friction fit around the conductor~ 26 and communications wire 28 80 as ~`; to create a seal ~herebe~ween. The gs~ket 58 al~o has three of holes 199 for receiving screws 64 therethrough.
"~, 10 f~ .~ Electrical Connector Inlet A~sembly 20 Reerring now to Figures 19~53, electrical connector ~ inlet assembly 20 includes (1) an ou~er stationary inlet i~ housing 200 fixedly coupled to vehicle 12, ~2) an inner~ 15 movable inlet housing 202 movably coupled to outer inlet i:i '~J~ housing 200, (3) a universal ~oint assembly 204 for movably ~1 coupling i~ner inlet housing 202 to outer inlet housing 200, (4~ sn inlet contact assembly 206 movably coupled to inner inlet housing 202, (5) an actuation assembly 208 movably coupled to inner inlet housing 202 for operating ~ inlet contact assembly 206, and (6) a break-away assembly ,`~3 210 ~or releasing electrical connector 16 from electrical connector inlet assambly 20 upon application of an ~3 exces~ive force between electrical connector 16 and electrical connector inlet a~sembly 20.
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~! Outer Inlet Housina 200 Re~erring to Figures 20-23 and 40-50, outer inlet housing 200 is preferably molded as an integral, one-piece, unitary member from a hard, rigid non-conductive material ^ ~-such as plastic. Outer inlet housing 200 has a top wall ~ i-220, a pair of ~ubstantially identical ~ide walls 222 extending downwardly and substantially perpendicularly to ~¦ top wall 220, a bottom wall 226 extending between ~he lower ,, ~,;i ., ` 212~873 . . `
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.., ends of side wall~ 222, a rear wall ~28 for mounting outer inlet housing 200 to vehicle 12, and an open front 230 for ~i receiving inner movable inlet housing 202 therethrough.
~ii Accordingly, outer inlet housin~a 200 i8 rigidly coupled to 1 5 vehicle 12 and movably supports inner inlet housing 202 to ,., vehicle 12 as discussed below.
Top wall 220 of outer inlet hou~ing 200 has an inverted U-~haped channel 234 and a pair of flat sections 236 and 238 extending outwardly from inverted V-shaped channel 234 to side walls 222 of outer inlet housing 200.
Inverted ~-shaped channel 234 ha~ a pair of horizontally aligned pivot hole~ 240 extending therethrough with their longitudinal axis extending substantially perpendicular to side walls 222. Pivot holes 240 are horizontally aligned to receive a portion of universal ioint assembly 204 for pivotally coupling inner inlet hou~ing 202 about a horizontal aSxi~ between side walls 222 of outer inlet ~, r housing 200. ; --~
Side walls 222 of outer inlet housing 200 ars preferably substantially flat planar msember~ which extend substantially perpendicular to top wall 220 as well as bottom wall 226 and rear wall 228. Side walls 222 are ~ubstantially parallel to each other, and spaced apart for receiving inner inlet housing 202 therebetween.
Bottom wall 226 is a substantially flat wall with a ~¦ mounting hole 242 extending therethrough for mounting a `~
portion of break-away as~embly 210 thereto. Bottom wall 226 is substantially parallel to flat sections 236 and 238 of top wall 2:20 and spaced from top wall 220 for receiving inner inlet hou~ing 202 therebetween. ~;
~i;, Rear wall 228 of outer inlet housing 200 has three i -~i mounting holel3 244 for fixedly and rigidly securing outer inlet housing 200 to vehicle 12. The rear wall 228 also ~3 has a conductor mounting ~ection 246 formed along it~

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lower end for ~ecuring the electrical conductors of the ... ~ inlet contact a~6emb1y 206 thereto as discus~ed below in more detail.
:~; Conductor mounting sect.ion 246 includes five pa6sageways 251, a clamping plate 256 removably ?oupled to ~ rear wall 228 by four ~crews 258 to overly portion~ of ,',?1 passageways 251 and to secure the inlet conductors thereto.
::~ Passageways 251 are defined by four divider~ 261 a~ well as by a first flange 266 with five cutouts 271 and a second , 10 flange 276 with five cu~outs 277. Dividers 261 ex~end fr~m ¦ the rear wall 228 into the interior of outer inlet housing 200. Dividers 261 are tapered at their free ends and provide in~ulation bet~een the inlet conductors.
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;1 15 Inner Inlet Housinq 202 . -Referring to Figures 24-26, inner inlet housing 202 includes a pair of substantially identical side walls 302, a front contoured wall 304 extending between side walls 302, and a bo~tom wall 306 extending between iside walls 302. Preferably, inner inlet hou~ing 202 is molded as an . ;~:~
integral, one-piece, unitary member from a hard, ri.gid non~
conductive material such as plastic. Inner inlet housing 202 is movably coupled to outer inlet housing 200 by universal ~oint a88embly 204 as di~cu~sed below.
Side walls 302 of inner inlet housing 202 are : ~:
substantially identical, and thus like reference numerals ~^
will be used to idantify the same parts on each of the side walls 302. Each of the side walls 302 includes an :
outwardly extending mounting flange 310 with a pair of upper mounting holes 311 for mounting a portion of universal ~oint assembly 204 to inner inlet housing 202 via . ~:~
screw~ (not shown), and a lower mounting hole 313 for :~
.~ mounting a portion of braak-away a~sembly 210 to inner inlet hou~ing 202. `~
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~3 Each of the ~ide walls 302 further includes a ver~ical control ~lot 314, an angled control slot 316, and a curved .-, control 810t 318. Control ~lot:s 314, 316 and 318 control the movement of the inlet con~act assembly 206 relative ~o inner inlet housing 202 for expo~ing and extending ~he ~, inlet contacts a~ well as concealing and retracting the .! inlet contact~.
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~ Each of the side walls 302 is also provided with thrae kr.-~ pivot pins 320, 322 and 324, two pivot holes 3~6 and 328, ., 10 a triangular clearance opening 330 and an arcuate clearance ~: opening 332 for coupling actuation a~semb~y 208 thereto as discussed below in more detail. The in3ide ~urface of each of the side walls 302 has a pair of rail~ 334 extending parallel to angled control slot 316 for engaging and ~:! 15 controlling the movement of part of the inlet contact ,~ assembly 206 as discus~ed below.
Front wall 304 of inlet housing 202 includes an inlet cavity 336 for receiving electrical connector 16 therein, a ledge 338 for cooperating with hook 90 of electrical connector 16, a pair of threaded holes 340 for securing the front portion of universal joint assembly 204 thereto by scr0ws 342.
Inlet cavity 336 i~ formed by a 8ub8tantially curved wall 344 and a lower ~lat wall 346 which extend between side walls 302 to form an inlet pocket with a rectangular opening for receiving electrical connector 16 thereon.
Curved wall 344 includes an arcuate recess 348 positioned ad~acent each of the side walls 302 of inner inlet housing 202. Recesses 348 are arcuate and aligned with curved slotS 3ï8 fonned in side walls 302. Curved wall 344 al~o includes five spaced contact openings 350 and five reinforcing tubes 352 extending from the interior surface of curved wall 344 and aligned with contact openings 350.
Lower wall 346 of inlet cavity 336 includes a pair of "`,:''' ~':' , ,;,,1 . .~1~;
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., ~;j clearance openings 35~ which are aligned with recesses 348, . and a locking pin 356 pro~ecting upwardly into inlet cavity ! 336 for engaging recess 189 formed in contact cover 50 of ~Z electrical connector 16. ~he clearance openings 354 permit - 5 movement of the inlet contact ass~mbly 206, while locking : pin 356 retains electrical connector 16 within inlet cavity `.'l 336, as discussed below~
-, Bottom wall 306 of inner inlet housing 202 is substantially planar and extends between side walls 302.
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Bottom wall 3D6 is provided with a ~emicircular cutout 356 .. :: -~`~i for accommodating a part of $he break-away assembly 310 as :
discussed below. : ;.
Optionally, a sensor 358 can be mounted in a recess formed in each of the side walls 302 of inner inlet housing 202 ad~acent inlet ~avity 336 as seen in Figure 42.
Sensors 358 are electrically coupled to microprocessor 24 to pro~ide various information to the microprocessor such -~
as the charging capability of electrical connector 16. ~ .-In particular, sensors 358 are preferably reed switches coupled to the side walls 302 of inner inlet housing 202 ad~acent inlet cavity 336~ Sensors 358 are ~ d activated by one or more of the magnet~ 119 on electrical connector 16. Specifically, when electrical connector 16 is inserted into cavity 336 of electrical inlet connector assembly 20, one or more of the magnets 119 will be positioned ad~acent the reed switches or sensors 358 for activating microprocessor 24. Accordingly, microprocessor ::
24 will not be actuated until the electrical connector 16 i8 correctly E~ositioned within inlet cavity 336. If the !"
electrical connector 16 is ab~ent from inlet cavity 336 or not correctly positioned within the inlet cavity 336, the il reed switches or ~ensors 358 will sense the absence or .~ incorrect positioning of the electrical connector 16 to r ' ~
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prevent the contact pins 409 and the hood 510 from being ~i extended.
Reed switches or sensors 358 are conventional reed i switches or sensors, and ~hus, will not be discussed or -~ 5 disclosed in detail hers3in. Moreover, their electrical connections with microprocessor 24 are conventional electrical connections which will not be disclosed or illustrated in detail herein. Basically, reed switches 358 preferably include a pair of spaced contacts which are normally open, b~t closed when sub~ected to the magnetic field of magnets 119. Accordin~ly, the closing of the contacts of the reed ~witches 358 conveys information to microprocessor 24 as discussed below.
Magnets 119 are mounted in side walls 100 of electrical connector 16 so that they are positioned ad~acent one or more of the sensor~ 358. Specifically, by selecting one or more magnets 119, the reed switchs3s 358 can signal the microprocessor 24 to indicate the current flow or amperage rating of the electrical connector 16.
In other words, ~y selecting the number of magnets 119, it is possible to indicate whether a 810w charge, fast charge or normal charge i8 being supplied to vehicle 12 by electrical connector 16. More specifically, if a magnet is applied to the right ~ide wall 100 of electrical connector 16, then the corresponding sensor 358 will be activated by the right side magnet to indicate a slow charge. If a ~l magnet i8 coupled to the left side wall lO0 of electrical connector 16 with no magnet on the right side wall lO0 of electrical connector 16, then electrical connector 16 will acti~ate the left side sensor 358 of the inlet assembly 20 to indicate a normal charge to microprocessor 24. If a magnet 119 i~ attached to both the right and left side walls 100 of electrical connector 16, then both the right ~1 !
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and left sensors 358 will be activated by the magnets ll9 ~:~ to indicate a fast charge to the microprocessor 24.
In this manner, microprocessor 24 can adjust the circuitry of vehicle 12 to acco~modate the amperage rating ',~ 5 or magnitude of power from the electrical connector 16. In `, addition, microproces~or 24 can send a signal via communications wire 28 to power source 14 to prevent any current flow from electrical connector 16 to inlet assembly `~ 20, if the electrical connector 16 i8 incompatible with the circuitry of the vehicle 12.

Vniversal Joint Assembly ~04 ~s seen in Figures 19, 20 and 41, universal ~oint assembly 204 includes a front mounting bracket 360 coupled to the front end of inner inlet housing 202 by screws 342, a rear mounting bracket 362 coupled to the rear end of inner inlet housing 202 by screws 312, a first pivot tube 366 extending between mounting brackets 360 and 362, a se~ond pivot tube 368 rigidly coupled perpendicularly to first pivot tube 366, a first pivot pin 370 rotatably ~; received within fir~t pivot tube 366, and a second pivot pin 372 rotatably received within second pivot tube 368.
Front bracket 360 includes a pivot hole 374, a rectangular opening 376 and a pair of mounting holes 378.
Pivot hole 374 couples the front end of inner inlet hossing 202 to first pivot pin 370 of universal ~oint assembly 204.
Rectangular opening 376 is sized to overly the opening of inlet cavity 336 to allow electrical connector 16 to pass therethrough as well as parts of actuation assembly 208.
~ounting holes 378 are sized to receive screws 342 for ~;~J;:~' securing front bracket 360 to inner inlet housing 202.
Rear br~-cket 362 is substantially U-shaped with a ,l~; centrally located pivot hole 380 located along its bight portion, a ~irst pair of mounting holes 382 formed along ~ ;{ ~:-. ...
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' one of the leg portions, and a second pair of mounting ,~ holes 384 along the other leg portion. Pivot hole 380 ~'" pivotally couples the rear porti,on of inner inlet housing 202 to outer inlet housing 200 via pivot pin 370 of universal joint assembly 204. ~[ounting hole~ 382 and 384 receive screws 312 for securing rear bracket 362 to side walls 302 of inner inlet housing 202 via threading screws 312 into mounting holes 311 formed in inner inlet housing 202.
First pivot tube 366 extends substantially perpendicularly to second pivot tube 368. First pivot tube ~l 366 receives first pivot pin 370 therein for rotational movement, while second pivot tube 368 receives second pivot pin 372 therein for rotational movement. First pivot pin 370 has a threaded bore 390 at each end for receiving a ficrew 392 for fastening ~irst pivot pin 370 to front i",,l bracket 360 and rear bracket 362 of inner inlet housing 202. Likewise~ second pivot pin 372 has a threaded bore 394 at each end for receiving one of the screws 396 to secure pivot pin 372 to outer inlet housing 200.
Accordingly, universal ~oint assembly 204 allows inner inlet housing 202 to rotate or move about the longitudinal ~', axes of pivot tube~ 366 and 368 relative to outer inlet housing 200. The amount of movement between the two ~} 25 housings 200 and 202 i8 limited by the clearance between ,'''~ the two housings 200 and 202. Moreover, the break-away ~;1 assembly 210 al~o limits or prevents relative movement ~¦ between the tw~ ho-lsing 20 and 207 as discussed below.

".l, 30 Inlet Contact .ssembly 206 , As seen in Figures 20, 34-36 and 41, inlet contact as~embly 206 includes five electrical inlet contacts 401-405 movably coupled to inner inlet housing 202 by a movable contact bail 406, and a movable contact cover assembly 408 ~ ~!.', ",`i ~, '~; :' !,:

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for exposing and concealing electrical contacts 401-405.
Inlet contact assembly 206 is operatively coupled to actuation as~embly 208 such that actuation a88embly 208 j`jj~1; moves the inlet con~acts 401-40!5 as well as move~ contact cover assembly 408 upon insertion of electrical connector 16 into inlet cavity 336.
~ ach of the electrical contacts 401~404 are substantially identical except for their relative size.
Specifically, elec~rical contacts 402, 403 and 404 are power contacts which are all substantially the ~ame size.
Electrical contact 401 i~ a ground contac~ which is slightly smaller than the electrical p~wer contacts 402, '3 403 and 404. Electrical contact 405 i8 a communications connector with a plurality of contacts.
~ach of the electrical inlet contacts 401-405 includes a contact pin 409 fixedly coupled to contact bail 406 for r~ movement therewith, a conductive wire 410 coupled at one ~, end to one of the contact pins 409, and an end connector ~, 411 coupled to the other end of each conductive wire 410 i~ 20 for coupling one of the electrical conductors 412 of vehicle 12 thereto, respectively. ~he communications r,~;il contact 40S has a plurality of contacts for engaging ,~ communications connector 36, while the contact pins 409 of the remaining contacts 401-404 are ~olid, 3ingle contacts for engaging contacts 34 of electrical connector 16. Of course, communlcations contact 405 can have a single contact, if desired.
Contact pins 409 of contacts 401-405 each have a main body portion 413 for coupling conductive wire 410 thereto, and a cylindrical pin portion 414 for electrically coupling the electrical connector inlet assembly 20 to electrical ! connector 16. Nain body portion 413 ha~ an axially extending threaded hole 415 for receiving a thumb screw ., i, .

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416, and a transverse bore 417 communicating with hole 415 .', for receiving conductive wire 410.
Bore 417 is sized to recei1ve one of th~ ends of its respective conductive wire 410 t:herein. Conducti~e wires ;l 5 410 are secured to main bod~ portions 413 of contact pins 409 by thumb screws 416. Specifically, thumb screws 416 are threaded into holes 415 until they engage conductive wires 410 to crimp them wit~in bores 417. Thus, thumb screw 416 electrically couples conductive wire 410 to main body portion 413.
Cylindrical pin portion 414 of each contact pin 409 is provided with an annular recess 421 for receiving a C-clip 423 to retain contact pin 409 within bail 406. Contact pins 409 are constructed of any suitable conductive material such as brass. ~ach of the contac~ pins 409 are coupled to bail 406 for reciprocal movement therewith to ~l electrically engage and disengage contacts 34 and 38 of electrical connector 16.
Each of the end connectors 411 includes a connector pin 422, a pair of washers 424, and a pair of nuts 426.
;:~ One of the washers 424 and one of the nuts 426 are attached on opposite ends of each of the connector pins 422.
~: Specifically, each of the connector pins 422 has a pair of oppositely extending threaded ~hafts 428 and 430 with a ! 25 centrally located flange 432 positioned between shafts 428 and 430-End connectors 411 are ~ixedly coupled within passageways 251 by po~itioning one of the shafts 430 within ~^,.; each of the cutouts 271 and then sQcuring each of the end ., 30 connectors 411 therein ~ia one of the washers 424 and one of the nuts 4;26. The other shafts 428 of end connectors 411 are fixedl~y coupled to conductors 416 in a conventional manner via the! other one of the washers 424 and the other ~ one of the nuts 426.
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~ Contact drive bail ~06 is a substantially rectangular c~i~i member having five contact receiving cavities 434 for ;~ supporting main bodies ~13 of inLet contact pins 409. Each of these cavities 434 has a rectangular cross-section with a cutout 436 in one wall for receiving one of ~he conductive wires 410 therein, and a bore 438 for xeceiving pin portion 414 of one of the inlet contact pins 409 therein. Each of the cavities 434 receives one of the main ~ I
bodies 413 of electrical inlet contact pins 409~ while each of the bores 438 receives one of the pin portions 414 of -j electrical inlet co~tact pins 409.
Contact pins 409 are secured ~ithin cavities 434 by C-1 clips 423 to prevent relative movement ~herebetween.
j Contac~ drive bail 406 al60 includes a slide member 440 and i! 15 a pair of parallel rails 442 extending outwardly from each ; of its opposite longitudin~l ends for engaging rails 334 on the interior surfaces of side walls 302 of inner inlet housing 202 therein. In other words, rails 442 on each of jJ the side walls 302 straddle one of the slide members 440 to ~ ~ `
form a pair of parallel slots for slidably receiving rails j 334 of inlet housing 202. Each of the slide members 440 has a threaded hole ~45 for receiving a threaded pin 448.
Pins 448 are designed to slidably secure contact drive bail 406 to side walls 302 o inner inlet housing 202 via angled ! ~ontrol 810ts 316. Preferably, contact drive bail 406 is ;~ molded as an integral, one-piece unitary m~mber from a ij hard, rigid no~-conductive material ~uch as plastic.

Contac~ Cover_Assembl~ 408 A8 seen in Figures 20, 33~ 41-44 and 47, contact cover ;~ sssembly 408 includes a curved contact cover 460, a pair of ~ drive linXs 462 and a connecting rod 464. Contact cover `~ assembly 408 ils preferably controlled by actuation a6sembly 1 208 so that a ussr can expose or conceal the inlet contact ;;~
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s, Contact covetr 460 is prefPrably molded as an integral ;`~ one-piece, unitary mem~ter from a hard, rigid non-conductive 5 material such as plastic. Contact cover 460 has a pair of ,~ arcuate slide arms 468 located at each of its ends, and a pair of detentes 470 for engagins notches 188 formed in contact cover 50 of electrical connector 16 to exptose contacts 34 and 38 of electrical connector 16 to inlet contact pins 409. Each of the axms 468 ha~ a pivot hole ~, 472 for r~ceiving a threaded pin 473 which extends outwardly therefrom for engaging curved control slots 318.
Specifically, pivot hol~s 472 extend through curved control slots 318, and are then coupled to one of the ends of i~s ~`~i 15 respective c~ive link 462 via pins 473. The other ends of ~J?~ the drive links 462 are connected to the ends of connecting rod 464 in a conventional manner such as by C-clips or screws.
Connecting rod 464 is slidably received in vertical control slots 314 of side walls 302 for 1iding movement relative to inner inlet housing 202. Accordingly, movement of connecting rod 464 causes drive link6 462 to reciprocate contact cover 460 via pivot pins 472 sliding in curved ~I control slots 318. Preferably, connecting rod 464 has an overlying sleeve 466 or engaging vertical control slots 314 to provide smooth sliding movQment of connecting rod 4S4 within control slots 314.
~ Arcuate slide arms 468 are positioned within curved j~ rece6ses 348 of inlet cavity 336 of the inner inlet housing 202 for sliding movement therein. Accordingly, as .' connecting rod 464 slides vertically within vertical control slot 314, arcuate slide trms 468 of cover 460 is ~;~ reciproca~e within cuxved recesses 348 with a portion of ~: t",~

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Actuation Assembly 208 --Referring to Figures 20, 27-29 and 40-53, actuation assembly 208 includes (1~ an actuation unit 500 pivotally coupled to inner inlet housing 202 by a first pivot rod ~ :~
502, (2) a drive unit 504 pivotally coupled to imler inlet housing 202 via a ~econd pivot rod S06, (3) a cam unit 508 .i~ 10 pivotally coupled to innPr inlet housi~g 202 via second :.
pivot rod 506, (4) a hood or weathershield 510 fixedly coupled to cam unit 508 for movemen~ therewith, and (5) a pair of connector control la$ch units 512 with one coupled to each of the side walls 302 of inner inlet housing 202. -:.
Actuation unit 500 includes a handle 520, a pair of `~ substantially identical side actuation plates 522 rigidly ; .
~;;,1 coupled to handle 520, a lower connecting plate 526 .~ extending between side actuation plates 522, and a torsion `,t`~ spring 528 positioned on first pivot rod 502 for biasing `~ 20 actuation unit 500 forwardly to a grab position or an .~ extended position. `~
Handle 520 is preferably molded as a unitary, one-piece, unitary member from a hard, rigid non-conductive material such as plastic. ~andle 520 is preferably U-shaped and fixedly coupled to each of the side actua~ion `¦ plates 522 by screws 530 and pins 532. ;
: Side actuation plates 522 are substantially identical, '. and each includes an inwardly extending drive pin 534 with .~. .
a steel bushing 536 thereon for engaging drive unit 504. :
~ 30 Each of the ~ide actuation plates 522 al~o includes a pivot !~ hole 538 for receiving pivot rod 502, and a s~op member :
542. Preferably, side actuation plates 522 are integrally formed with lower connecting plate 526, and are constructed of a sheet material such as aluminum. -.:. :

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,: ! ' ' 1 Torsion spring S28 i5 a conventional torsion spring which is positioned on pivot rod 502 with one end of the torsion spring engaging lower connecting plate 526 and the other end of torsion sprin~ engaS~ing a portion of the inner ':J 5 inlet housing 202 for normally biasing actuation unit 500 forwardly to a grab position or an extended position.
As se n in Figure 28, drive unit 504 ifi substantially U-shaped and preferably made of sheet material such as steel. Drive unit 504 includes a pair of ~ubstantially identical side drive plates 544, an upper ~-shaped connecting member 545, and a pair of tor~ion springs 548 positioned on the ends of pivot rod 506 for normally biasing drive plates 544 forwardly to an extended position.
~'! Each of these drive plates 544 includes a pivot hole 548 for receiving pivot rod 506, an inwardly extending pin 550 for engaging one of the torsion springs 548 positioned on pivot rod 506, an arcuate slot 552 for receiving the outwardly extending pivot pin 322 of inner inlet housing 202, an L-shaped control ~lot 554 for receiving drive pin 534 with bushing 536 of actuation unit 500, and a latch slot 556 for engagin~ connector control latch uni~ 512.
;~i Connecting member 546 is secured to each of the drive plates 544 by rivets os other conventional fasteners. In particular, the connector member 546 includes a bight 2S portion 558 extending between drive plates 544, and a pair of legs 560. Each of the legs 560 is connected to one of the respectlve drive plates 544, and includes a control slot 562 for use with the motor driven version discussed ~;~ below.
As seen in Figure 27, cam unit 508 is substantially U~
i~ shaped and molded as an integral, one-piece, unitary member from a hard, rigid non-conductive material such as plastic or any other suitable material. Control unit 508 includes a pair of substantially idsntical cam plates 570 connected 212~?,73 , .~ .......................................................................... .

!: to opposite ends of hood 510. Cam plates 570 are substantially parallel to each o~her and pivot together about pivot rod 506.
3~ Each of the cam plates 570 includes (1) a pivot hole 572 for receiving pivot rod 506 therein, (2) a hole 574 for ~ receiving a connecting rod 576 therein, (3) a Pirst arcuate ;~. slot 578 with its arc positioned about the pivot hole 572 j J, for receiving pin 550 of one of the drive plates 544, (4) a second arcuate slot 580 with its arc positioned around pivot hole 572 for receiving pivot pin 324 of inner inlet housing 202 therethrough, (5) a third arcuate slot 582 with it~ arc positioned about the pivo~ hole 572 for engaging release latch 650, (6) a first cam slot 584 for controlling movement of the contac bail 406, and (7) a ~econd cam slot 586 for receiving the ends of connecting rod 464 to control ~ the movement of contact cover 460.
!,~ The pair of torsion springs 548 normally bias cam unit :-........... 508 and hood 510 rearwardly for retracting the contact pins ~! 409 and for moving the contact cover 460 to conceal the 2~ contact pins 409 from inlet cavity 336. Specifically, one end of each of the torsion springs 548 engages one of the pins 550 of drive plates 544 and the other ends of each of the torsion springs 548 engages the connecting rod 576.
Accordingly, torsion springs 548 causes a scissor action between drive plates 544 and cam plates 570, i.e., drive ~, plates 544 are biased forwardly, while cam plates 570 are ~-. biased rearwardly by springs 548.
.~ ach of the connector latch units 512 is coupled ~o t one of the ~ide wall~ 302 of inner inlet housing 202. As seen in Figures 30 and 31, each of the connector latch units 512 inc:ludes an upper connector latch S00 for engaging elect:rical connector 16 to release actuation unit 500, a lower connector latch 602 for locking actuation unit . 500 in the ret:racted position, and a pair of compression '~

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~prings 604 and 606 for controlling the movement of latches !~j'j 600 and 602. Upper latch 600 is movably coupled to inner inlet housing 202 by pins 320 and 322 and biased in a counterclockwise direction ~bout pin 320 by first compression spring 604. Lowe!r latch 602 i8 pivotally coupled to inner ~nlet housing Z!02 by pin 324 and biased in a counterclockwise direction about pin 324 by second compression spring 606.
As seen in Figure 30, upper latch 6no includes a first slot 610 extending horizontally for receiving pin 320 of inner inlet housing 202, a second 810t 612 with a U-~haped ; configuration for receiving pin 322 of inner inlet housing ~; 202, a first tab 614 extending through rectangular j clearance opening 330 of inner inlet hou~ing 202 for engaging electrical connector 16, a downwardly e~tending abutment member 618 for engaging lower lat~h 602, and an upwardly extending spring abutment 620 with a horizontally extending tang 622 for engaging fir~t compression spring As seen in Figure 31, lower latch 602 includes a pivot hole 630 at one end for receiving pin 324 of inner inlet ~-;J
housing 202, and a latching tab 634 at the other end for engaging stop 542 of actuation plate 522. Lower latch 602 also includes an upwardly extending abutment 634 for engaging downwardly extending abutment 618 of upper latch ~i 600, and a downwardly ex~ending abutment 636 for engaging second compression spring 606.
As seen in Figure3 52-55, when electrical connector 16 is in~erted into inlet cavity 336 of inner inlet housing 202, first tabs 614 of upper latches 600 will engage the bottom edges of side walls 100 of electrical connector 16.
First tabs 614 of upper latches 600 will then slide along the bottom ed/aes of side wall~ 100 of electrical connector 16 causing upper latches 600 to move downwardly against the ~! . ~

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i force of compression springs 604. Eventually, notches 118 ,~ of electrical connector 16 will engage first tabs 614 of upper latches 600 once electrical connector lfi is .1 completely inserted into inlet cavity 336.
This downward movement of upper latches 600 by .1 electrical connector 16 also causes lower latches 602 to move downwardly since abutments 618 of upper latches S00 engage abl~tments 634 of lower latches 602. Abutments 618 . of upper latches 600 are maintained vertically aligned with 3;~ 10 abutments 634 of lower latches 602 since springs 604 hold pins 322 in the forward legs of U-shaped slots 612.
Accordingly, as lower latches 60~ pivot downwardly about ;1 pivot pins 324, tabs 634 of lower latches 602 will disengage from stops 542 of actuation plates 522, which in turn allows the torsion spring 528 of actuation unit 500 to move actuation plates 522 and handle 520 forwardly to a grab position. In other words, actuation unit 500 will be `!'i pivoted forward about pivot rod 502 by torsion spring 528 until pins 534 of actuation plates 522, which are positioned within L-shaped slots 554 of clrive plates 544, abut against the forward vertical edges of ~-shaped lot~
554 of drive plates 544.
Now, a user may grab the handle 520 to fur~her pivot actuation unit 500 forwardly. This further movement of actuation member 500 causes the drive unit 504 and the cam unit 508 also to move fo~wardly which in turn causes the inlet contact cover 460 to move upwardly and the contact pins 409 to ~xtend within the inlet cavity 336.
Specifically, further forward movement of actuation unit 500 by the user also cau~es clrive unit 504 to move forwardly since pins 534 of actuation plates 522 engage the forward vertic:al edges of L-shaped 810t~ 554. Thus, drive . unit 504 moves forwardly as plns 534 of actuation plates 522 move a~onq the vertical portions of L-shaped slots 554 ` 2~2~73 ~
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of drive plates 544. This is possible since actu~tion unit 500 has a different pivot axis from the pivot axis of drive unit 504. Since rive unit 504 is coupled to cam unit 508 by release latch 650, cam unit 508 also moves forwardly with actuation unit 500 and drive unit 504 upon forward movement of actuation unit 500 from the grab position to -~ the extending position.
.~ As seen in Figures 32 and 40, release latch 650 is `~ releasably coupled to cam unit 508 and fixedly coupled to drive unit 504 so that they all normally ~ove togetherO
However, if a break-away force occurs between outer inlet ~ hou~ing 200 and inner inlet housing 202 as discussed below, then release latch 650 disengages from cam unit 508 to allow cam unit 508 to pivot rearwardly by torsion springs il 15 588. Drive unit 504 and release latch 650, on the other ~, hand, remain coupled together and biased forwardly by torsion springs 548.
As electrical connector 16 is removed from inlet cavity 336 of inner inlet housing 202, upper latches 600 - 20 will be pulled forward by electrical connector 16 to allow lower latches 602 to move upwardly to lock actuation unit 500 in the retracted position. Specifically, the forward movement of upper latches 600 occurs because first tabs 614 are positioned within notches 118 of electrical connector 16 and the outward movement of electrical connector 16 is transmitted to upper latches 600. The forward movement of upper latch2s 600 by electrical connector 16 disengages abutments 618 of upper latches 600 from abutments 634 of lower latches 602. New, compression springs 606 pivot lower latches 602 upwardly about to pivot pin 324 so that latching tabs 634 engage stops 542 of actuation plates 522.
This forward movement of upper latches 600 i8 permitted due to pins 320 ri.ding along the horizontal slots 610 and pins ;~ 322 riding in the U-shaped slots 612. In other words, pins ,,, , :

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I 320 and 322 along with 810ts 610 and 612 control the :~ movement of each of the upper latches 600. When upper latches 600 are moved forward by electrical connector 16, compression springs 6Q4 are compressad between a ledge of inner inlet housing 202 and spring abutment 620. Once electrical connector 16 i8 completely removed from inlet cavity 336, tabs 614 di~engage notches 118 of electrical connector 16, which in turn causes compression springs 604 ~ to move upper latches 600 rearwardly to their original .l 10 positions. As upper latches 600 move rearwardly, pins 322 move from the rearward le~s of the U-shaped 810~s 612 back to the bottom of the bight portions of the U-shaped slots 612 beneath the forward legs of the U-shaped slot~ 612.
:~.; Release latch 650 is substantially ~-shaped, and includes a bight port~on 652 and a pair of leg portions 654 extendin~ upwardly from bight portion 652. Preferably, release latch 650 is constructed from a hard, rigid material ~uch as steel or an~ other suitable material.
Release latch 650 is normally biased upwardly by a pair of springs 655 which are attached at one of their ends to the bight portion 652 and ~t their other ends to one of the inner side walls 302 of inner inlet housing 202 as seen in ~;~ Figure 41.
Each of the leg portions 654 of release latch 650 is ~,` ~ 25 substantially identical, and includes a first pivot qlot 656 ~xtending vertically for receiving pivot rod 506 : therein, a second slot 658 extending vertical for receiving one of the pins 550 of drive plates 544 therein, and an outwardly extending flange 660 for raleasably coupling cam unit 508 to c~ive unit 504. Each of the leg portions 654 are positionecl between one of the side walls 302 of inner inlet housing 202 and one of the cam plates 570 of cam unit 508.

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,..j . - 40 -.. ~ ' First pivot 810t 656 i~ a longitudinally extending oblong hole so that release latch 650 can move ~ii longitudinally on pivot rod 506 as well as pivot about pivot rod 506. Similarly, second slot 658 iis al~o a ;-: 5 longitudinally extending oblong hole for allowing ~ longitudinal movement of release latch 650 about pins 550 i~ of drive plates 544. Thus, release latch 650 can move ~ longitudinally along drive plates 544, but always pivots i``~ with c~ive plates 544.
.;;, 10 Specifically, release latch 650 moves with drive unit 504, since the drive plates 544 and the leg portions 654 .~J all pivot about~pivot rod 502 and the leg portions 654 of release latch 650 are secured to drive plates 544 by pins 550 of drive plates 544 as well as by flanges 660 of release latch 650. Accordingly, as drive unit 504 moves ~ forwardly or rearwardly, the release latch 650 will also ;~ move forwardly or rearwardly with drive unit 504.
During normal use, release latch 650 is coupled to cam unit 508, since flanges 660 of release latch 650 engage shelves 583 of 810ts 582 formed in cam plates 570.
Accordingly, as drive unit 504 moves forwardly or rearwardly by actuation unit 500/ cam unit 508 will also move forwardly or rearwardly with drive unit 504 ~o long as flanges 660 of release latch 650 engage shelves 583 of cam , 25 plates 570. However, if a sufficient break-away force occurs between the outer inlet housing 200 and the inner inlet housing 202, then break-away assembly 210 will move release latch 650 downwardly 80 that flanges 660 of release latch 650 disengage shelves 583 of cam plates 570. Now, flanges 660 of release latch 650 can freely slide within slots 582 of c:am plates 570 so that torsion springs 588 can mo~e cam plat;es 570 rearwardly. This rearward movement causes the contact pin~ 409 to retract from electrical ' t .,, '' .
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'`1 1:', ~ connector 16 and to move inlet contact cover 460 to conceal r~
the retracted contact pins 409.
Bight portion 652 has an upwardly extending flange 670 .1 with an upwardly extending slot 1;72 for receiving a portion ~ 5 of break-away assembly 210 to move release latch 650 /~ between a latched position coupling clrive unit 504 to cam .j' unit 508 and an unlatch as di~cussed below.
~'' Break-away Assembly 210 Referring now to Figures 20, 41, 50 and 51, break-away ~ assembly 210 încludes (1~ a trigger support 700 rigidly ~3 coupled to inner inlet housing 202 by a pair of screws 702, (2) a trigger lever 704 pivotally coupled to trlgger support 700 by a pivot pin 706, (3) a compression spring 708 positioned within trigger ~upport 700 for biasing trigger lever 704 in a counterclockwise direction, (4) a ball bearing 710 positioned within trigger fiupport 700 for engaging tric3ger lever 704, and (5) a ball bearing cup 711 located in support hole 242 of the outer inlet housing 200 for engaging ball bearing 710.
As best seen in Figures 37-39, trigger support 700 includes a rear wall 712 with a pair of mounting holes 714, a front wall 716 extending substantially parallel to rear wall 712 with a ~lot 717, a pair of side walls 718 extending perpendicularly between rear wall 712 and front wall 716, and a bottom wall 720 for supporting trigger lever 704 as well as ball bearing 710 and compression spring 708.
In particular, bottom wall 720 ha~ a pair of ~ 30 intermediate support walls 722a and 722b extending upwardly '~'`I'A~ from bottom wall 720 and between rear wall 712 and front wall 716, ancl a pair of U-shaped walls 724a and 724b extending upwa~rdly from bottom wall 720 and outwardly from support walls 722a and 722b, respectively. Support walls ,i, .. .

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722a and 722b form a channel 726 which is aligned with slot .1 717 of front wall 716 for rec:eiving ~rigger lever 704 therein. Support walls 722a and 722b al80 form a pair of cylinder~ 728 and 730 $or supporting ball bearing 710 and compre~sion ~pring 708 ther~in~. Cylinder 728 is aligned ;, with a hole 732 extending ~hrough bottom wall 720 for 1~ slidably supporting ball bearing 710 therein. The cylinder ,~i, 730, on the other hand/ supports compre~sion ~pring 708 therein. Specifically~ the bottom end of the compres~ion . 10 spring 708 e~gageB bo~tom wall 720, while the top end of compression 6pring 708 engages a portion of trigger lev~r 704. The U-shaped wall~ 724a and 724b axe aligned with a 810t 734 formad in bottom wall 720 for receiving pivot pin 706 therein.
Trigg~r lever 704 i~ positioned within channel 726 ~ormed by the pair of parallel 8upport walls 722a and 722b which extend upwar~ly from bottom wall 720, while pivot pin 706 is positioned in 810t 734 which extends perpendicularly to channel 726. Accordingly, trigger lever 704 i6 pivotally held within channel 726 by pivot pin 706 80 that ~: one end of trigger lever 704 i8 received within cylinder 728 for engaging ball bearing 710 and the other end of the trigger lever 704 extends through cylinder 730 for engaging compression spring 708 to bias trigger l~er 704 sbout pivot pin 706 and against bight portion 652 of relea e latch 650.
As seen in Figures 20, 41 and 50, trigger lever 704 has a first end 742, a second end 744/ a pivot hole 746, and a spring engaging protrusion 748 located betw2en second end 744 and p~vot hole 746 for engaging the upper end of compression ~,pring 708. Trigger lever 704 i8i normally biased in a counterclockwi6e direction by compression spring 708 about pivot pin 706 80 that first end 742 of ~, trigger lever 706 pushes ball baaring 710 downwardly ~`i `! i' ., ,, ";
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against ball bearing cup 711 ancl ~econd end 744 of trigger lever engages flange 670 for biasing release latch 650 ~, upwardly. More specifically, the second end 744 of trigyer ~1, lever 704 is sized that the upper surface of $rigger lever 704 engages the upper end of slotR 672 of relea~e latch 650 and the lower surface of second end 744 of trigger le~er i`1 704 engages bight portion 652 o release latch 650.
Accordingly, upward or downward movement of trigger lever ~i 704 will cause release latch 650 to move either upwardly or downwardly therewith.
Compre~sion spring 708 and ball bearing 710 are conventional, and thus, will not be di~cus~ed in detail.
Of course, it will be apparent to those ~Xilled in the art from this disclosur~ that other b~asing ~echanisms and sliding members can be u~ed in place of c~mpression spring 708 and ball b~aring 710 as needed or desired.
Ball baaring cup 711 i~ substantially circular in top plan view and has a short circular shaft 750 extending downwardly from its bottom ~urface for engaging support ~; 20 hola 242 of the outer inlet housing 200, and an upper recess 752 for receiving ball bearing 710 which i~
supported in inner inlet housing 202 by trigger support 700.
Recss3 752 of ball bearing cup 711 includes a conical portion 754 and a cylindrical portion 756 concentrically ~¦ arranged abou~ conical portion 754 such that in the normal ~"~ rest position ball bearing 710 8it8 within conical portion 754. Upon a force bein~ applied between outer inlet housing 200 ~d inner inlet hou~ing 202, ball bearing 710 will ride out of conical portion 754 up into cylindrical i portion 756 against the force of first end 742 of trigaer !''"~ lever 704. Specifically, ball bearing 710 i8 normally held within conical portion 754 by first end 742 of trigger lever 704 due tG the counterclockwise force applied to :~`, , ' , .; ~ ~ .
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~i trigger lever 704 by compression spriny 708. When the -~
.~l break-away force i8 applied between outer inlet housing 200 and inner i~let housing 202, inner inlet housing ~02 along with ball bearing 710 will move relative to outer inlet hou~ing 200 and ball bearing cu~) 711 since univer~al ~oin~
88sembly 204 movably couples inner inle~ hou~ing 202 ~o outer inlet housing 200. ~his relstive movement between inner inlet hou~iing 202 and outer inlet housing 200 causas the ball bearing 710 to ride up onto cylindrical portion 756 of ball bearing cup 711, which in turn cause~ trigger ~ :
lever 704 to pivot clockwise about pivot pin 7060 Trigger lever 704 then moves relea~e latch 650 downw~rdly causing flanges 660 of release latch 650 to disengage from the : -~
shelves 583 of the cam plate~ 570. Once release latch 650 disengages the shelve~ 583 of cam plate~ 570, the cam unit 508 with hood S10 will be bia~ied rearwardly by torRiion .
spring 528 to retract contact pins 409 and move contact r''- ' cover 460 to conceal contact pin~ 409.
,,~;j~,!ZO pperation of ~lectrical Çonnector Assembly 10 Referring now to Figures 3-6 and 40~55g electrical ` --o connector 16 has its electrical contact~ 34 and 38 -completely concealed by contact cover 50 p~ior to insertion `~
1~ o~ electrical co~nector 16 into electrical connector inlet i~J! ~ 25 assembly 20, while the contact pin8 409 of electrical . connector inlet as~embly 20 are completely concealad by ~: contact covor 460. Thus, inadvertent contact with either ~ of the electrical contac~s 34 and 38 of elec~rical s~ connector 16 or the electrical contact pin~ 409 of alectrical connector inlet a~sembly 20 by the user is .Y prevented, as well as, the ingres~ of water or , contaminants. ~
. In operation, electrical connector 16 i8 inserted into ~:inlet cavity 336 o~ electrical connectvr inlet assembly 20 ;

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`.~. by first engaging hook 94 of ~slectrical connector 16 on ledge 338 of inner i~let housing 202, and then ~wingin~
electricsl connector 16 downwardly into inlet cavity 336 of electrical connector inlet assembly 20. Inlet cavity 336 i8 sized to receive electrical connector 16 therein with little or no hand force by the user to in~ert electrical connector lS into electrical connector inlet assembly io.
~oreover, the cavity 336 iB sized to allow contact cover 50 :l, of ~lectrical connector 16 to ba pivoted be~ween its closed position and its open position for exposing contacts 34 and 38.
Once electrical connector 1~ i5 fully inserted into inlet ¢avity 336 of inlet a~embly 29, side walls 100 of il electrical connector 16 engage tab8 614 of upper latches 600 to release actuation unit 500 from the retracted position to the grab position. A180, full insertion of electrical connector 16 cause6 the notches 188 formed in .. ;i contact cover 50 of electrical connector 16 to engage ,~ detentes 470 forme~ on contact cover 460 of inlet asse~bly ~-1 20 20. Specifically, dur~ng the downwiiqrd swinging of ~;~ electrical connector 16, the upper latches 600 are moved downwardly by electrical connector 16 ~ince tab~ 614 are positioned to engage the ~ide walls 100 of electrical , connector 16 before elec~rical connector 16 is completely swung downwardly to its rest position. This downward movement of upper latche~ 600 causes lower latche~ 602 to also mov~ dow~wardly since abutments 618 of upper la~ches 600 engage abutment 634 of lower latches 602. In other words, upper latches 600 are pivoted downwardly against the force of compIession springs 604 by electrical connector 16 ~i and lower latches 602 are moved downwardly again6t the ~; force of compression ~prings 606 by upper latche6 600.
~his downward movement of lower latches 602 disengages tabs 632 from stop members 542 of actuation plates ~22 to allow ~ ,1!

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~ - 46 .s , ,,~ actuation unit 500 with handle 520 to rotate forwardly about pivot rod 502 due to tor~;ion spring 5~. In other words, lower latches 602 release actuation unit 500 ~o that spring 528 rotates handle 520 to a grab positi~n for 5 permitting a u~er to make the electrical connection between ;~, electrical connector 16 and electrical connector inl~t assembly 20.
~ow that the electrical connector 16 i~ fully inserted into inlet ca~ity 336, the magn~t ox magnets ll9 will activate sensor or ~en80r8 358. The ~ensor or sensor~ 358 . " ;~ ~
will then send a signal to microprocessor~ 24 to ~ndicate the magnitude or level of the charging power being ~upplied by electrical connector 16. The microproces~or 24 can then ad~ust it8 circuitry to accept or re~ect the power or energy from the power ~ource 14 once electrical connection i8 accomplished. In other words, the microproce~sor 24 can 3 prevent the power ~ource from sending power to recharge the bat~ery 22 if the current of the electr~cal connector 16 i8 incompatible with the vehicle'~ circuitry. Preferably, the vehicle's circuitry i8 designed to ad~ust its input to J accommodate the current level being supplied thereto.
~ow, the user grabs ha~dle 5~0 of actuation unit 500 and pu118 it forward about pivot rod 502 which in turn ~il causes drive unit 504, cam unit 508 and release latch 650 all to pivot forwardly along with hood 510. Specifically, drive pin 534 with bushing 536 of actuat;on unit 500 engages the L-shaped 810t 554 of drive plates 544 for ~i moving drive unit 504 forwardly with actuation unit 500.
~rive unit 504 in turn moves cam unit 508 therewith ~ince latching tab~ 660 of release latch 650 engage latch slots 556 of drive unit 504 and engage shelve~ 583 of cam unit 508. Accordingly, movement of the actuation unit 500 from ~;`l the grab po~ition to the e~tended position causes driYe ~ ,.................................................................... . .
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~, unit 504 as well as cam unit 508 and release latch 650 ~o ~:
also move forwardly to the extended position~
This mov~ment of cam unit SID8 drives the inlet contact : ~ .
.~ pins 409 from the~r retracted po8ition to t~eir extended .:
., 5 position ~o engage electrical contacts 34 and 38 of .;::
.~ electrical connector 160 A180, sLmultaneously the contact - covers 50 and 460 axe moved out of the way fox exposing the ,..
respective contact~ 34 snd 38 of alectrical connector 16 ~o ~ -:~ inlet contact pins 409 of inlet assembly 20. Specifically, the ~orward movement of the cam pla~e~ 570 with ~ach of .
.~ their three control slot~ 314, 316 a~d 318 ~ontrol the ~-. movement of inlet contact aBsembly 206 for expo~ing and : :
.,i~ ,, , j extending the inlet contact pins 409 as well as for i~ concealing and retracting the inlet contact pins 409. More pecifically, the contact pins 409 are driven from the retracted position~ to their forward or extended positions :~`' 8inc9 contact drive bail 406 is slidably coupled within i.~. angled control ~lots 316 and ~ngage first cam 510t8 584 of cam plates 570. In other words, a~ cam plat~s 570 move 20 forward, the first cam 810t8 584 engage the pins of the ~; contact drive bail 406 to move tha contact drive bail 406 along angled control slots 316.
1 The contact cover~ 50 and 460 are al50 controlled by the forward movement of cam plate~ 470 to expo~e and 25 conceal the contacts of the respective connector~ 16 and 20. In particular, the ends of connecting rod 464 are po~itioned within second cam 810t8 586 SO that the forward moYement of cam plate~ 570 cause8 the co~necting rod 464 to move vertical:Ly downwardly within vertical control 810t8 314. This downward movement of connecting rod 464 in turn CaU8eS drive linX8 462 to move contact cover 460 along arcuate control ~lot~ 318 from a position concealing contact pins 4L09 to a position e~posing contact pins 409.
Specifically, pivot pins 472 of contact cover 460 are ~, I . .
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connected to one of the ends of drive link8 462 and ~ positioned with arcua~e control slots 318. ~oreover, the ,~ arcuate ælide arms 468 of contact cover 460 are xeeeived in .î the recesses 348 of the inlet cav~ty 336 to ensure smooth 5movement of contact cov~r 460 from a position concealing ~ contact pins 409 to a position exposing contact pins 409.
j~ This sliding movement of contact co~er 460 causes the contact co~er 50 of electrical connector 16 to al~o pivot y downwardly to expo~e contacts 34 and 38 of electrical .. 10connector 16. In particular, detentes 470 of contact covex 460 are received ~n notches 188 of contact cover 50 80 that .,,contact cover 460 and c~ntact cover 50 move togeth~r when .icam unit 508 pivots about second pivot rod 506.
Now that the electrical contacts 34 and 38 of electrical connector 16 are engaged with the contact pins 409 of the inlet as~e~bly 20, microprocessor 24 sends a signal to powar source 14 via communications wire 28 to indicate whether to ~tart charging the battery 22 of vehicle 12 or to prevant charging of the battery 22 due to incompatibility. Once the mlcroprocessox 24 initiates the charging processes, the energy i8 ~hen supplied from power source 14 to the battery 22 of ~ehicle 12. Upon full charge of battery 22, mlcroprocessor 24 will send another sign~l to the power source 14 via communications wire 28 to ;l 25 stop the flow of rurrent.
the event th~t the vehicle 12 is hit when being ~,recharged, the break-away assembly 210 will cause the inlet ,~contact a~sembly 205 to retract the inlet contact pins 409 ,~from the contacts 34 and 38 of the electrical connector 16 ~ 30 as well as cause the inlet contact cover 460 to move from `.,its position e.xposing the contact pins 409 to its retracted ~,position concealing contact pins 4Q9 and the contact cover 50 to mova from its open position expo~ing contacts 34 and ~l38 to it8 clo,~ed position concealing contacts 34 and 38.

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1 Specifically, any relative movement between outer inlet hou~ing 20 and inner inlet housing 202 will cau e break-away assembly 210 to cause release latch 650 to disengage shelves 583 of the cam plates 57~ which in turn allows ~; 5 torsion springs 588 to rotate cam plates 570 rearwardly.
This rearward movement o~ cam plates 570 by torsion ~pring 588 causes the contact pins 409 to retract and the lnlet `~ cover 460 to move from a po~ition exposing the contact to a po~ition concealin~ the contact pins 409 afi discussed ,~, 10 above in more detail~ In other word~, cam slots 584 and ! 586 engages the ends of contact dsive baLl 406 and the ends . of connecting rod 464, re~pectively, to retract contact pins 409 and contact cover 460, re~pectively. Accsrdingly, -~ once the contact pin8 409 have been retracted and the contact covers 50 and 460 closed, electrical connector 16 i~ free to be pulled from inlet cavity 336.
~
Second ~hodiment of the I~vention seen $n Figures 56-58, a second embodiment of an electrical connector lnlet a88embly 20~ in accordance with the present invention i8 illustratsd in con~unction with electrical connector 16. Electrical connector inlet assembly 20' i8 sub~tantially identical ~o electrical connector inlet a88e~b7y 20 of the fir~t embodLment illustrated in Figures 1-55, except that electxical connector inlet a88embly 20~ has been modified to be an automatic or motorized version of the first embodiment.
Mor~ specifically, the actuation unit 500 of the first ~,, embodiment ha~ been replaced with a motor 800, and a drive r l 30 arm 802 for automatically dri~ing the drive unit 504 as well as cam unit S08 upon insertion of electrical connector 16, into inlet cavity 336.
Electrical connoctor 16 includes one or more magnet~
119 mounted thereto for activating one or both of the ..

21h~73 ''', : ' :1 _S()~

'1 ~en~ors 358 of the electrical connector inlet as~embly 20~
1 Accordingly, the construction and assembly of electrical i-, connector inlet as~e~bly 20' will not be di~cussed or , illustrated in detail herein.
;' 5 Referring to electrical cc)nnector inlet as~embly 20' hown in Figure 57, motor 800 i~ fixedly coupled to one of ~ the side walls 222 of outer inlet housing 200 in a '?~ conventional manner, such as by a bracket and a pair of threaded f~steners. Motor 800 i8 a conventional reversible , 10 electric motor which i8 powered by battery 22 of vehicle 12 a~ shown in Fisure 1. ~o or 800 ha~ an output ~haft 808 ,~, with a cylindrical worm 810 fixedly coupled thereto for rotation therewith.
particularly seen in Figure 58, drive arm 802 has 15 a connecting portion 812 with a fir6t drive pin 814 at one ', end and a second drive pin 816 at the other end.
Specifically, firfit drive pin 814 extends outwardly from ~ one end o~ connecting portion 812 for engaging control ~lot :~ 562 of connecting member 546 of drive unit 504, while ~`, 20 second pin 816 axtends outwardly from the other end of connecting portion 812 in the opposite direction for pivotal movement within a hole formed in side wall 222 of outer ~nlet housing 2~0.
:; AB seen in Figure 56, drive pin 816 has a worm gear 25 820 fixedly coupled thereto for engaging cylindrical worm . ~ 810 o~ motor 800. While drive arm 802 is illustrated a~
~ being movably coupled to motor 800 by worm 810 and worm ,~ gear 8201 it will be app~rent to tho~e skilled in the art ~ from this di~closure that drive arm 802 can be movably "~ 30 couplcd to motor 800 in many different ways. For example, motor 800 can be mounted directly to drive pin 816.
. Accordingly, when motor 800 i~ energized by battery 22 .~ ~ia microproce~sor 24, motor 800 will rotate output shaft .: 808 and cylindrical worm 810. Cylindrical worm 810 will i;
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; .;, , j. ., then rotate the worm gear 820 coupled to the second drive pin 816 for moving drive arm 802. The drive arm 802 will in turn extend or retract drive unit 504 which i8 coupled to cam unit 508 via relea~e latch 650 to ex~end or retract --'' '. ~! . ..
contact pins 409 as fully discussed above pertaining to the first embodiment.
Motox 800 is preferably acti~ated by sensor~ 358 which detect the insertion of plug or electrical connector 16 therein via ~agnets 119. 5ensors 358 and ma~net~ 119 are illustrated in the figures relating to the first embodiment, and thus, are not illu~trated in the figures of this embodiment. Therefore, only the differences will now be discu~sed in this ambodiment. In particular, ~ensors 358 are prefer~bly reed switches coupled to the side walls 302 of inner inlet housing 202 ad~acent inlet cavity 336.
Sensors 358 are activated by one or more magnets 119 on electrical connec~or 16. Specifically, when electrical connector 16 i8 inserted into cavity 336 of elsctrical inlet connector as~embly 20', one or more of ~he ma~nets 119 will be positioned ad~acent the reed switches or sensors 358 for activating the motor via microprocessor 24.
i`~ Accordingly, motor 800 will not be actuated until ~he ~ electrical connector 16 iQ correctly positioned within ,~ inlet ca~ity 336. If the electrical connector 16 is absent ~ i 25 from inlet cavity 336 or not correctly positioned within :~.Y the inlet cavity 336, then reed switches or sensors 358 will sense the absence or incorrect positioning of the i,~ electrical c~nnector 16 to prevent the contact pins 409 and ;~ ~ the hood S10 i.rom bein~ extended. Once the vehicle 12 has ,. 30 been fully charged, then microprocessor 24 s~nds a signal to motor 800 Eor rotating drive unit 504 and cam unit 508 rearwardly by dr~ve arm 802. Drive unit 504 i8 releasably coupled to ciYIm unit 508 by release latch 650 for disconnecting electrical connector 16 from inlet assembly ; . 1 `~:.,` .
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. i 20' in substantially the same manner as discussed above with reference to the manual versTon of the fir~t embodimient.
Reed switche~ or sensors 358 are conventional reed ~' 5 switches or sensoxR, and ~hu6, will not be discus~ed or ! disclosed in detail herein. ~oreover, their electrical j connection with microprocessor 24 and microproces~ors . connection with motor 800 are conventional electrical connection~ which will not be disclo~ed or illu~trated in detail herein.
:~ Magnet~ g are mounted in side wall~ 100 of ~ electrical connector 16 80 th~t they are positioned ad~acent one or more of the ~ensors 358. Specifically, by selecting one or more magnets, the reed awitches can signal .`, 15 the microproce3sor 24 to indicate the voltage rating of the -~ electrical connector 16. In other words~ by selecting the number of magniets coupled to electrical connector 15, it is possible to indicate whether a 810W charge, a fast charge ~! or a normal char~e i~ being supplied to vehicle 12 by olectrical conne~tor 16. More 3pecifically, i~ only a ~;. magnet i8 coupled to the right side wall 100 of electrical .~ connec~or 16, then the only corre~ponding ~ensor 358 will be activated by the right side magnQt to indicat~ a ~low charge to the microprocessor. I~ only a magnet 119 i8 coupled to the left ~ide wall 100 of electrical connector 16 with no magnet on the right side wall 100 of slectrical , connector 16, ~hen e~ectrical connector 16 will activate the left side sen60r 358 of the inlet a88embly 20' to indicate a no~al charge to micrOproce8Bor 24. If a magnet 119 is couplecl to both the right and left ~3ide wall8 100 of ~:i; electrical connector 16, then both the right and left .~ sensors 358 will be activated by the magnets 119 ~o indicate a fa~3t charge to the microprocessor 2~.

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Third Embodiment of the Invention A~ seen in Figures 59-61, a third embodiment of an ! electrical connec~or inlet a~embly 20'' in accordance with the present invention i~ illustr,ated for use in con~unction with electrical connector 16. Electrical connector inlet assembly 20 ' ' i8 ~ubstantially identical to electrical connector inlet assembly 20 of the fir~t embodiment i;i illustrated in Figures 1-55, except that electrical connector inlet assembly 20'' i8 a ~implified ~ersion without any actuation unit, drive unit, relea~e latch, -j connector la~ch unit or break-away assembly.
In particular, the handle 520~ of electrical connector inlet a~sembly 20'' ha~ been made integral with .~ the hood 510'' of cam unit 508'' 80 a~ to eliminate actuat~on unit 500 and drive unit 504 as well as connector latch unit 512 and break-away a882mbly 210 of the first embodiment. Accordingly, electrical connector inlet assembly 20'' will not be discussed or illustrated in detail herein, and the same reference numerals ~ill be used ~0 to identify the part8 of inlet assembly 20'' which are identical to the first embodiment.
Specifically, electrical connector inlet assembly 20'~
includes 11~ an outer stationary inlet housing 200'' fixedly coupled to vehicle 12 in a con~entional manner, (2) an inner ~tationary inlet housing 202'' fixedly coupled within outer inlet housing 200'', (3) an inlet contact .-. as~embly 206' ' movably coupled to inner inlet housin~
202'', and (4) an sctuation as~embly 208'' movably coupled ~: to inner inlet housing 202 ~ ~ for operating inlet contact . 30 a~sembly 206~.
outer ~nlet housing 200' ' is preferably molded as an i. integral, one-piece, unitary member from a hard, rigid non-. conductive mat:erial such as plastic. Outer inlet housing 200 ' ' has a top wall 220 ' ', a pair of substantially : ~ , ...
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' - ~4 -.., ~`, identical ~ide walls 222'' extending substantiallyr ~, perpendicularly to top wall 220'~, a bottom wall 226'~
`~, extending between the lower enlds of side walls 222'', a rear wall 228'' extending between side wall~ 222 r ~ ~ and a front opening 230'' wi~h an annular rubber ga~ket 232'' for receiving inner inle~ housing :202~ therethrough. Outer ~ inlet housing 200'' i~ rigidly coupled to vehicle 12 with ... ~ gasket 232'' engaging a portion of ve~icle 12 about an 3. access panel 234~. Outex hou~ing 200~' also rigidly 10 supports inner inlet housing 202'' to vehicle 12 as discus~ed below.
Top wall 220~' of outer inlet housing 200'' has a flat section 236~ and an inclined section 238'' extending upwardly and outwardly from flat section 2~6~. Top wall 15 220'' also has a transverse recess 240~ formed on its interior sur~ace between ~lat section 236'~ and inclined section 238'' for receiving a rubber ga~ket 241~'. Rubber ; gasket 241~ ongagas hood 510~ of actuation assembly 298 ; for sealing the space between outer inlet housing 200'' and 20 hood 510'' , Side wall~ 222'' of outer inlet housing 200'~ are '~ preferably ~ubstantially flat pla~ar m~mber~ which extend substantially perpendicular to top wall 220'' as well as bottom wall 226'' and rear wall 228''. Side walls 222'~
~, 25 are sub~tantially parallel to each other, and ~paced apart for receiving inner inlet housing 202'' therebetween.
ttom wall 226'' is a substan~ially flat wall with a pair of mounting hole~ 242'' for receiving a first pair of mounting screws 243'' for rigidly coupling inner inlet housing 202'' to outer inlet housing 2U0''. Bottom wall `'. 226 ~ ~ al80 .Lncludes five conductor holes 245'' for .~l receiving inlet conductors or wires 246'' therein, and four ~'J.'¦ mounting holss 247'' for rigidly coupling part of inner inlet housing 202'~ to outer inlet housing 200'' by i 212~73 : :;
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mounting ~crews 248''. Bottom wall 226~ s~bstantially parallPl to flat section 236~ of top wall 22n ~ ~ ~ and j spaced vertically from top wall 220'' ~or recei~ing inner '''.~!/ inlet housing 202'' therebetween.
Rear wall 228'' i8 a subst:antially flat wall which extends between top wall 220'', side wall~ 222'' and bottom ~ wall 226~. Rear wall 228'' can be fixedly mounted to ,!~ vehicle 12 in a conventisnal manner.
Inner inlet housing 202'~ i~clude~ a pair of substantially identical side wall~ 302~, a front contoursd wall 304'' extending between side walls 302'', a bottom wall 306'' e~tending ~etween side walls 302'', and a removable wall 308~. Preferably, inner inlet housing 202~ is moldéd as an integral, one-piece, unitary member ;l 15 from a hard, rigid non-conductive material such as plastic.
Inner inlet housing 202'' is rigidly coupled ~o outer inlet hou~ing 200~' by ~crews 243~' and 248''.
Side walls 302~ of inner inlet hou~ing 202~ are ~ubstantially identical, and thu~ like reference numerals will be used to identify the sa~e parts on each of the side wall~ 302~'. Each of the sids walls 302~ includes an outwardly extending mount~ng flange 310~ with three mounting holes 311'~ for mounting rear wall 308'' to inner inlet hou~ing 202~' via screws 312~o ~ , 25 Bach of the side walls 302'' further includes a `?~ ~ vertical control ~lot 314'~, an angled control slot 316~, and a curved con~rol ~lot 318''. Control slots 314'', 316' and 318~ control the movement of the inlet contact assembly 206'' relative to inner inlet hou~ing 202'' for exposing and extending the inlet contacts as well as concealing and retracting the inlet contacts. The inside ~urface of each of the ~ide walls 302'' has a pair of rails 334'' extending parallel to angled control 810t 316'' for ' ~1 , : ~2~7.3 . .

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engaging and controlling the movement of part of the inlet ~; contact as~embly 206~ as discussed below.
The actuation assembly 208'' is coupled to each of the side walli 302~ by a pivot hole 326'~, a pi~ot slot 328~, recefis 330'' formed in the e~terior surface, a pair of mounting holes 332'', and a U-shaped shelf 333'' formed on the interior surface as discussed below.
Front wall 304'' of inlet housing 20~'' includes an ~ inlet cavity 336'' for receiving electrical co~lector 16 `- 10 therein, and a ledge 338'' for cooperating with hook ga of electrieal connector 16.
Inlet cavity 336'' i~ formed by a substantially curved wall 344'' and a l~wer flat wall 346'' which extend between side wall~ 302'' to ~orm an inlet pock~t with a rectangular ~¦ 15 opening for receiving elsctrical connector 16 thereon.
Curved wall 344~ includes arcuate recesses 348~
positioned ad~acent each of the sids walls 302~ of inner inlet housing 202~. Recesse~ 348~ are arcuate and aligned with curved 810t8 318'' formed in side walls 302 1 20 Curved wall 344'' also ~ncludes ~ive spaced contact openings 350'' and five reinforcing tubes 352'' extending from ths interior surface of ~urve,d wall 344~ and aligned with contact opening~ 350''.
Lower wall 346'' of inlet cavity 336'' includes a pair ~i 25 of clearance openings 354'' which are aligned with recesses 348'', and a locking pin 356'' pro~ecting upwardly into inlet cavity 336'' ~or engaging recess 189'' of electrical connector 16. The clearsnce openings 354~ permit movement of the inlet contact assembly 206~, while locking p~n ~3 30 356'' retain~ electri~al ~onnector 16 within inlet ca~ity, a~ di~cussed below.
Rear wall 308'' has a flat plan~r section 360'' with four divider~ 361'' extending sub~tantially perpendicularly therefrom, a conductor mounting section 362~ sxtending , ~, ~ ." .. ; ....

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ou~wardly therefrom, and six mouIlting holes 363~ extending through flat section 360~ for receiving screws 312~.
~' Dividers 361'' extend from rear wall panel 360'' into .~ the interior of inner inlet housing 202''. Divider6 361'' -`
:~ 5 are tapered at their free endls and provide in~ulationbetween the inlet conductors 246''. Accordingly, dividers ..
361'' along with ~ide walls 302'' define ~ive pa~sageways for receiving in each of the pa3sageways one of the inlet conductors 246''.
Conductor mounting section 362'' include~ a ~tationary :
clamp member 370~ and a movable clamp member 372~' coupled to stationary clamp member 370~ by a pair of screws 374~
Stationary clamp 370'' has five holes 378'' extending '~ therethrough for receiving inlet conductors 246''. One of the holes 378~ aligned with each of ~he pa3sageways formed by dividers 361''. Stationary clamp 370'' al80 has : .
~ four threaded mount~ng holes 380~ for rec~iving screws '~ 248~ for fixedly securing the rear end of inner inle~
housing 202~ to outer inlet housing 200''.
Preferably, a rubber molded gasket 382'~ is positioned bstween connector mounting section 362~ and bottom wall `
226'' of outer inlet housing to prevent the in~ress of water and other contnminants. Gasket 382'' has fi~e hole~
384'' aligned in a row for receiving inlet ~onductors 246'' :
therethrough and four holes 386'' for receiving screws : 248'' therethrough. -~
Mova~le clamp 372'' has five curved recesses 388'' for .: ~ .
engaging inlet conductors 246~' and a pair of holes 390 .~ for receiving screws 392'' therein to secure mo~able clamp `~
~: 30 372'' to stat.Lonary clamp 370''. Stationary clamp 370'' also has five curved reces~es 394'' for mating with ,~
recesses 388~ of movable clamp 372~ to fixedly secure inlet conductors 246'' therebetween.

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i - 58 -i As seen in Figure 60, inl~et contact assembly 206~
' includes five electrical inlet contact pins 409~ ~only one :~ shown) movably coupled to inner inlet housing 202'' by a ~-1 moYable contact bail 406~, ancl a movable contact cover assembly 408~ for exposing and concealing electrical contact pins 409~. Inlet contact a~sembly ~06'' is operatively coupled to actuation assembly 208~ ~uch that ~i actuation assembly 208'~ moves the inlet contact pins 409 as well as mo~es contact cover a ~embly 408'' upon insertion of electrical connector 16 into inlet cavity ~ach of the electrical contac pin8 409'~ are substantially identical except for their relative 5ize.
Specifically, three of the electrical contact pins 403'' are power aontacts which are all substantially the same ~1 size. Of the two remaining electrical contact pin8 409'', 61 one electrical contact i8 a ground contact and the other i8 a communications contact. The ground contact i8 slightly smaller than the electrical power contacts, while the '~ 20 communications contact i8 even smaller than the ground contact.
Contact pins 409'' each have a main body portion 413'~
for coupling conductive wirs 410'' thereto, and a cylindrical pin portion 414'' ~or electrically coupling the ~2~ electrical connector inlet assembly 20~' to electrical connector 16. Main body portion 413'' has an axially sxtending threaded hole 415'' ~or receiving a thumb screw ,J 416'', and a tran~ver~e bore 417'' communicating with hole s~ 415'' ~or receiv~ng co~ductive wire 410''.
Bore 417'' i~ ~ized to receive one of the ends of its re~pective con~tuctive wire 410'' therein. Conductive wires ~ 410'' are ~ecured to main body portions 413'' of contact ;~ pins 409'' by thumb 8CrewG 416''. Specifically, thumb ;~ ~crews 416'' are threaded into holes 415'' until they ! ~
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., :'' 1 engage conductive wires 410'' to cri~p them within bores 417''. Thus, thumb ~crew 416'' electrically couples conductive wire 410~ to main body portion 413~
Cylindrical pin pvrtion 4L14~ of each contact pin ~, 5 409'' i~ provided with an annular reces~ for receiving a C~
clip 423'' to retain contact pin 409'' to bsil 406'~.
~-i.$ Contact pins 409~ are con~tructed of any suitable ~ conductive material such as brass. Each of ~he contact J3~ pins 409'' are coupled to bail 406'' for reciprocal ,,~i; 10 moveMent therewith to electrically engaye and di~engage contacts 34 and 38 of electrical eonnec~or lfi.
Contact drive bail 406~' is ~ubstantially identical to contact drive bail 406 of the fir~t ~mbodiment.
Accordingly, contact drive bail 406~ will not be discu~sed in detail. Generally, contact drive ball 406'' i a substantially rectangular member having five contact receiving cavities 434~ for fiupporting main bodies 413 of inlet con act pins 409~ ach of these eaYltie~ 434~
has a rectangular cross-section with a cutout 436'' in one wall for receiving one o~ the conductive wires 410'' `~ therain, and a bore 438'' or receiving pin portion 414'' ~J of one of ~he inlet con~act pins 409'~ therein. ~ach of `~ the cavitio~ 434'' receive~ one of the main bodies 413~ of electrical inlet contact pin8 409'', while each of the ~25 bores 438''~ receives one of the pin portions 414'' of electrical lnlet contact pins 409~. Contact pins 409 are secured within cavities 434'' by C-clips 423~5 to prevent relative movement therebetwe~n.
Contact cover a~sembly 408'' include~ a curved contact cover 460'', a pair of drive link8 462'' and a connecting _od 464''. Contact cover assembly 408'' i8 preferably ~,. controllad by actuation a~sembly 208'' 80 that a user can expose or conceal the inlet contact pinE 409~ only after r!
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mating electrical connector 15 has been fully inserted into ~`l inlet cavity 336''.
Contact cover 460'' is preferably molded as an integral one-piece, unitary m~er from a hard, rigid non~
conductive material such as plastic. Contact cover 460'' ha6 a pair of arcuste ?~lide arms 468'' located At each of its ends, and a pair of detentes 470'' for engaging notches 188 formed in contact cover 50 of electrical cornector 16 ~o expose contacts 34 and 38 of electrical conn~ctor 16 to inlet contact pin8 409''. ~ach of the ~rm8 46B'' has a pivot pin 472'' extending outwardly therefrom for engaging curved con~rol ~lots 318'', Specifically, pivot pins 472'' extend through curved control slots 318'', and are then coupled to one of the ends of it~ re~pective drive link 462''. The other end~ of the drive links 462'' are connected to the ends of connect~ng rod 464'' in a , conventional manner. Connecting rod 464~ ha~ an overlying sleeve 466'' w~ich is slidably received in vertical control slots 314'' of side walls 302'' for ~liding movement rela~ive to inner inlet housing 202''. Accordingly, movement of connecting rod 464'' with sleeve 466'' cause~
drive links 4b2'' to reciproca~e contact cover 460'' via pivot pins 472'' sliding in curved control ~lots 318''.
Arcuate slide arms 468'' are positioned within curved xecfes~es 348'' of inlet cavity 336'' of the inner inlet housing 202'' for sliding movement therein. Accordingly, as connecting rod 464'' slides verticAlly within vertical control 310t 314'', arcuate slide arms 468'' of cover 460'' reciprocate within curved recesses 348'' with a portion of arms 468'' moving through clearance openings 354'' formed in lower wall 346'' of inlet cavity 336''.
Actuation assembly 208'' includes (1) a cam unit 508'' t'~3 pivotally coupled to i~ner inlet housing 2C2'' via a pivot rod 506'', (2) a hood or weathershield 510'' fixedly .". i -,~,"~
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~, coupled to cam unit 508' ' for movement therewith, and ~3) a hood latch unit 512~ coupled to the side wall~ 302~ of inner inlet housing 202''.
Cam unit 508~ i8 ,substantially U-shaped and molded a~
an integral, one-piece, unitary member ~rom a hard, rigid non-conduct$ve material ~uch as pla6tlc or ,any other ~uitable material. Control unit 508~ includes a pair of ~, substantially idsntical cam plates 570~ co~nected to oppo,3ite ends of hood 510''. Cam plate6 570'' are substantially parallal to each other and pivot together about p vot rod 506 D
Each of the cam plates 570'~ include~ ~1) a pivot hole .i 572~ for receiving pivot rod 506~ ~herein, (2) a first cam zlot 584~ for controlling movement of the contact bail 406~, and (3) a second cam slot 586~ for receiving the end~ of connecting rod 464~ to control the movement of contact cover 460''.
s~ In particular, pivot rod 506'' extend~ through pivot hole~ 326'' of inner inlet housing 202'' and through pivot ~i 20 holes 572'' of cam plates 570'' for pivotally mounting cam ~: unit 508'' to inner inlet housing 202''- A C-clip 578~ i8 .~ coupled to each of the ends of pivot rod 506'~ to $ecure pivot rod 506'' to inner inlet housing 202' ' and cam unit 508''. Accordingly, cam unit 508'' i8 movably coupled to inner inlet housing 202'' and operatively roupled to ~;Z contact a~sembly 206'' to extend and retract contact pin~
;`Z 409'' a6 well a~ to move contact cover 460'' between a po8ition concealing contact pin8 409~ and a positisn 3 exposing contact pins 409''. Since cam unit ~08 ' ' is , . . .
.l 30 operatively coupled to contact a~sembly 206'' in ~;
substantially the same manner as in the fir~t embodiment, ~:
the movem~nt of contact a~sembly 206'' will not be ,~
~¦ illustrated or discussed in detail. - ;~

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Hood 510~ has a handle 520~' for moving hood 510'~
and cam pla~s 570~ a~out pi.vot rod 506~, a pair of locking teeth 5B2~ formed on the interior surfa~e of hood ~10'' fox engaginy hood latch unit 512'', and a stop rib 5 594'' formed on the hood's upper surface for engaging gasket 241~ of outer inlet housing 200~' in the extended position.
The hood latch unit 512'' includes (1) a latch plate 600'' pi~otally coupled to side walls 302'' by pivot slot~
328'', ~2) a pair of compression spring~ 602'' coupled to side walls 302'' via U-shaped shelves 333'' to bias latch plate 600'' upwardly to engage locking teeth 582'' on hood 510'', (3) a pair of electromagnets 604~ fixedly coupled to sidewalls 302~' of inner inlet housing 202~ by screws 606'', and (4) a pair of reed switches or sensors 608'~
coupled to side walls 302'~
Latch plate 600'' includes a pair of outwardly extending flanges 610~ fo~ engaging pivot slot~ 328~, and an upwardly ext~nding flange 612'' for engaging locking teeth 582''. Latch plate 600'' i~ msde of a metallic material capable o~ being moved ~y electromagnet~ 604''.
Normally, when hood 510~ i8 in it~ retractad position, latch plate 600'' is pivoted upwardly by springs 602'~ 80 that flange 612'' engage locking teeth 582'' to lock hood .~ 25 510'' in the retracted position.
Electromagnets 604'' are positioned ad~acent latch plate 600'' ~o that upon energizing slectromagnets 604'' lstch plate 600'' i8 pulled down~ardly against the force of spring~ 602~' to dlsengage flange 612'~ from locking teeth 582''. ~lec1:romagnets 604'' are electrically coupled to microprocessor 24 illustrated in Figure 1 80 that electromagnets S04'' are not energized until connector lb i8 in~erted therein. Specifically, when electrical connector 1~ is inserted into inlet ca~ity 336'', the ~J
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~, magnet or magnets 119 o~ electxic:al connector 16 closes one ,l or both of the reed ~witches 608'' which in turn sends a ~ ;
~, ; signal to microproce~sor 24 to energize electromagne~s 604'' for unlockiny hood 510''. Of cour~e, once electromagnsts 604~ are de~nergized, latch plate 600'' ~wings upwardly to engage the interior surface of hood ;, 510'' or locking teeth 582''.
LocXing teeth 582'' have a saw tooth type , con~iguration which allows hood S10'' to mov2 rearwardly even when el~ctromagnets 604'' are deenergized.
Accordingly, ~hen hood 510'' i~ moved from the extended position to the retracted pos~tion, locking teeth 582'' and ;`l locking plate 600~ act as a rachet so that locking plate 600~ can ride ov~r locking teeth 582'' in the rearward direction but not in the forward direction.
.!. ~ ;
i Fourth_Embodiment of the Invention -~
A~ sQen in Figure 62, a fourth embodiment of an electrical connector inlet a~sembly 20''~ in accordance with the present invention i8 illustrated for use in ~on~unction with electrical connector 16. Electrical connector inlet a~sambly 20~' i6 substantially identical to el~ctri~al connector inlet as~embly 20'' of the third embodiment illustrated in Figures 59-61, except that electrical connector inlet a88embly 20' ' ' has been modifisd to be an automatic or motorized version. Accordingly, only the differences between electrical connector inlet ~i3 assemblies 20~ and 20''' will be discus6ed and illustrated .,.~ - .
herein.
Top wsll 220''' of outer inlet housing 200''' is extended to accommodate a reversible, electric motor 800''' and a drive train 802''' for movin~ cam unit 508''' between a retracted position and an extended position. A gasket '~;

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801''' i3 coupled to the front wall of outer inlet hou~ing 200''' for engaging the upper surface of hood 510'~
~"~ Motor 800''' i8 fixedly coupled to the top wall 220 .; . .
`f of outer inlet housing 200''' in a conventional ma~ner, and electrically coupled to microprocefisor 24 ~chematically ~ illustrated in Figure 1. Microprocessor 24 contrQls motor .~ 800~ via a pair of reed switches or sensors mounted to inner inlet housing 200''' a~ di~cus~edi~bove in the second embodiment. Motor 800''' has an output ~haft 808''' for ~:
.i, 10 driving the dr~ve train 802''' to move cam unit 50B''' between the retracted position and the extended position.
Drive train 802''' include6 a first gear 810''' fixedly coupled to the output shaft 808''', a second gear : - :
812''' driven by first gear 810''', a th~ead~d ~ha~t 814''' ~ 15 rotatably mounted to outer ~let housing 200~, and a ..
,~ threaded follower 816'~ threadedly mounted on threaded shaft 814~
Second gear 812''' i5 fixedly coupled at one end of !:`~ ', ,~ ~'' ' threaded shaft 814''' for rotation with threaded ~haft 814~ by motor 800~'' ~ia first gear 810'''. Accordingly, second qear 812~'~ meshes with first gear 810~'' to rotate threaded ~haft 814'~ upon activation of motor 800 Threi~ded follower 816''~ has a threaded cylinder `~1 820''' for engaging threaded shaft 814''' and pair of trunion pins 822''' for engaging a pair of flanges 824''' extending upwardly from hood 510~'' of cilm unit 508'''.
Accordingly, as threaded shaft 814''' is rotated by motor 800 ' ' ' via geisrs 810 ' ' ' and 812 ' ' ', the threaded follower 816''' mo~es axially along threaded shaft 814' ' ' to either extend or retract cam unit 508''' and hood 510~
This ext:ension or retraction of cam unit 508' ' ' electrically couples or uncouples electrical connector inlet as~embly 20 ' ' ' to electrical connector 16 in sub3tantially the si3me manner as discus~ed above pertaining ~,'':,. ,' i .~
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.d to cam unit 508~. Accordingly, the operation of electrical connector inlet assembly 20''' will be readily apparent to those ~killed in the art fro~ the other .j embodiments disclo~ed herein. :
~ s It will also be apparent from this disclosure that `~ certain aspects of this invention can be utilized with . inductive couplings. For example, the compdtibility detenmination mechanism, e.g., the sen~ors and m2ignets, as ~ well as the wea*her~hield can be used with inductive :`( 10 couplings. Accordin~ly, the scope of the appending claims .-i should not be limited to electrically conductive contacts, unless expre~sly claimed.
While several\ ~mbodimen~ have been chosen to illustrate the invention, it will ~ under~ood by those ~: 15 ~killed in the art that variou~ chanqes and modifications ii can be made herein without departing from the scope of the invention as defined in the appended claims.

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Claims (21)

1. An electrical connectors inlet assembly for recharging a battery of an electric vehicle, comprising:
a first housing with a mounting member for rigidly coupling said first housing to a structure of the vehicle;
a second housing with an inlet cavity for receiving a mating electrical connector with a first set of electrical contacts therein;
a joint assembly movably coupling said first housing to said second housing for limited relative movement therebetween;
a second set of electrical contracts movably coupled to said second housing for movement between a retracted position remote from said inlet cavity and an extended position located within said inlet cavity for electrically engaging the first set of electrical contacts of the mating electrical connector;
an actuation mechanism operatively coupled to said second set of electrical contacts for moving said second set of electrical contacts between said retracted position and said extended position; and a break-away mechanism for disengaging the first set of electrical contacts of the mating electrical connector from said second set of electrical contacts when coupled together and after application of an excessively high force therebetween, said break-away mechanism including a release mechanism for moving said second set of contacts form said extended position to said retracted position upon a predetermined amount of relative movement between said first and second housings, and a trigger mechanism operatively coupled between said first and second housings for sensing relative movement between said first and second housings and operatively coupled to said release mechanism for activating said release mechanism.

2. An electrical connector inlet assembly according to claim 1, wherein said actuation mechanism includes a cam member normally biased to a retracted position by said release mechanism, and a drive member normally biased to an extended position, said release mechanism being coupled to said drive member and releasably coupled to said cam member.

3. An electrical connector inlet assembly according to claim 2, wherein said trigger mechanism includes a movable member movably supported in a trigger support coupled to said second housing, and a stationary member with a camming surface coupled to said first housing for engaging said movable member.

4. An electrical connector inlet assembly according to claim 3, wherein said movable member includes a ball slidably coupled to said trigger support for engaging said camming surface, and a trigger lever pivotally coupled to said trigger support with a first end of said trigger lever engaging said ball and a second end of said trigger lever engaging said release mechanism.

5. An electrical connector inlet assembly according to claim 4, wherein said camming surface of said stationary member includes a cone-shaped recess and an annular ring surrounding said cone-shaped recess.

6. An electrical connector inlet assembly according to claim 5, wherein said trigger mechanism includes a spring for biasing said trigger lever against said ball.

7. An electrical connector inlet assembly according to claim 6, wherein said release mechanism includes a release latch coupled between said drive member and said cam member and a spring for normally biasing said cam member to its retracted position.

8. An electrical connector inlet assembly according to claim 7, wherein said release latch is movably coupled to said drive member for movement therewith between their retracted and extended positions.

9. An electrical connector inlet assembly according to claim 8, wherein said release latch includes a tab for selectively engaging a shelf formed in said cam member, and for engaging a slot formed in said drive member.

10. An electrical connector inlet assembly according to claim 9, wherein said cam member and said drive member are pivotally coupled to said second housing about a first pivot rod.

11. An electrical connector inlet assembly according to claim 10, wherein said latch member has a slot for receiving said first rod.

12. An electrical connector inlet assembly according to claim 11, wherein said second end of said trigger lever engages said release latch for moving said release latch about said first pivot rod to disengage said tab from said shelf when said ball moves sufficiently relative to said cone-shaped recess.

13. An electrical connector inlet assembly according to claim 12, wherein said joint assembly includes a pair of transverse pivot members coupled between said first and second housings.

14. An electrical connector inlet assembly according to claim 13, wherein each of said pivot members includes a pivot pin rotatably positioned within a tube, and said tubes of said pivot members being rigidly coupled together.

15. An electrical connector inlet assembly according to claim 2, wherein said release mechanism includes a release latch coupled between said drive member and said cam member and a spring for normally biasing said cam member to its retracted position.

16. An electrical connector inlet assembly according to claim 15, wherein said release latch is movably coupled to said drive member for movement therewith between their retracted and extended positions.

17. An electrical connector inlet assembly according to claim 16, wherein said release latch includes a tab for selectively engaging a shelf formed in said cam member, and for engaging a slot formed in said drive member.

18. An electrical connector inlet assembly according to claim 17, wherein said cam member and said drive member are pivotally coupled to said second housing about a first pivot rod.

19. An electrical connector inlet assembly according to claim 18, wherein said latch member has a slot for receiving said first rod.

20. An electrical connector inlet assembly according to claim 2, wherein said joint assembly includes a pair of transverse pivot members coupled between said first and second housings.

21. An electrical connector inlet assembly according to claim 20, wherein each of said pivot members includes a pivot pint rotatably positioned within a tube, and said tubes of said pivot members being rigidly coupled together.