The present disclosure relates to a universal serial bus
(USB) charger for vehicles and, and more particularly to a water-resistant USB
5 charger for a two-wheeled vehicle that can charge a power source, such as a battery,
of the electronic device by using a power source of the vehicle.
BACKGROUND:
Electrical connectors are widely used to connect electrical or electronic devices
10 with each other. For example, USB connecting ports are very common for
connecting various electrical or electronic devices with each other. Generally, USB
ports are also utilized for charging a power source, such as a battery, of the
electronic device. Generally, vehicles are provided with USB receptacle ports for
facilitating connecting or charging various electronic devices carried by the
15 passengers using the power source of the vehicle.
Conventional technology incorporated in many four-wheeler USB chargers is
suitable for stationary application and enclosed environment. The design of such
chargers is similar to chargers available on stationary devices like computers,
20 peripheral devices, home chargers, etc. In the automotive two-wheeler industry
demand for USB chargers is also growing. Original equipment manufacturers
(OEMs) are fitting chargers on scooters or motorcycles at various locations like
handlebar, boot box, etc. which is comfortable for their end customer. Vibration
levels at these locations vary from 5G to 20G. The external environment can be
25 slightly humid to heavy rains or during washing when such locations are subjected
to high-pressure water jets. Under such conditions, the conventional chargers
cannot work as water may go inside and short circuit the electronic circuitry.
Therefore, to use the same USB charger for the two-wheeler automotive industry,
it is essential to encapsulate the PCB circuitry in the potting compound to provide
30 long-lasting protection against such an environment. The potting also ensure that
3
PCB and its electronic components are rigidly held so that vibration, shock, and
resonance have no harmful effect upon them.
An assembly of the USB receptacle port, hereinafter referred to as a USB assembly
5 (1a), in accordance with an example of the prior art as shown in FIG. 1 consists of
a housing (2), a cap (3) and a nut (4) for tightening the USB assembly (1) with the
panel having a round hole to accommodate the circular body. It is having a twowire arrangement that carries power from a 12V battery (not shown) to a PCB
assembly (6). The PCB assembly (6) fits into the housing (2). The construction and
10 drawbacks of the prior art are detailed below with reference to exploded view as
shown in FIG. 2.
The housing (2) is covered from the backside with a base (5) through a snap-lock
arrangement (5a) as shown in the exploded view in FIG 2. The base (5) has a two15 hole arrangement (5b) which allows the wires of a wiring harness (7) to pass
through it to the PCB assembly (6). The water can enter the housing (2) through
gaps between the wire and the holes as the wire is a loose fit in the hole to facilitate
assembly. It also has a hole (5c) in the center to allow water to drain out if it gets
inside the housing (2). The hole will drain water only when the USB assembly (1)
20 is mounted vertically. The hole is also not covered which means water can enter
through this hole inside the housing (2). The PCB assembly (6) is located in the
housing (2) between two thin walls to support it and prevent its movement in two
directions. The movement along the axis of the housing (2) is restricted on the front
side by the housing (2) and backside by the base (5). The PCB assembly (6) and its
25 electronic parts are protected by water and dust using a thin conformal coating (not
shown). The protection provided by the conformal coating is for the mild
environment and it does not provide effective protection to leaded parts unless
applied with sufficient thickness, which requires special equipment and material
and is costly. A ring (3a) acts as a dampener and helps to absorb vibration from the
30 panel. This dampening is also not sufficient for overhanging housing (2) and housed
4
delicate electronic parts of the PCB assembly (6), which is supported inside the
housing (2) as described above.
From the above description of the prior art, it is clear that protections for water,
5 dust, and vibration to the PCB assembly (6) are suitable only for the mild
environment. However, for harsher conditions, more protection is required. The
present disclosure is directed to address one or more problems as discussed above
and other problems associated with the art.
10 SUMMARY OF THE DISCLOSURE
One or more shortcomings of conventional systems are overcome, and
additional advantages are provided through the assembly as claimed in the
present disclosure. Additional features and advantages are realized through the
techniques of the present disclosure. Other embodiments and aspects of the
15 disclosure are described in detail herein and are considered a part of the claimed
disclosure. The present disclosure achieves the above-stated objective by
providing a water-resistant electrical connector assembly.
In an embodiment of the present disclosure, the electrical connector assembly
20 comprises a PCB assembly having a PCB, a connector receptacle mounted on the
PCB, and a plurality of electronic components mounted on the PCB. A PCB
housing defining a cavity for receiving the PCB assembly. The PCB housing is
having an open side and a close side. The open side configured for receiving the
PCB assembly with the connector receptacle jutting out from the open side. A
25 sealant material filling the cavity, the sealant material encapsulates the plurality of
the electronic component of the PCB assembly. A main housing configured for
receiving and supporting the PCB housing. The main housing having a front portion
and a rear portion, the rear portion configured for inserting the PCB housing with
the open side of the PCB housing positioned adjacent to the front portion. The front
30 portion configured for positioning the connector receptacle and allowing access to
the connector receptacle from outside the main housing.
5
In an embodiment of the present disclosure, the main housing defines a hole at the
front portion for allowing access to the connector receptacle from outside the main
housing.
5 In an embodiment of the present disclosure, the electrical connector assembly
comprises a cap detachably attached to the front portion of the main housing. The
cap is configured to cover the hole.
In an embodiment of the present disclosure, the PCB housing defines a PCB
10 housing hole at the close side of the PCB housing.
In an embodiment of the present disclosure, the electrical connector assembly
comprises a wire grommet attached to the close side of the PCB housing. The wire
grommet defines a plurality of holes for providing a passage to the wiring harness
15 to connect with the PCB assembly.
In an embodiment of the present disclosure, the main housing defines a snap-lock
arrangement to rigidly hold the PCB housing.
20 In an embodiment of the present disclosure, the PCB housing defines guide
channels for guiding the insertion of the PCB assembly into the PCB housing and
supporting the PCB assembly inside the PCB housing.
In an embodiment of the present disclosure, the main housing defines a drain hole
25 at a lateral surface configured to drain out the water entering inside the main
housing.
In an embodiment of the present disclosure, the PCB housing defines a drain hole
at a close side configured to drain out the water entering inside the main housing.
30
6
In an embodiment of the present disclosure, a method of assembly of the electrical
connector assembly is disclosed. The method includes inserting the PCB assembly
into the PCB housing such that the connector receptacle jutting out from the open
side. The method further includes injecting the sealant material inside the PCB
5 housing for filling the cavity and encapsulating the plurality of the electronic
component of the PCB assembly. After that inserting the PCB housing into the main
housing with the open side of the PCB housing positioned adjacent to the front
portion of the main housing. The front portion configured for positioning the
connector receptacle and allowing access to the connector receptacle from outside
10 the main housing. Finally attaching the cap to the front portion of the main housing
to cover the hole.
In an embodiment of the present disclosure, the electrical connector assembly is a
USB charging device and is adapted for mounting on a two-wheeled vehicle.
15
The foregoing summary is illustrative only and is not intended to be in any way
limiting. In addition to the illustrative aspects, embodiments, and features described
above, further aspects, embodiments, and features will become apparent by
reference to the drawings and the following detailed description.
20
BRIEF DESCRIPTION OF DRAWINGS
The novel features and characteristics of the disclosure are set forth in the appended
claims. The disclosure itself, however, as well as a mode of use, further objectives,
and advantages thereof, will best be understood by reference to the following
25 detailed description of an embodiment when read in conjunction with reference to
the accompanying drawings wherein like reference numerals represent like
elements and in which:
Figure 1 illustrates a perspective view of the USB charger for a vehicle according
30 to the prior art USB charger.
7
Figure 2 illustrates an exploded perspective view of the USB charger for a vehicle
according to the prior art USB charger.
Figure 3 illustrates a perspective view of the USB charger for a vehicle according
5 to an embodiment of the present disclosure.
Figure 4 illustrates an exploded perspective view of the USB charger for a vehicle
according to an embodiment of the present disclosure.
10 Figure 5 illustrates a perspective view of a PCB housing in a USB charger for a
vehicle according to an embodiment of the present disclosure.
Skilled artisans will appreciate that elements in the drawings are illustrated for
simplicity and have not necessarily been drawn to scale. For example, the
15 dimensions of some of the elements in the drawings may be exaggerated relative to
other elements to help to improve understanding of embodiments of the present
disclosure.
DETAILED DESCRIPTION
20 While the embodiments in the disclosure are subject to various modifications and
alternative forms, specific embodiment thereof has been shown by way of example
in the figures and will be described below. It should be understood, however, that
it is not intended to limit the disclosure to the particular forms disclosed, but on the
contrary, the disclosure is to cover all modifications, equivalents, and alternatives
25 falling within the scope of the disclosure.
Before describing in detail, the various embodiments of the present disclosure it
may be observed that the novelty and inventive steps that are in accordance with
the present disclosure resides in the construction and assembly of an electrical
30 connector assembly. It is to be noted that a person skilled in the art can be motivated
8
from the present disclosure and can perform various modifications. However, such
modifications should be construed within the scope of the invention.
Accordingly, the drawings are showing only those specific details that are pertinent
5 to understanding the embodiments of the present disclosure so as not to obscure the
disclosure with details that will be readily apparent to those of ordinary skill in the
art having the benefit of the description herein.
The terms “comprises”, “comprising”, or any other variations thereof, are intended
10 to cover a non-exclusive inclusion, such that an assembly, setup, system, device
that comprises a list of components does not include only those components but
may include other components not expressly listed or inherent to such system or
device or setup. In other words, one or more elements in the system or apparatus or
device proceeded by “comprises a” does not, without more constraints, preclude the
15 existence of other elements or additional elements in the assembly or system or
apparatus. The following paragraphs explain the present disclosure. The invention
in respect of the same may be deduced accordingly.
The following paragraphs describe the present disclosure with reference to the
20 accompanying drawings.
The present disclosure provides for the electrical connector assembly. In the
embodiment as illustrated herein, a USB connector assembly is shown. The USB
connector assembly as disclosed herein may be used as a USB charging port for a
25 two-wheeled vehicle such as a motorcycle, or a USB port for connection with other
components on the vehicle. It may be understood that the disclosure may be
implemented in any other electrical connector as suitable.
FIGs. 3 - 5 illustrate a USB connector assembly, hereinafter referred to as the USB
30 assembly (1), in accordance with an embodiment. The term USB assembly is used
for referring to a USB socket that is configured to receive a USB plug for a USB
connection. As shown, the USB assembly (1) has a main housing (8), a PCB
9
assembly (9), a PCB housing (10), a wiring harness (7), a cap (3), a wire grommet
(11), and a sealant material positioned in the PCB housing (10). The USB assembly
(1) as disclosed herein is configured for use in a two-wheeled vehicle such as a
motorcycle. However, the USB assembly (1) in accordance with the present
5 disclosure may be used in any other vehicle or any other environment as suitable.
FIG. 4 illustrates an exploded perspective view of the USB assembly (1) in
accordance with an embodiment of the present disclosure. The PCB assembly (9)
comprises a PCB (9a), a connector receptacle (16), and a plurality of electronic
10 components (9b). The connector receptacle (16) and the plurality of electronic
components (9b) are mounted on the PCB (9a) as known in the art. There may be
other electrical or electronic (active or passive) components (not shown) such as
capacitors or diodes on the PCB (9a) as required. The electronic components (9b)
of the PCB assembly (9) are soldered along with a couple of wires of the wiring
15 harness (7) onto the PCB (9a) for input power from a 12V battery (not shown). The
PCB (9a) may be made of any material known in the art.
FIG. 5 shows a perspective view of the PCB housing (10) in accordance with the
present disclosure. The PCB housing (10) is configured to be placed over the PCB
20 assembly (9). The PCB housing (10) defines a cavity for receiving the PCB
assembly (9). The PCB housing (10) has an open side (10c) and a close side (10e).
The open side (10c) is configured for receiving the PCB assembly (9) with the
connector receptacle (16) jutting out from the open side (10c). The cavity may be
filled or potted using the sealant material. The sealant material is used to
25 encapsulate the PCB assembly (9) for protecting it from any mild environment of
water ingress, moisture, dust, etc.
The sealant material may be any suitable material known in the art that can be
poured into the PCB housing (10) in a liquid state and then the sealant solidifies for
30 sealing the PCB assembly (9). When the sealant is poured in, the sealant may fill in
the cavity and surround the electronic components of the PCB assembly (9). After
10
solidification, the sealant ensures that any electrical and electronic components of
the USB assembly (1) are prevented from contact with moisture or water. The
sealant material can be poured from the open side (10c) of PCB housing (10). No
exact measurement of sealant height or volume is required.
5
In an embodiment, as shown, the PCB housing (10) is provided with a set of guide
channels (10a). The guide channels (10a) are provided on opposite internal surfaces
of the PCB housing (10). The guide channels (10a) act as a guide for the insertion
of the PCB assembly (9) inside the PCB housing (10). The guide channels (10a)
10 may also be utilized to restrict the movement of PCB assembly (9) in one direction,
i.e. the PCB assembly (9) can only move along a depth of PCB housing (10). The
PCB housing (10) defines a PCB housing hole (10b) at the close side (10e). The
PCB housing hole (10b) is configured to plug the wire grommet (11). Three snaps
(10d) are provided at equal distance along a rear periphery of the PCB housing (10).
15 These three snaps (10d) are configured for engaging with the corresponding snaplock holes provided in a rear portion (8c) of the main housing (8) such that the PCB
housing (10) can be rigidly held inside the main housing (8). Further, PCB housing
(10) defines a drain hole (10f) at the close side (10e) such that if the water enters
inside the main housing (8), it can be drained out through the drain hole (10f). In
20 an embodiment, as shown, a top surface (10g) and a bottom surface (10h) of the
PCB housing (10) are kept flat. When the PCB housing (10) is put into the main
housing (8), the flat outer surfaces (10g, 10h) of the PCB housing (10) along with
a cylindrical inner surface of the main housing (8) define a passage running along
a longitudinal axis of the USB assembly (1). If water enters inside the main housing
25 (8) the passages guide the water towards the drain hole (10f), from where the water
can egress from the USB assembly (1).
Further as shown in FIG. 4 the wire grommet (11) is attached to the close side (10e)
of the PCB housing (10) through the PCB housing hole (10b). The wire grommet
30 (11) defines a plurality of holes (11a) for providing a passage to the wiring harness
(7) to connect with the PCB assembly (9). The wire grommet (11) is designed in
11
such a manner that the plurality of holes (11a) or the PCB housing hole (10b) does
not allow any liquid to pass through, after the insertion of the wires through it. The
wire grommet (11) may be made of any suitable material for sealing the PCB hole
(10b) and the wire holes (11a).
5
The construction of the main housing (8) will now be described. The main housing
(8) is cylindrical in shape and is adapted to house the PCB assembly (9) along with
PCB housing (10). The main housing (8) is having a front portion (8b) and a rear
portion (8c). The main housing (8) defines a rectangular opening (12) at its front
10 portion (8b) to receive the connector receptacle (16). The connector receptacle (16)
facilitates connecting or charging of various electronic devices. The main housing
(8) is provided with a flange (14) around the front portion (8b) thereof. The flange
(14) is configured to fix the main housing (8) to a panel. That is when the USB
assembly (1) is inserted into an installation hole and installed on the vehicle, the
15 flange (14) closely contacts the surface of the panel to fix the USB assembly (1). A
snap-lock arrangement (13) is provided near the housing flange (14). The snap-lock
arrangement (13) helps in holding the PCB housing (10) through a snap-lock
mechanism from the front portion (8b) of the main housing (8). Further, three holes
(15) are provided at the rear portion (8c) of the main housing (8) along its periphery
20 at equal distance. These holes (15) are used to hold the PCB housing (10) through
the snaps (10d) from the rear portion (8c) of the main housing (8). The main
housing is designed such that if the water enters inside the main housing (8), it
cannot reach to the PCB assembly (9) and will drain out through a drain hole (8a)
located at a lateral portion (8d) in the main housing (8).
25
Further, the front portion (8b) of the main housing (8) is configured for the
installation of the cap (3). The cap covers the opening (12) of the main housing (8)
when not in use. The cap (3) is provided with a ring (3a), which is made of soft
material like EPDM or PVC rubber. The ring (3a) is compressed between the flange
30 (14) from its front side and the panel from the backside when in assembled
12
condition. The ring (3a) acts as a dampener and helps to absorb vibration occurred
from the panel of the vehicle.
Further, a method of assembling an electrical connector is disclosed. As an
5 example, the method of assembling the USB assembly (1) is described herein. For
assembling the USB assembly (1), first, the PCB (9a) may be connected with the
connector receptacle (16) and the wiring harness (7). After this, the PCB assembly
(9) is fitted into the PCB housing (10) through the guide channels (10a). The epoxy
potting can be done from the open side (10c) of PCB housing (10) using the sealant
10 material. The dimensions of the PCB assembly (9) is kept such that the connector
receptacle (16) stays outside the PCB housing (10) so that sealing material does not
enter the connector receptacle (16). All the parts of the PCB assembly (9), except
the connector receptacle (16), remain rigidly held in the sealant material. Due to
which, the effect of water, dust, and vibration is negligible. Therefore, there is no
15 need for a conformal coating of the PCB assembly (9) after the curing of the sealant
material. After this, the PCB housing (10) is slid into the main housing (8) and
rigidly held in it by means of the snap locks (10d) provided at the equal distance
along the rear periphery of the PCB housing (10).
20 In an embodiment of the present disclosure, illumination to the connector receptacle
(16) may be provided so that it is visible from a distance in a dark or poorly lit
environment. Such illumination can be provided by adding a LED to the PCB
assembly (9). The geometry and other configuration of the USB assembly (1) can
be modified in such a way that it provides uniform illumination around the
25 connector receptacle (16).
The present disclosure provides for a USB socket for any off-road or on-road
vehicles. The USB socket may be used as a USB charging port in two-wheeled
vehicles. Generally, USB chargers are manufactured to operate in an enclosed
30 environment such as office, residence, or vehicle environment. Such USB chargers
are not completely sealed for the potting purpose which is the prime requirement in
13
the automotive industry where it fails due to harsh environment and dynamic
conditions. Further, an easy potting process from the front side is disclosed in terms
of maintaining quality. The disclosed assembly has low rejection due to the easy
potting process. Furthermore, an overall increase in the life of the USB socket can
5 be achieved due to the proper drainage of water through the drain holes.
It is to be understood that a person of ordinary skill in the art may develop a system
of similar configuration without deviating from the scope of the present disclosure.
Such modifications and variations may be made without departing from the scope
10 of the present invention. Therefore, it is intended that the present disclosure covers
such modifications and variations provided they come within the ambit of the
appended claims and their equivalents

We claim:
1. An electrical connector assembly (1) comprising:
a PCB assembly (9) comprising:
a PCB (9a);
5 a connector receptacle (16) mounted on the PCB (9a);
a plurality of electronic components (9b) mounted on the
PCB (9a);
a PCB housing (10) defining a cavity for receiving the PCB
assembly (9), the PCB housing (10) having an open side (10c) and a close
10 side (10e), the open side (10c) configured for receiving the PCB assembly
(9) with the connector receptacle (16) jutting out from the open side (10c);
a sealant material filling the cavity, the sealant material encapsulates
the plurality of electronic component (9b) of the PCB assembly (9);
a main housing (8) configured for receiving and supporting the PCB
15 housing (10), the main housing (8) having a front portion (8b) and a rear
portion (8c), the rear portion (8c) configured for inserting the PCB housing
(10) with the open side (10c) of the PCB housing (10) positioned adjacent
to the front portion (8b), the front portion (8b) configured for positioning
the connector receptacle (16) and allowing access to the connector
20 receptacle (16) from outside the main housing (8).
2. The electrical connector assembly (1) as claimed in claims 1, wherein the
main housing (8) defines an opening (12) at the front portion (8b) for
allowing access to the connector receptacle (16) from outside the main
25 housing (8).
3. The electrical connector assembly (1) as claimed in claim 2, comprising a
cap (3) detachably attached to the front portion (8b) of the main housing (8),
the cap (3) configured to cover the opening (12).
17
4. The electrical connector assembly (1) as claimed in claim 1, wherein the
PCB housing (10) defines a PCB housing hole (10b) at the close side (10e)
of the PCB housing (10).
5 5. The electrical connector assembly (1) as claimed in claim 4, comprising a
wire grommet (11) attached to the PCB housing hole (10b) at the close side
(10e) of the PCB housing (10), said wire grommet (11) defines a plurality
of holes (11a) for providing a passage to a wiring harness (7) to connect
with the PCB assembly (9).
10
6. The electrical connector assembly (1) as claimed in claim 1, wherein the
main housing (8) defines a snap-lock arrangement (13) to rigidly hold the
PCB housing (10).
15 7. The electrical connector assembly (1) as claimed in claim 1, wherein the
PCB housing (10) defines guide channels (10a) for guiding insertion of the
PCB assembly (9) into the PCB housing (10) and supporting the PCB
assembly (9) inside the PCB housing (10).
20 8. The electrical connector assembly (1) as claimed in claim 1, wherein the
main housing (8) defines a drain hole (8a) at a lateral portion (8d) configured
to drain out the water entering inside the main housing (8).
9. The electrical connector assembly (1) as claimed in claim 1, wherein the
25 PCB housing (10) defines a drain hole (10e) at the close side (10e)
configured to drain out the water entering inside the main housing (8).
10. A method for assembling the electrical connector assembly (1) as claimed
in claims 1 to 9 comprising steps of:
30 − inserting the PCB assembly (9) into the PCB housing (10) such that
the connector receptacle (16) jutting out from the open side (10c);
18
− injecting the sealant material inside the PCB housing (10) for filling
the cavity and encapsulating the plurality of electronic component
(9b) of the PCB assembly (9);
− inserting the PCB housing (10) into the main housing (8) with the
5 open side (10c) of the PCB housing (10) positioned adjacent to the
front portion (8b) of the main housing (8), the front portion (8b)
configured for positioning the connector receptacle (16) and
allowing access to the connector receptacle (16) from outside the
main housing (8);
10 − attaching the cap (3) to the front portion (8b) of the main housing
(8) to cover the opening (12).
11. The electrical connector assembly (1) as claimed in claim 1, wherein the
electrical connector assembly (1) is a USB charging device and is adapted
15 for mounting on a two-wheeled vehicle.