Patent Application
20230124123
The subject matter herein relates generally to power connectors.
Power connectors are used to power devices, such as appliances. In known appliances, the appliance wiring exits the appliance, such as from the rear of the appliance. The owner electrically connects the building wiring (line, neutral, ground) to the appliance wiring. For example, wire nuts may be used to directly connect the building wiring to the appliance wiring. The building wiring may include a plug cord coupled to the appliance and having a plug at an end of a cable assembly, where the plug is coupled to an outlet of the building to supply power to the appliance. Some known appliances include terminal blocks having terminals. The appliance wiring and the building wiring are connected to the terminals. However, access to the terminals is typically restricted making connection of the building wiring to the terminals difficult. Additionally, the appliance wiring and the building wiring are typically made at different times, which may lead to disconnection of the appliance wiring or loss of parts.
A need remains for a power connector for connecting wiring of an appliance with building wiring in a reliable manner.
In one embodiment, an appliance power connector is provided and includes a terminal block having a base. The base includes an upper surface and a lower surface. The base includes a pocket. The terminal block includes an upper shroud and a lower shroud. The upper shroud has upper shroud walls extending from the base forming an upper chamber above the upper surface. The lower shroud has lower shroud walls extending from the base forming a lower chamber below the lower surface. The appliance power connector includes a power terminal coupled to the terminal block. The power terminal includes a main body, an upper stud extending from a top of the main body and a lower stud extending from a bottom of the main body. The main body is received in the pocket. The upper stud is located in the upper chamber above the base for connection to an upper power cable terminal. The lower threaded stud is located in the lower chamber below the base for connection to a lower power cable terminal.
In another embodiment, an appliance power connector is provided and includes a terminal block having a base. The base includes an upper surface and a lower surface. The base includes pockets spaced apart along the upper surface. The terminal block includes an upper shroud and a lower shroud. The upper shroud has upper shroud walls extending from the base forming upper chambers above the upper surface. The upper shroud walls separate the upper chambers from each other. The upper chambers is aligned with the pockets. The lower shroud has lower shroud walls extending from the base forming lower chambers below the lower surface. The lower shroud walls separate the lower chambers from each other. The lower chambers is aligned with the pockets. The appliance power connector includes power terminals coupled to the terminal block at the pockets. The power terminals include a line terminal, a neutral terminal and a ground terminal. Each power terminal includes a main body, an upper stud extending from a top of the main body and a lower stud extending from a bottom of the main body. The main body has a locating surface. The main body is received in the corresponding pocket with the locating surface engaging the terminal block to locate the power terminal relative to the terminal block. The upper stud is located in the corresponding upper chamber above the base. The lower threaded stud is located in the corresponding lower chamber below the base. The lower stud of the line terminal is configured to be coupled to an appliance line wire of an appliance wire harness and the upper stud of the line terminal is configured to be coupled to a building line wire. The lower stud of the neutral terminal is configured to be coupled to an appliance neutral wire of the appliance wire harness and the upper stud of the neutral terminal is configured to be coupled to a building neutral wire. The lower stud of the ground terminal is configured to be coupled to an appliance ground wire of the appliance wire harness and the upper stud of the ground terminal is configured to be coupled to a building ground wire.
In a further embodiment, a power connector system for an appliance is provided and includes an appliance wire harness having an appliance line wire, an appliance neutral wire, and an appliance ground wire. The power connector system includes an appliance power connector coupled to the applicant wire harness and configured to be coupled to a building wire harness. The appliance power connector includes a terminal block and power terminals coupled to the terminal block. The power terminals include a line terminal, a neutral terminal and a ground terminal. The power connector system includes the terminal block including a base has an upper surface and a lower surface. The base includes pockets spaced apart along the upper surface. The terminal block includes an upper shroud and a lower shroud. The upper shroud has upper shroud walls extending from the base forming upper chambers above the upper surface. The upper shroud walls separate the upper chambers from each other. The upper chambers is aligned with the pockets. The lower shroud has lower shroud walls extending from the base forming lower chambers below the lower surface. The lower shroud walls separate the lower chambers from each other. The lower chambers is aligned with the pockets, The terminal block includes an appliance mounting feature for mounting the terminal block to the appliance. Each power terminal includes a main body, an upper stud extending from a top of the main body and a lower stud extending from a bottom of the main body. The main body is received in the corresponding pocket. The upper stud is located in the corresponding upper chamber above the base. The lower threaded stud is located in the corresponding lower chamber below the base. The lower stud of the line terminal is coupled to the appliance line wire of the appliance wire harness by a first threaded nut. The lower stud of the neutral terminal is coupled to the appliance neutral wire of the appliance wire harness by a second threaded nut, and the lower stud of the ground terminal is coupled to the appliance ground wire of the appliance wire harness by a third threaded nut.
In an exemplary embodiment, the building wiring 12 is connected to one side of the appliance power connector 100 and the appliance wiring 14 is connected to and opposite sides of the appliance power connector 100. The appliance power connector 100 may be mounted to the appliance 50, such as a frame, a wall, or another component of the appliance 50. The appliance power connector 100 may be mounted internally within the interior of the appliance 50. The appliance power connector 100 may be mounted to a back or the bottom of the appliance 50 such that the building wiring 12 is not viewable from the top or front of the appliance 50. Other mounting locations are possible in alternative embodiments.
In an exemplary embodiment, the building wiring 12 includes a building line wire 20, a building neutral wire 22, and a building ground wire 24. Optionally, terminals 26, such as ring terminals, may be provided at the ends of the wires 20, 22, 24. The wires 20, 22, 24 may be part of a wire assembly. For example, the wires 20, 22, 24 may be part of a single power cable. For example, the wires 20, 22, 24 may be surrounded by a jacket, sheath, tube, and the like. The building wiring 12 supplies power to the appliance power connector 100 and the appliance wiring 14 to power the appliance 50.
In an exemplary embodiment, the appliance wiring 14 includes an appliance line wire 30, an appliance neutral wire 32, and an appliance ground wire 34. Optionally, terminals 36, such as ring terminals, may be provided at the ends of the wires 30, 32, 34. The wires 30, 32, 34 may be part of a wire assembly. For example, the wires 30, 32, 34 may be part of a single power cable. For example, the wires 30, 32, 34 may be surrounded by a jacket, sheath, tube, and the like. Alternatively, the wires 30, 32, 34 may be individual wires that are grouped together as a wire harness. The appliance wiring 14 supplies power to the appliance 50 from the appliance power connector 100.
Optionally, the power connector system 10 may include one or more electrical components 16 between the appliance power connector 100 and the appliance wiring 14 or between the appliance wiring 14 and the appliance 50. For example, the electrical component 16 may be a circuit protection device. The electrical component 16 may include a circuit board. The electrical component 16 may be directly connected to the appliance power connector 100. Alternatively, the electrical component 16 may be remote from the appliance power connector 100 and electrically connected to the appliance power connector 100 by the appliance wiring 14.
The terminal block 102 is manufactured from a dielectric material, such as a plastic material. In an exemplary embodiment, the terminal block 102 is a molded part. For example, the terminal block 102 may be an injection molded. The terminal block 102 includes a top 110 and the bottom 112. The terminal block 102 includes a front 114 at the rear 116 opposite the front 114. The front 114 and the rear 116 extend between the top 110 and the bottom 112. Optionally, the front 114 and the rear 116 are generally planar and parallel to each other. However, the front 114 and the rear 116 may be nonplanar in alternative embodiments. The terminal block 102 has opposite sides 118 between the front 114 and the rear 116. Optionally, the sides 118 may be curved. Alternatively, the sides 118 may be planar and parallel to each other. In an exemplary embodiment, the terminal block 102 is elongated along a longitudinal axis that extends between the sides 118. The front 114 and/or the rear 116 may be parallel to the longitudinal axis. The terminal block 102 may have other shapes in alternative embodiments.
The terminal block 102 includes a base 120 having an upper surface 122 and the lower surface 124. The base 120 is configured to hold the power terminals 104. In an exemplary embodiment, the base 120 includes pockets 130 that receive corresponding power terminals 104. Optionally, the pockets 130 extend entirely through the base 120. For example, the pockets 130 are open at the upper surface 122 and open at the lower surface 124. In an exemplary embodiment, the power terminals 104 are loaded into the pockets 130 through the upper surface 122. Portions of the power terminals 104 extend above the upper surface 122 and portions of the power terminals 104 extend along the lower surface 124. As such, the power terminals 104 are accessible from above and below the base 120 for connection to the corresponding terminals 26, 36.
In an exemplary embodiment, the upper portion 132 is shaped differently than the lower portion 134. In the illustrated embodiment, the lower portion 134 is cylindrical and the upper portion 132 is polygonal shaped, such as being hexagonal shaped. For example, the upper portion 132 includes a plurality of flat wall segments 138 (for example, six wall segments 138) surrounding the outer perimeter of the pocket 130. The lower portion 134 and/or the upper portion 132 may have other shapes in alternative embodiments. In various embodiments, the lower portion 134 and the upper portion 132 may have the same shape but may have different sizes, such as different diameters.
In an exemplary embodiment, the terminal block 102 includes one or more interference features 140 extending into the pocket 130. The interference features 140 may be provided on one or more of the wall segments 138. The power terminal 104 is configured to engage the interference features 140 when received in the pocket 130. The interference features 140 may hold the power terminal 104 in the pocket 130 by an interference fit. In various embodiments, the interference features 140 are crush ribs. The terminal block 102 may include other types of securing features in alternative embodiments, such as latches, clips, tabs, slots, grooves, and the like in the pocket 130 configured to interface with the power terminal 104 to hold the power terminal 104 in the pocket 130.
Returning to
The upper shroud 150 includes upper shroud walls 152 extending upward from the base 120. The upper shroud walls 152 form upper chambers 154 above the upper surface 122 of the base 120. The upper chambers 154 are aligned with the pockets 130. In the illustrated embodiment, three upper chambers 154 are stacked side-by-side along the longitudinal axis of the terminal block 102 with the upper shroud walls 152 separating the upper chambers 154 from each other. Portions of the power terminals 104 extend into the upper chambers 154. The upper shroud walls 152 provide protection for the power terminals 104 and electrical isolation between the power terminals 104. In an exemplary embodiment, the upper shroud walls 152 are non-continuous. For example, the upper shroud walls 152 have gaps or spaces therebetween that form windows 156. In the illustrated embodiment, the terminal block 102 includes front windows 156 at the front 114 and rear windows 156 at the rear 116. The windows 156 provide access to the power terminals 104 in the upper chambers 154, such as for viewing the connection between the power terminals 104 and the building wiring 12 or for access by a tool to make the electrical connection between the power terminals 104 and the building wiring 12. The upper shroud walls 152 extend between the front 114 and the rear 116. In the illustrated embodiment, the upper shroud walls 152 are curved making semicircular wall segments between the power terminals 104. The upper shroud walls 152 may have other shapes in alternative embodiments, such as being planar and perpendicular to the front 114 and/or the rear 116.
The lower shroud 160 includes lower shroud walls 162 extending upward from the base 120. The lower shroud walls 162 form lower chambers 164 below the lower surface 124 of the base 120. The lower chambers 164 are aligned with the pockets 130. In the illustrated embodiment, three lower chambers 164 are stacked side-by-side along the longitudinal axis of the terminal block 102 with the lower shroud walls 162 separating the lower chambers 164 from each other. Portions of the power terminals 104 extend into the lower chambers 164. The lower shroud walls 162 provide protection for the power terminals 104 and electrical isolation between the power terminals 104. In an exemplary embodiment, the lower shroud walls 162 are non-continuous. For example, the lower shroud walls 162 have gaps or spaces therebetween forming windows 166 that provide access to the power terminals 104 in the lower chambers 164. The lower shroud walls 162 extend between the front 114 and the rear 116. In the illustrated embodiment, the lower shroud walls 162 are planar and perpendicular to the front 114 and/or the rear 116. The lower shroud walls 162 may have other shapes in alternative embodiments.
In an exemplary embodiment, the terminal block 102 includes mounting portions 170 configured be mounted to the appliance 50. For example, the mounting portions 170 may be mounted to the frame or a wall of the appliance 50. In the illustrated embodiment, the mounting portions 170 are provided at the bottom 112 of the terminal block 102. The lower shroud walls 162 define the mounting portions 170. In an exemplary embodiment, a fastener openings 172 pass through the terminal block 102 at the mounting portions 170. The fastener openings 172 to receive fasteners 174 used to secure the terminal block 102 to the appliance 50. The fasteners 174 may be threaded fasteners configured to be threadably coupled to the appliance 50. Other types of fasteners may be used in alternative embodiments. In other various embodiments, the terminal block 102 may be secured to the appliance 50 by other types of securing features, such as latches, clips, mounting brackets and the like.
The power terminals 104 are used to electrically connect the building wiring 12 with the appliance wiring 14. In an exemplary embodiment, the power terminals 104 are double ended power terminals configured to be electrically connected to the wiring 12, 14 at opposite ends of the power terminals 104. Each power terminal 104 includes a main body 200, an upper stud 202 and a lower stud 204. The upper stud 202 extends from a top 206 of the main body 200. The lower stud extends from a bottom 208 of the main body 200. The upper stud 202 is aligned with the lower stud 204 along a central axis of the power terminal 104. In various embodiments, the upper stud 202 is a threaded stud and the lower stud 204 is a threaded stud. However, the studs 202, 204 may be smooth posts rather than being threaded studs in alternative embodiments.
In an exemplary embodiment, the main body 200 is approximately centered along the power terminal 104. The main body 200 has a different shape than the studs 202, 204. For example, in the illustrated embodiment, the main body 200 has a polygonal shape, such as a hexagonal shape, while the studs 202, 204 are generally cylindrical shaped. In an exemplary embodiment, the main body 200 is wider than the studs 202, 204 having exposed surfaces at the top 206 and at the bottom 208. The bottom 208 may be seated against the shoulder 136 of the pocket 130 when the power terminal 104 is loaded into the terminal block 102.
The main body 200 includes a plurality of flat surfaces 210 around an outer perimeter of the main body 200. The flat surfaces 210 may face corresponding wall segments 138 when the power terminal 104 is received in the pocket 130. One or more of the flat surfaces 210 may engage the crush ribs 140 to mechanically secure the power terminal 104 in the terminal block 102, such as by an interference fit. In an exemplary embodiment, one or more of the flat surfaces 210 define a locating surface 212 for the power terminal 104. The locating surface 212 is configured to engage the terminal block 102 to locate the power terminal 104 relative to the terminal block 102. In an exemplary embodiment, the locating surface 212 engages the corresponding wall segment 138 of the pocket 130. The locating surface 212 positions the power terminal 104 relative to the terminal block 102 in one or more directions perpendicular to the central axis of the power terminal 104. The locating surface 212 may resist rotation of the power terminal 104 relative to the terminal block 102. Optionally, all of the flat surfaces 210 may form locating surfaces 212, with each of the flat surfaces 210 engaging the corresponding wall segments 138 to position the power terminal 104 in the terminal block 102.
The upper stud 202 includes a shank 220 extending from the main body 200 to a distal end 222 at a top of the power terminal 104. At least a portion of the shank 220 includes threads 224 along the exterior thereof. The upper stud 202 is configured to be threadably coupled with the threaded nut 106. The threaded nut 106 includes internal threads 226 threadably coupled to the threads 224 of the upper stud 202.
The lower stud 204 includes a shank 230 extending from the main body 200 to a distal end 232 at a bottom of the power terminal 104. At least a portion of the shank 230 includes threads 234 along the exterior thereof. The lower stud 204 is configured to be threadably coupled with the threaded nut 108. The threaded nut 108 includes internal threads 236 threadably coupled to the threads 234 of the lower stud 204. Optionally, the lower stud 204 has the same diameter as the upper stud 202. However, in alternative embodiments, the lower stud 204 may have a different diameter as the upper stud 202.
In an exemplary embodiment, the lower shroud walls 162 have heights that are greater than the height of the lower studs 204 such that the bottoms of the lower shroud walls 162 are located below the distal ends 232 of the lower studs 204. As such, the bottom of the terminal block 102 may be mounted to a mounting structure, such as the appliance without damaging the power terminals 104 and without interference from the lower studs 204. The windows 166 provide access to the lower studs 204, such as for electrical connection to the appliance wiring 14. Optionally, the lower chambers 164 may be open at the bottom 112 to allow loading of the ring terminals 36 onto the lower studs 204 from below the appliance power connector 100. For example, the appliance wiring 14 may be connected to the appliance power connector 100 prior to mounting the appliance power connector 100 to the mounting structure of the appliance 50. In an exemplary embodiment, multiple appliance line wires 30 and/or multiple appliance neutral wires 32 and/or multiple appliance ground wires 34 may be connected to the line terminal 104a, the neutral terminal 104b, and the ground terminal 104c, respectively. The threaded nuts 108 may be threadably coupled to the power terminals 104 to mechanically and electrically connect the ring terminals 36 to the power terminals 104.
In an exemplary embodiment, the upper shroud walls 152 have heights that may be greater than the height of the upper studs 202 such that the tops of the upper shroud walls 152 are located above the distal ends 222 of the upper studs 202. Alternatively, as in the illustrated embodiment, the upper shroud walls 152 have heights less than the height of the upper studs 202. The distal ends 222 of the upper studs 202 are located above the tops of the upper shroud walls 152. The windows 156 provide access to the upper studs 202, such as for electrical connection to the building wiring 12. Optionally, the upper chambers 154 may be open at the top 110 to allow loading of the ring terminals 26 onto the upper studs 202 from above the appliance power connector 100. The threaded nuts 106 may be threadably coupled to the power terminals 104 to mechanically and electrically connect the ring terminals 26 to the power terminals 104.
In use, the appliance wiring 14 (
After the appliance wiring 14 is connected to the appliance power connector 100, the appliance power connector 100 may be mounted to the appliance 50. After the appliance power connector 100 is mounted to the appliance 50, the building wiring 12 (
It is to be understood that the above description is intended to be illustrative, and not restrictive. For example, the above-described embodiments (and/or aspects thereof) may be used in combination with each other. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from its scope. Dimensions, types of materials, orientations of the various components, and the number and positions of the various components described herein are intended to define parameters of certain embodiments, and are by no means limiting and are merely exemplary embodiments. Many other embodiments and modifications within the spirit and scope of the claims will be apparent to those of skill in the art upon reviewing the above description. The scope of the invention should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. In the appended claims, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” Moreover, in the following claims, the terms “first,” “second,” and “third,” etc. are used merely as labels, and are not intended to impose numerical requirements on their objects. Further, the limitations of the following claims are not written in means-plus-function format and are not intended to be interpreted based on 35 U.S.C. § 112(f), unless and until such claim limitations expressly use the phrase “means for” followed by a statement of function void of further structure.
