Electrical coupler for a first car of a multi-car vehicle

A coupler system comprising:

• a mechanical coupler for mechanically coupling a first car of a multi-car vehicle to a second car of the multi-car vehicle;
• and
• an electrical coupler attached to a portion of the mechanical coupler, the electrical coupler adapted to couple ends of cables of the first car to ends of cables of the second car, the electrical coupler comprising:
• a housing comprising:
• an end opening, and
• a rim surrounding the end opening,
• the housing extending along a longitudinal axis (A);
• an insulation block arranged in the end opening, the insulation block comprising:
• a flat endface facing towards an outside of the housing and arranged perpendicular to the longitudinal axis (A) of the housing, the flat endface situated in an endface plane (B);
• wherein the endface has defined therein holes that lead through the insulation block, or recesses that lead into the insulation block;
• wherein at least one hole or recess is configured to receive an end of at least one of said cables and such that the at least one cable end protrudes from the hole or the recess over the endface towards the outside of the housing;
• a lid having a closed position and an open position;
• wherein:
• in said closed position, the lid is arranged in front of the endface of the insulation block;
• and
• in said open position, the lid is arranged along a side of the housing;
• the lid further comprising:
• a housing contact surface that, in the closed position of the lid, contacts or is in close proximity to a lid contact surface of the housing arranged on the rim, and wherein the lid contact surface at least partially lies in or runs parallel to the endface plane (B);
• wherein
• (a) an arm is attached to the lid and to the housing so as to enable a rotation of the arm relative to the housing around a rotational axis such that the rotational axis about which the arm rotates relative to the housing is oriented parallel to the endface plane, or
• (b) a series of arms are connected to each other so as to enable one arm to rotate relative to a neighboring arm about a rotational axis (C), wherein one arm of the series of arms is attached to the housing, and wherein attachment of the arm to the housing enables a rotation of the arm relative to the housing around a rotational axis (D), whereby the rotational axis (D) about which this arm rotates relative to the housing is oriented parallel to the endface plane (B), and wherein one arm of the series of arms is attached to the lid;
• wherein a base plane (E) is defined as being oriented perpendicular to the endface plane (B) and contains the rotational axis (D), about which the arm that is attached to the housing rotates relative to the housing;
• wherein a reference line that lies in or runs parallel to the endface plane (B) and runs parallel to the base plane (E), runs through a point of the lid contact surface that is furthest away from the base plane (E) in one direction;
• and
• wherein a part of the housing contact surface crosses a reference plane (F) that contains the reference line and which reference plane (F) runs perpendicular to the base plane (E) at a point closer to the base plane (E) than the references line is, as the lid is moved from the closed position to the open position.

A method for assembly of an electrical coupler, the electrical coupler having:

• a housing having an end opening, an entry opening arranged opposite the end opening, and a rim surrounding the end opening, the housing extending along a longitudinal axis (A);
• and
• an insulation block comprising:
• a flat endface having defined therein holes that lead through the insulation block, or recesses that lead into the insulation block;
• wherein the method comprises:
• arranging the endface of the insulation block perpendicular to the longitudinal axis (A) of the housing, the flat endface situated in an endface plane (B);
• inserting an end of a cable within a corresponding one of said hole or recess of the insulation block, the end of the cable protruding from the hole or the recess over the endface;
• inserting the insulation block through the entry opening into the housing;
• attaching the insulation block to the housing such that the insulation block is arranged in the end opening of the housing;
• providing a lid having a closed position in which the lid is arranged in front of the endface of the insulation block, and an open position in which the lid is arranged along a side of the housing;
• wherein the lid further comprises a housing contact surface that in the closed position of the lid contacts or is in close proximity to a lid contact surface of the housing arranged on the rim, wherein the lid contact surface at least partially lies in or runs parallel to the endface plane (B);
• attaching one of:
• (a) an arm to the lid and to the housing to enable a rotation of the arm relative to the housing around a rotational axis such that the rotational axis about which the arm rotates relative to the housing is oriented parallel to the endface plane;
• and (b) a series of arms to each other to enable one arm to rotate relative to a neighboring arm about a rotational axis (C), wherein one arm of the series of arms is attached to the housing, and wherein attachment of the arm to the housing enables a rotation of the arm relative to the housing around a rotational axis (D), whereby the rotational axis (D) about which this arm rotates relative to the housing is oriented parallel to the endface plane (B), and wherein one arm of the series of arms is attached to the lid;
• wherein a base plane (E) is defined as being oriented perpendicular to the endface plane (B) and contains the rotational axis (D), about which the arm that is attached to the housing rotates relative to the housing;
• wherein a reference line that lies in or runs parallel to the endface plane (B) and runs parallel to the base plane (E), runs through a point of the lid contact surface that is furthest away from the base plane (E) in one direction;
• and wherein
• a part of the housing contact surface crosses a reference plane (F) that contains the reference line and which reference plane (F) runs perpendicular to the base plane (E) at a point closer to the base plane (E) than the references line is, as the lid is moved from the closed position to the open position.