Connector assembly

• US 9,793,642 B2
• Filed: 08/09/2012
• Issued: 10/17/2017
• Est. Priority Date: 08/22/2011
• Status: Active Grant

• Current Assignee: Lear Corporation
• Original Assignee: Lear Corporation
• Inventors: Natter, Brantley, Riddle, Randall, Kwasny, Keith R., Poulin, Marc, Lopez, Juan
• Primary Examiner(s): Gilman, Alexander
• Application Number:
  US13/570,484
• Publication Number:
  US 20130052853A1
• Time in Patent Office: 1,895 Days
• Field of Search: 439345, 439660, 439891, 439680
• CPC Class Codes: B60L 2270/40 related to technical updates when adding new parts or software
• CPC Class Codes: B60L 53/16 Connectors, e.g. plugs or sockets, specially adapted for charging electric vehicles
• CPC Class Codes: B60L 53/18 Cables specially adapted for charging electric vehicles
• CPC Class Codes: B60L 53/31 Charging columns specially adapted for electric vehicles
• CPC Class Codes: H01R 13/506 assembled by snap action of the parts
• CPC Class Codes: H01R 13/6335 comprising a handle
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 10/7072 Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
• CPC Class Codes: Y02T 90/12 Electric charging stations
• CPC Class Codes: Y02T 90/14 Plug-in electric vehicles

Abstract

A connector assembly is provided with a housing forming an exterior, an inlet end, a cavity, and an outlet end. The housing has a recess formed within the exterior and at least one aperture formed through the housing within the recess for venting the cavity. A cord extends through the inlet end into the cavity. The first housing portion has a first fastener mechanism formed within the cavity. The second housing portion is provided with a second fastener mechanism sized to extend into the first housing portion cavity for engagement with the first fastener mechanism to fasten the first housing portion and the second housing portion together. A molded material is disposed within the cavity for engaging the fastened first and second fastener mechanisms for minimizing unfastening of the first and second fastener mechanisms. Retainers are provided for cords of varying thicknesses.

Claims

1. A connector assembly comprising:

a housing forming an exterior, an inlet end, a cavity, and an outlet end, the housing having a recess formed within the exterior and at least one aperture formed through the housing within the recess for venting the cavity; and

a cord extending through the inlet end into the cavity;

wherein the housing forms a handle with a handle exterior; and

wherein the recess is formed in the handle exterior.

2. The connector assembly of claim 1 wherein the housing comprises:

a receptacle housing portion at the outlet end in electrical communication with the cord;

a first handle housing portion extending from the inlet end to the receptacle housing portion; and

a second handle housing portion extending from the inlet end to the receptacle housing portion, the second handle housing portion being sized to be assembled to the first handle housing portion to collectively retain the receptacle housing portion therebetween, and collectively provide the cavity;

wherein the first handle housing portion and the second handle housing portion collectively form the handle exterior.

3. The connector assembly of claim 2 wherein the first handle housing portion and the second handle housing portion collectively form the handle exterior;

wherein the first handle housing portion has a first fastener mechanism formed within the cavity; and

wherein the second handle housing portion has a second fastener mechanism sized to extend into a cavity of the first handle housing portion for engagement with the first fastener mechanism to fasten the first handle housing portion and the second handle housing portion together.

4. The connector assembly of claim 3 further comprising a molded material disposed within the cavity for engaging the fastened first and second fastener mechanisms for minimizing unfastening of the first and second fastener mechanisms.

5. The connector assembly of claim 2 wherein the housing further comprises:

a first retainer oriented within a cavity of the first handle housing portion adjacent the inlet end;

a second retainer oriented within the first handle housing portion cavity spaced apart from the first retainer and the inlet end;

a third retainer oriented within a cavity of the second handle housing portion, opposing the first retainer and spaced apart from the first retainer a first distance for engaging a cord of a first thickness; and

a fourth retainer oriented within the second handle housing portion cavity spaced apart from the third retainer, opposing the second retainer and spaced apart from the second retainer a second distance that is different than the first distance for engaging a cord of a second thickness.

6. The connector assembly of claim 2 further comprising a grommet oriented about the cord and retained within the first handle housing portion and the second handle housing portion.

7. The connector assembly of claim 2 further comprising:

a plurality of conductive receptacles oriented within sockets in the receptacle housing portion, the receptacles being in electrical communication with the cord; and

a backer plate fastened to the receptacle housing portion for retaining the receptacles within the sockets.

8. A connector assembly comprising:

a first housing portion forming an exterior, an inlet end, a cavity, and an outlet end, the first housing portion having a first fastener mechanism formed within the cavity;

a second housing portion sized to be assembled to the first housing portion, the second housing portion formed with an exterior, an inlet end, a cavity, and an outlet end, each corresponding to the first housing portion, the second housing portion comprising a second fastener mechanism sized to extend into the first housing portion cavity for engagement with the first fastener mechanism to fasten the first housing portion and the second housing portion together;

a cord extending through the inlet ends of the first and second housing portions; and

a molded material disposed within the cavity for engaging the fastened first and second fastener mechanisms for minimizing unfastening of the first and second fastener mechanisms.

9. The connector assembly of claim 8 wherein the first housing portion is further defined as a first handle housing portion and the second housing portion is further defined as a second handle housing portion, whereby the first and second handle housing portions collectively provide a handle.

10. The connector assembly of claim 9 further comprising a receptacle housing portion retained between the first and second handle housing portions at the outlet end, the receptacle housing portion being in electrical communication with the cord.

11. The connector assembly of claim 10 further comprising:

a plurality of receptacles oriented within sockets in the receptacle housing portion, the receptacles being in electrical communication with the cord; and

a backer plate fastened to the receptacle housing portion for retaining the receptacles within the sockets.

12. The connector assembly of claim 9 wherein the housing further comprises:

a first retainer oriented within the first handle housing portion cavity adjacent the inlet end;

a second retainer oriented within the first handle housing portion cavity spaced apart from the first retainer and the inlet end;

a third retainer oriented within the second handle housing portion cavity, opposing the first retainer and spaced apart from the first retainer a first distance for engaging a cord of a first thickness; and

a fourth retainer oriented within the second handle housing portion cavity spaced apart from the third retainer, opposing the second retainer and spaced apart from the second retainer a second distance that is different than the first distance for engaging a cord of a second thickness.

13. The connector assembly of claim 9 further comprising a grommet oriented about the cord and retained within the first handle housing portion and the second handle housing portion.

14. A connector housing assembly comprising:

a first housing portion forming an inlet end and a cavity;

a first retainer oriented within the first housing portion cavity adjacent to the inlet end;

a second retainer oriented within the first housing portion cavity spaced apart from the inlet end and the first retainer;

a second housing portion sized to be assembled to the first housing portion, the second housing portion formed with an inlet end and a cavity, each corresponding to the first housing portion;

a third retainer oriented within the second housing portion cavity adjacent to the inlet end, opposing the first retainer and spaced apart from the first retainer a first distance for engaging a cord of a first thickness; and

a fourth retainer oriented within the second housing portion cavity spaced apart from the inlet end and the third retainer, opposing the second retainer and spaced apart from the second retainer a second distance that is different than the first distance for engaging a cord of a second thickness.

15. The connector housing assembly of claim 14 further comprising:

a fifth retainer oriented within the first housing portion cavity spaced apart from the first retainer and the second retainer; and

a sixth retainer oriented within the second housing portion cavity spaced apart from the third retainer and the fourth retainer, opposing the fifth retainer and spaced apart from the fifth retainer a third distance that is different than the first and second distances for engaging a cord of a third thickness.

16. A connector assembly comprising:

a connector housing assembly according to claim 14;

a cord extending through the inlet end into the cavity; and

a receptacle housing portion at an outlet end of the first and second housing portions in electrical communication with the cord.

17. The connector assembly of claim 16 further comprising a grommet oriented about the cord and retained with the first housing portion and the second housing portion.

18. The connector assembly of claim 16 further comprising:

a plurality of conductive receptacles oriented within sockets in the receptacle housing portion, the receptacles being in electrical communication with the cord; and

a backer plate fastened to the receptacle housing portion for retaining the receptacles within the sockets.

19. The connector housing assembly of claim 14 wherein the first retainer and the third retainer are generally coaxial with the second retainer and the fourth retainer.

20. The connector housing assembly of claim 15 wherein the first retainer and the third retainer are generally coaxial with the second retainer and the fourth retainer;

and

wherein the first retainer and the third retainer are generally coaxial with the fifth retainer and the sixth retainer.