Power cable plug connector
A power cable plug connector including an electronics configuration and terminal configuration arranged to conduct an incoming power signal from a power source and filter harmful transient power signals away from the power signal. The electronics configuration is covered by an electronics housing and the negative space therein is filled with silicone encapsulate. The terminal configuration is overmolded to form the terminal housing. The terminal housing and electronics housing are fastened together to form a rugged internal assembly. The power cable plug connector includes an overmolded outer housing to prevent debris, temperature, shock, moisture, and vibration from damaging the electronics configuration and terminal configuration.
1 . A power cable plug connector ( 100 ) device comprising:
an internal assembly ( 162 ) comprising:
an electronics configuration ( 120 ) including a printed circuit board ( 122 ), a surge protection device ( 124 ), and a second connector ( 126 ); and
a terminal configuration ( 140 ) including at least one or more contacts ( 142 ), a first connector ( 176 ), a power cable ( 144 ), and at least one power wire ( 146 ) partially enclosed within the power cable ( 144 ) and electrically connected to the one or more contacts ( 142 ); and
an outer housing ( 112 ) formed by overmolding the internal assembly ( 162 );
whereby the internal assembly ( 162 ) conducts an incoming power signal ( 56 ), filters a transient power signal ( 58 ), and detects one or more circuit measurements so that a protected, non-transient power signal ( 59 ) is transmitted to a system circuit ( 60 ) via the power wire ( 146 ), and
wherein an electronics housing ( 111 ) is configured to receive the electronics configuration ( 120 ) such that the second connector ( 126 ) is positioned outside the electronics housing ( 111 ).
2 . The device of claim 1 , wherein a silicone encapsulate ( 132 ) fills negative space within the electronics housing ( 111 ) after the electronics configuration ( 120 ) is placed therein.
3 . The device of claim 1 , wherein a terminal housing ( 110 ) is formed by overmolding the terminal configuration ( 140 ) after the power wires ( 146 ) of the power cable ( 144 ) are electrically connected to the one or more contacts ( 142 ).
4 . The device of claim 3 , wherein the terminal housing ( 110 ) is configured to retain the terminal configuration ( 140 ) such that the first connector ( 176 ) is positioned outside the terminal housing ( 110 ).
5 . The device of claim 1 , further comprising a connecting wire ( 174 ) electrically connected to the one or more contacts ( 142 ) and the first connector ( 176 ) positioned outside of a terminal housing ( 110 ).
6 . The device of claim 1 , wherein a plurality of electronics wires ( 130 ) facilitates electrical communication between the first connector ( 176 ) and the second connector ( 126 ).
7 . The device of claim 1 , wherein the surge protection device ( 124 ) defines a variable resistor configured to conduct the incoming power signal ( 56 ) and filter the transient power signal ( 58 ) away from the incoming power signal ( 56 ) when the incoming power signal ( 56 ) exceeds the predetermined power signal threshold ( 61 ) so that the protected, non-transient power signal ( 59 ) propagates throughout the system circuit ( 60 ).
8 . The device of claim 1 , wherein the electronics configuration ( 120 ) further includes a circuit analyzer ( 125 ) for detecting the one or more circuit measurements.
9 . The device of claim 8 , wherein the electronics configuration ( 120 ) further includes an electrically connected LED display ( 128 ) for indicating a circuit status based on the one or more circuit measurements detected by the circuit analyzer ( 125 ).
10 . The device of claim 1 , wherein the outer housing ( 112 ) forms a handle ( 164 ) to facilitate gripping the device ( 100 ).
11 . The device of claim 1 , wherein the terminal configuration ( 140 ) comprises three contacts ( 142 ) configured and arranged to engage a 20-amp or 30-amp power source receptacle.
12 . The device of claim 1 , wherein the terminal configuration ( 140 ) comprises four contacts ( 142 ) configured and arranged to engage a 50-amp power source receptacle.
13 . A power cable plug connector ( 100 ) device comprising:
an internal assembly ( 162 ) comprising:
a terminal configuration ( 140 ) including at least one or more contacts ( 142 ), a power cable ( 144 ) and one or more power wires ( 146 ), wherein the one or more power wires ( 146 ) are electrically connected to the one or more contacts ( 142 ), and wherein the terminal configuration ( 140 ) is overmolded forming a terminal housing ( 110 ); and
an electronics configuration ( 120 ) including a printed circuit board ( 122 ), a surge protection device ( 124 ), a circuit analyzer ( 125 ), wherein the electronics configuration ( 120 ) is positioned substantially inside an electronics housing ( 111 ); and wherein the surge protection device ( 124 ) defines a variable resistor configured to conduct the incoming power signal ( 56 ) and filter the transient power signal ( 58 ) away from the incoming power signal ( 56 ) when the incoming power signal ( 56 ) exceeds the predetermined power signal threshold ( 61 ) so that the protected, non-transient power signal ( 59 ) propagates throughout the system circuit ( 60 ); and
wherein the electronics housing ( 111 ) is mechanically fastened to a top surface ( 152 ) of the terminal housing ( 110 )
whereby the internal assembly ( 162 ) conducts an incoming power signal ( 56 ), filters a transient power signal ( 58 ), and detects one or more circuit measurements so that a protected, non-transient power signal ( 59 ) is transmitted to a system circuit ( 60 ) via the power wire ( 146 ).
14 . The device of claim 13 , wherein a silicone encapsulate ( 132 ) fills negative space within the electronics housing ( 111 ) after the electronics configuration ( 120 ) is placed therein.
15 . The device of claim 13 , wherein the outer housing ( 112 ) is made of a thermoplastic material.
16 . The device of claim 13 , wherein the terminal configuration ( 140 ) comprises three contacts ( 142 ) configured and arranged to engage a 20-amp or 30-amp power source receptacle.
17 . The device of claim 13 , wherein the terminal configuration ( 140 ) comprises four contacts ( 142 ) configured and arranged to engage a 50-amp power source receptacle.
18 . The device of claim 13 , wherein the terminal configuration ( 140 ) includes a first connector ( 176 ), and the electronics configuration ( 120 ) includes a second connector ( 126 ), and a plurality of electronics wires ( 130 ) facilitate electrical communication between the first connector ( 176 ) and the second connector ( 126 ).
19 . A power cable plug connector ( 100 ) device comprising:
an internal assembly ( 162 ) comprising:
an electronics configuration ( 120 ) including a printed circuit board ( 122 ), a surge protection device ( 124 ), and a second connector ( 126 ); and
a terminal configuration ( 140 ) including at least one or more contacts ( 142 ), a first connector ( 176 ), a power cable ( 144 ), and at least one power wire ( 146 ) partially enclosed within the power cable ( 144 ) and electrically connected to the one or more contacts ( 142 ); and
an outer housing ( 112 ) formed by overmolding the internal assembly ( 162 );
whereby the internal assembly ( 162 ) conducts an incoming power signal ( 56 ), filters a transient power signal ( 58 ), and detects one or more circuit measurements so that a protected, non-transient power signal ( 59 ) is transmitted to a system circuit ( 60 ) via the power wire ( 146 ); and
wherein a plurality of electronics wires ( 130 ) facilitates electrical communication between the first connector ( 176 ) and the second connector ( 126 ).
20 . The device of claim 19 , wherein the surge protection device ( 124 ) defines a variable resistor configured to conduct the incoming power signal ( 56 ) and filter the transient power signal ( 58 ) away from the incoming power signal ( 56 ) when the incoming power signal ( 56 ) exceeds the predetermined power signal threshold ( 61 ) so that the protected, non-transient power signal ( 59 ) propagates throughout the system circuit ( 60 ).