GB2552333A

GB2552333A - An electrical connection assembly

Info

Publication number: GB2552333A
Application number: GB1612449.7A
Authority: GB
Inventors: Brierley Houlker Roger; Reginald George Honychurch Houlker Frederick
Original assignee: Individual
Current assignee: Individual
Priority date: 2016-07-19
Filing date: 2016-07-19
Publication date: 2018-01-24
Anticipated expiration: 2036-07-19
Also published as: GB201612449D0; GB2552333B

Abstract

An electrical connection assembly comprises a first electrical cable 2 with a first electrical terminal (eg part of terminal block 9) at a first end, a second electrical cable 1 with a second electrical terminal at a first end and a plug or socket 3 connected to the second end, and a connection block/housing which in use encloses the first and second terminals which in use are connected to each other. A pair of elastomeric sleeves 15 may cover the connection block to make it waterproof. The cables may be secured by strain relief glands (6, Fig 2) outside the housing and square retainer plates (7, Fig 2) within it. The plug 3 may be a seven pin plug for use with a trailer.

Description

(54) Title of the Invention: An electrical connection assembly Abstract Title: An electrical connection assembly (57) An electrical connection assembly comprises a first electrical cable 2 with a first electrical terminal (eg part of terminal block 9) at a first end, a second electrical cable 1 with a second electrical terminal at a first end and a plug or socket 3 connected to the second end, and a connection block/housing which in use encloses the first and second terminals which in use are connected to each other. A pair of elastomeric sleeves 15 may cover the connection block to make it waterproof. The cables may be secured by strain relief glands (6, Fig 2) outside the housing and square retainer plates (7, Fig 2) within it. The plug 3 may be a seven pin plug for use with a trailer.

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At least one drawing originally filed was informal and the print reproduced here is taken from a later filed formal copy.

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AN ELECTRICAL CONNECTION ASSEMBLY

Field of the Invention

The present invention relates to an electrical connection assembly, in particular an assembly for making an electrical connection; more particularly but not exclusively an assembly for making an exterior connection between a trailer or vehicle and an electrical supply.

Background

Increasing numbers of people or potential users enjoy camping and caravanning in many societies.

The freedom of exploring the highways of a country is very attractive to these users, but electronic and electric equipment is often equally attractive. Therefore many locations and forms of apparatus that are used for camping and caravanning will be accompanied at some level with an electric hook-up; for example trailer, caravan or tent extension lead. In addition or the alternative other non-recreational or sportbased vehicular apparatus, such as a horsebox, may provide users with similar problems.

This hook-up consists of a socket and plug, which must reliably and repetitively provide a secure, waterproof electrical connection; particularly given the conditions and frequency of use. This connection or security of waterproofing can be diminished in effectiveness by repeated connection and disconnection may be undertaken in non-standard conditions and/or in haste.

As a result the connection may be compromised and need replacement, which given current arrangements is liable to be fiddly and problematic.

Prior Art

Accordingly a number of patent applications have been filed in an attempt to resolve the problem or similar, including the following:

Chinese utility model CN 201 323 310 (JIANZHAO) which relates to the technical field of connectors, in particular to an integrated vehicular water-proof connector, comprising a plug and a socket; wherein the plug is provided with a connecting terminal therein, and the socket is provided with a plug jack matching with the connecting terminal therein, and a screw cap is sleeved on the plug; the inner side of the screw cap is provided with internal thread, and the outer side of the socket is provided with external thread matching with the internal thread of the screw cap; a flange for fastening the screw cap is moulded at the outer side of the plug; a ring groove is arranged at the front end of the plug, and a water-proof gasket matching with the socket is placed in the ring groove; when the plug of the connector is connected with the socket, the connecting terminal can be inlaid into the plug jack of the socket firstly, then the screw cap is secondly connected to the outside of the socket, as one end of the screw cap is fastened to the flange of the plug, the other end is connected with the socket by threads, the connection between the plug of the connector and the socket can be firmer.

United States patent application US 5 765 848 (SILVEY) discloses a trailer accessory for being connected to the tongue of a trailer, said trailer accessory comprising: a pinless boot composed of pliant material, said boot having at least one plug receptacle formed therein; a base connected with said boot; and connection member means for connecting said base to the tongue of a trailer; wherein said at least one plug receptacle has a predetermined shape for protectably receiving therein a selected trailer plug.

United States patent application US 5 722 854 (GEISLER) discloses a protective covering system for a trailer light connector comprising: a body having an upper and lower portion, the lower portion including an opening whereby the covering system can be readily and repeatedly attached to or detached from a trailer or a towing vehicle, a cap, the cap connected to the upper body portion of the body by a flexible connecting means, a holder, the holder attached to the upper portion of the body, whereby said cap can function as a cover for the holder.

Summary of the Invention

According to the present invention there is provided an electrical connection assembly comprising: a first electrical cable; a second electrical cable with a plug or socket; a plug or socket connected to a first end of the second electrical cable and a connection block which comprises a housing enclosing an electrical terminal block which in use connects to a first end of the first electrical cable and the second end of the second electrical cable.

In some embodiments the electrical terminal electrically connects the first end of the first electrical cable to the second end of the second electrical cable.

In some embodiments, the first cable may have an electrical connector at its second end. The electrical connector may be a terminal, a plug or a socket.

The electrical terminal block may comprise one or more electrical terminals. For example, the electrical terminal block may comprise one or more screw terminals or may comprise one or more lever terminals. In some embodiments the electrical terminal block comprises a plurality of electrical terminals.

In some embodiments the connection block may be a separate component which is arranged to connect to and enclose the first end of the first electrical cable and the second end of the second electrical cable when a user assembles the assembly. Alternatively, the connection block, the second electrical cable and the electrical terminal block may be formed integrally with each other so as to form a single component to which the first cable may be connected. In some embodiments the electrical terminal block of the connection block may be prewired to the second end of the second electrical cable, for example at manufacture. In such embodiments the assembly may be envisaged to comprise the connection block, the second electrical cable and the plug or socket.

In some embodiments the assembly may be assembled in use, and may comprise independently available connection block and/or plug/socket, wherein the secondary electrical cable may be prewired to the plug and/or may be prewired to the electrical terminal block of the connection block.

In some embodiments the assembly may comprise a waterproofing means for the connection block. In some further embodiments the block comprises the waterproofing means. The waterproofing means may comprise a covering means, arranged to provide a waterproof cover which covers the housing and limits water ingress into the connection block.

The waterproofing means may alternatively or additionally be arranged to cover the points where the cables enter the connection block, the housing or the electrical terminals. For example, in some embodiments the waterproofing means may comprise at least one gaiter.

The waterproofing means may be entirely or partially formed form a resiliently deformable material such as silicone, rubber or some other elastomer. The waterproofing means may comprise multiple layers, thereby limiting ingress, for example, the waterproofing means may comprise a plurality of layers wherein at least an outer layer is elastic.

In some embodiments the waterproofing means may comprise a waterproof sleeve which in use extends over all of, or a portion of the exterior of the housing. The sleeve may have a first opening at a first end which fits closely around one of the electrical cables, and may have a second opening at a second end which in use fits closely around the exterior of the housing. Therefore, sleeve may enclose one end of the housing. Alternatively, the sleeve maybe dimensioned such that the first opening at the first end fits closely around one of the electrical cables and the entirety of the housing fits through the second opening at the second end at fits within the sleeve.

The openings may be elastic such that when they are not manually displaced, the openings fit tightly around the components of the assembly. For example, when the sleeve is relaxed, the first opening may have an area smaller than the cross section of one of the electrical cables and the second opening may have an opening with a smaller area than a cross section through the housing substantially orthogonal to the axis of electrical cables where it intersects with the housing.

The sleeve may be formed from an elastomer such that when the sleeve is not manually displaced the sleeve fits tightly around the housing and or one of the electrical cables and may conform to the shape of the housing and cable. A tight elastic sleeve or opening may provide a tight watertight seal between the sleeve, and the housing and cable, thereby preventing water from entering the sleeve and waterproofing a portion of the assembly. The sleeve may be formed from neoprene.

The sleeve may be configured to slide onto and off of the housing. Therefore, the sleeve may be slid onto the housing when waterproofing is required and may be slid off of the housing to allow a user to open or access the interior of the housing. The sleeve may for example be configured to slide along the length of one of the electrical cables.

The sleeve may be substantially cup shaped, the open end of the cup shape being formed by a second opening dimensioned to fit tightly around the housing, and the smaller first opening being formed in the base of the cup shape which is dimensioned to fit around a portion of the electrical cable which extends from a second end of the housing opposite the first end.

In an example embodiment of the assembly where the housing is cuboid with cylindrical cables extending out of opposite faces of the housing, the first opening of may be a circular aperture with a radius equal to the radius one of the electrical cables. The second opening may be a square aperture with dimensions equal to those of the faces from which the cables extend. The cup shape may have depth greater than half of the length of the housing, and may have a depth equal to the length of the housing.

The waterproofing means may in addition to the first sleeve comprise a second sleeve which in use overlaps the first sleeve. The first sleeve may enclose a first end of the housing and the second sleeve may enclose a second end of the sleeve and may overlap the first sleeve such that the housing is entirely enclosed.

The first sleeve may have a first end dimensioned to fit tightly around the one of the two electric cables and a second end dimensioned to fit tightly around a portion of the housing, and the second sleeve may have a first end dimensioned to fit tightly around the other of the two electric cables and a second end dimensioned to fit tightly around the first sleeve and the housing when the first sleeve is fit tightly around the housing.

The housing may be entirely or partially formed from a substantially rigid material, such as from metal, alloy or thermoplastics. This may protect the terminals and connections of the cables from impacts and other sources of damage as housing is not liable to be deformed so as to compromise the safety or water-proofing of the connection block and the assembly.

The assembly may be envisaged for predominantly outdoor usage, and may therefore be ruggedised. The assembly may additionally or alternatively, be envisaged for usage liable to involve multiple or repeated connections and disconnections; wherein the assembly may be envisaged to be appropriate for usage with trailers, tents, or caravan hook-ups.

In this way the assembly may provide a resilient connection and reconnection solution to the problems outlined above.

The assembly may consequently be more robust and resistant to weather conditions so as to increase its life span and prevent the user from having to change it as frequently.

The assembly in some embodiments may comprise a moulded plug at the first end of the second electrical cable, which in use may be connected to the connection block via the second electrical cable. The plug may be wired at manufacture and in some embodiments may have an inaccessible interior and/or lead connections.

In some embodiments the secondary electrical cable may have a prewired and/or a moulded connection to the block. A moulded connection may provide waterproofing and may limit physical displacement.

This arrangement may displace the location of the electrical connection between the first electrical cable and a socket into which a plug on the end of the second electrical cable is inserted away from the plug to the connection block. This may advantageously dissipate along the second electrical cable, any forces exerted on the plug to displace it away from the socket.

Additionally, or alternatively, the second electrical cable may be arranged to be deformable, for example, the second electrical lead may be expandable. For example, in some embodiments the second electrical cable may be a spiral, coiled or helical cable which may be elongated in use. In other embodiments the second electrical cable may be provided on a spool.

In some embodiments the block may be arranged to facilitate the wiring of the terminals to the first electrical cable and/or the second electrical cable.

In some embodiments the block may comprise a housing wider than the cables or the plug. In such embodiments the terminals may advantageously be spaced apart so as to facilitate the connection of the electrical cables to the terminal block. For example, the terminals may be spaced apart laterally in a plane perpendicular to the axis along which the cables enter and exit the housing. The connection block may therefore be arranged to be significantly easier to wire up due to the greater spacing apart of terminals.

In some embodiments, the assembly may be made up of three main components: a trailer plug with a moulded electrical cable, a heavy duty terminal block for wiring up the trailer, and a coated neoprene sleeve to protect the connection block from weather conditions. The assembly may further comprise an additional electrical cable which in use is connected to the plug and moulded electrical cable using the connection block.

In some embodiments the block may have substantially the same size and/or dimensions as a standard 13A plug.

The connection block may comprise stainless steel connection screws in order to prevent rusting.

The connection block may comprise one or more displaceable cable retention mechanisms. These mechanisms may act to hold the first and/or second electrical cables into the connection block. For example, the connection block may comprise one or more screw-down bars which may be displaced and locked in place suing screws so as press against and hold a cable in place. These mechanisms may advantageously prevent cables form being pulled out of the connection block inadvertently.

In some embodiments the waterproofing cover and/or the housing may be neoprene coated with an impervious layer to prevent water ingress.

This cover or neoprene sleeve may be envisaged to cover the entire terminal block and entry points, and/or may be arranged to cover one or both of the electrical cable entries into the housing.

In some embodiments the block may include anti-cable-displacement means so as to limit displacement damage from tugging on the cable. For example, in some embodiments, the first and/or second electrical cables may have over moulded cable strain reliefs at their entrances into the housing thereby preventing the cable or wires from being pulled out if the cable is tugged.

In some embodiments the terminals may be arranged so as to facilitate access by a user. The housing of the connection block may be removable from the terminal block and/or may be openable for easy access. Such access may be envisaged not to compromise any mechanism or means arranged to limit exit of the cable from the block. The housing may have an openable lid allowing access to the block interior and terminals.

In some other embodiments the terminal block may be displaceable from the block. In some embodiments the terminals may be displaceable in a direction perpendicular to the axis along which the electrical cables enter and exit the block. For example, the terminals may be arranged to slide out of the block or housing orthogonally for easier wiring.

Brief Description of Figures

Figure 1 shows an exploded isometric view of an embodiment of the assembly;

Figure 2 shows a reverse exploded isometric view of the assembly;

Figure 3 shows an isometric view of the embodiment shown in Figure 1, with the block opened and cover removed;

Figure 4 shows an inlet end view of the embodiment shown in Figure 1, with cover removed;

Figure 5 shows an outlet end view of the embodiment shown in Figure 1, with cover removed; and

Figures 6 show plan views of the embodiment shown in Figure 1, with cover in place.

Detailed Description of Figures

Current trailer plugs are often at risk of breaking due to their construction. This results in the cable being pulled out of the housing during use. Re-wiring the plug can be counter-intuitive. Referring to the figures generally there is shown an electrical assembly facilitating the rewiring of a trailer plug according to the present invention.

The pictured embodiment consists of a moulded seven pin 5 plug 3, having a secondary electrical cable 1 extending from it to the interior of a connection block 100 where in use it is to be connected with an internal electrical terminal block 9. The embodiment further comprises an incoming primary electrical cable 2 from an electrical source entering the opposing end of the connection block 100 and arranged to be connected to the terminal block 9 so as to connect the two electrical cables 1, 2 to each other.

The terminal block contains a plurality of regularly spaced the screw connector terminals.

The two electrical cables are both physically connected to the housing of the connection block at entrances 11 to the housing. The entrances close over the cables and are apertures in a substantially rigid cuboid housing, formed from a thermoplastic material.

The housing is capable of opening to allow access to its interior, the terminal block and the electrical connections at the ends of the two cables. The opening is achieved in the pictured embodiment by the housing comprising two components connected by a hinge 20 along a long edge of the housing, and an interference fit bump catch 14 on the opposing edge which holds the housing in a closed configuration. In some embodiments for added security and to limit unauthorised access, the housing may comprise a locking mechanism, for example a grub screw.

Two neoprene sleeves 15, 18 provide a cover in use over the housing 100 and help to prevent water ingress thereto, through either the entrances 11 of the two cables, or the hinge 20 and housing opening. The cover comprises two neoprene sleeves which are resiliently deformable and have elasticity. The two sleeves 15, 18 are each arranged to cover one end of the housing and an entrance 11, the sleeves having a convex extension arranged to cover the overmoulded strain relief components 6 of the cables. The two sleeves are arranged to overlap each other in use so as to enclose the entirety of the housing.

The sleeves comprise a housing cover 10, 16 portion and an entrance cover portion 15,18. The entrances of the cable and lead connections are further secured in place using strain relief glands 6 outside the housing and square retainer plates 7 inside the housing which act to prevent the cables from being pulled out of the housing 100 accidentally, and support and strengthen the physical connection with respect to bending.

When they are removed from the housing 100, the sleeves 15, 16 may be slid along the cables, 1,2 such that they do not obstruct the housing, and they may be slid back on when waterproofing is required again.

The embodiment thereby comprises a fully sealed trailer plug with a separate terminal block containing screw connectors for rewiring. The neoprene sleeves cover covers the terminal block housing to protect and prevent water and dirt ingress.

The interior of the housing comprises two cable holders 17 which secure the cables in place preventing accidental removal. The housing further comprise rubber gland and grommet strain relief for keeping the housing entrance’s water resistant and providing a strengthened physical connection to the block housing, with a square retainer keeping the physical connection in place with reference to the housing, allowing for easier wiring.

The housing has stainless steel screw connectors for quick and easy wire connection.

The moulded plug thereby prevents unnecessary re-wiring as the cable or lead is less likely to be pulled out or broken.

Additionally, or alternatively, the large terminal block also allows for easier wiring if the cable has to be replaced, wherein the terminals are advantageously enabled to be further spaced apart than with standard plug wiring.

In order to rewire the user would:

Remove the waterproof protective sleeves 15, 18; then open the lid of the housing 100 and remove the terminals 9; then rewire the wires into the terminals 9; then place the cable and wire and retainers with the terminals 9 back into the housing 100; then screw the cable holders back into place to ensure a secure connection; and then replace the protective sleeves 15, 18.

With reference to Figures 12 there is shown an alternative embodiment of the assembly comprising a single elastic waterproofing sleeve 21 as a cover.

The invention has been described by way of examples only and it will be appreciated that variation may be made to the above-mentioned embodiments without departing from the scope of invention as defined by the claims, in particular but not solely combination of features of described embodiments.

Claims

1. An electrical connection assembly comprising: a first electrical cable with a first electrical terminal at a first end; a second electrical cable with a second electrical cable at a first end and a plug or socket connected to the second end; and a connection block which in use encloses the first and second terminals which in use are connected to each other.

2. An assembly according to claim 1 wherein a plug configured for connection with a socket is connected to the second end of the second electrical cable.

3. An assembly according to claim 1 or 2 wherein a 7 pin plug is connected to the second end of the second electrical cable.

4. An assembly according to claim 1, 2 or 3 comprising a waterproofing cover over at least part of the block in use.

5. An assembly according to claim 4 wherein the waterproofing cover comprises two separate parts.

6. An assembly according to claim 5 wherein the waterproofing cover comprises two sleeves.

7. An assembly according to claim 6 wherein the sleeves are elastic.

8. An assembly according to any preceding claim wherein the housing comprises an access to the terminals.

9. An assembly according to claim 6 wherein the housing comprises a hinge and hinged lid.

10. An assembly according to claim 8 or 9 wherein the housing comprises grub screw closure.

11. An assembly according to any preceding claim comprising strain relief glands.

12. An assembly according to claim 11 wherein strain relief glands connect each of the cables to the connection block.

Intellectual

Property

Office

GB1612449.7

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12. An assembly according to claim 9 wherein strain relief glands connect each of the cables to the connection block.

13. An assembly substantially as described herein with reference to figures 1 to

6.

5

14. An assembly substantially as described herein with reference to figure 7.

Amendment to the claims have been filed as follows

Claims

1. An electrical connection assembly comprising: a first electrical cable from an electrical source with a first electrical terminal at a first end; a second

5 electrical cable with a second electrical terminal at a first end and a moulded plug configured for connection with a socket connected to a second end; and a connection block which in use encloses and connects the first and second terminals within the connection block.

18 10 17

10 2. An assembly according to claim 1 wherein the wired plug is a 7 pin plug.

3. As assembly according to any preceding claim wherein the connection block is waterproof.

15 4. An assembly according to any preceding claim includes a waterproofing cover which extends over at least part of the connection block in use.

7. An assembly according to claim 6 wherein the sleeves are elastic.

8. An assembly according to any preceding claim wherein the connection block includes an access to the terminals.

9. An assembly according to claim 7 wherein the connection block is opened by 30 displacing a hinged lid.

10. An assembly according to claim 9 or 10 wherein the housing comprises a grub screw closure.