The present subject matter relates to systems and apparatuses for distributing electric power, and more particularly, for distributing electric power from a single source to multiple remote locations.
In some items, such as cabinets for use in, for example, kitchens or the like, or in furniture or other items there may be a need to provide electric power to one or more devices, such as lighting, located in the item. At times, the item containing the device(s) may be located remotely from a source of electric power. Thus, for example, a plurality of kitchen cabinets may be located near to or adjacent to one another and a driver circuit disposed in or adjacent one of the cabinets develops low voltage DC power from 110 volt AC utility power for LED lights and/or other low voltage electric loads in the cabinets. Some provision must be made in such an arrangement to deliver the low voltage power to the LED lights and/or other loads in the cabinets from the driver circuit.
In prior arrangements such as the foregoing, there was often a need to run separate wires between the driver circuit and the individual loads or groups of loads to prevent voltage drops occurring in one load or group of loads from adversely affecting the operation of other loads or load groups. Thus, the installer had to measure, cut, strip, mount, and interconnect multiple wires between the driver circuit and the loads, resulting in an unsightly and labor-intensive installation that was costly.
Kitchen and other cabinet manufacturers are currently looking to integrate low voltage wiring systems into their cabinets to facilitate LED lighting and other applicable low voltage power accessories. The intent is that the wiring or bussing system will be installed by the factory eliminating the need for custom installations by the consumer. However, two problems arise in such an arrangement. First, due to the geometry of standard cabinetry, the wiring system needs to be fitted with connectors within each cabinet and between adjacent cabinets after cabinet installation. Also, due to the nature of low voltage DC wiring, the voltage drop across long lines of wire needs to be minimized; otherwise, the LED drivers powering the lights cannot function. This places a limit on the overall length of the wiring system.
According to one aspect, an electric power distribution module comprises a housing enclosing an interconnection member, a first main connector formed in the housing having a first plurality of module contacts, and a second main connector formed in the housing having a second plurality of module contacts. The first main connector and the second main connector are configured to connect to electrical conductors to receive an electrical current from a power source. The interconnection member includes a plurality of conductive paths, where at least two conductive paths are in electrical connection with at least two of the first plurality of module contacts and at least two of the second plurality of module contacts. The electric power distribution module includes at least one output port comprising a pair of output port contacts electrically connected to the at least two conductive paths in electrical connection with the module contacts on the first main connector and the second main connector.
According to another aspect an electric power distribution system includes a driver circuit configured to provide a DC power, a first electric power distribution module, and a second electric power distribution module. The first electric power distribution module is configured to receive the DC power from the driver circuit. The first electric power distribution module includes a first main connector in electrical connection with a second main connector via a plurality of conductive paths between at least a pair of module contacts on the first main connector and at least a pair of module contacts on the second main connector. The first main connector and the second main connector are configured to connect electrically to either the driver circuit or a second electric power distribution module. The first electric power distribution module further includes at least one output port on the first electric power distribution module electrically connected with one of the at least one pair of conductive paths between the first main connector and the second main connector to provide power to a load in electrical connection with the at least one output port.
Other aspects and advantages will become apparent upon consideration of the following detailed description and the attached drawings wherein like numerals designate like structures throughout the specification.
Referring first to
In a general sense, the modules may be located in different locations or at the same location and in or adjacent different items or structures or the same item or structure. Further, only one module, or more than two modules, may be utilized to distribute electric power developed by the driver circuit 26 and/or another source of power (not shown). In a specific embodiment, the first module 20 is disposed in a first cabinet 30, the second module 22 is disposed in a second cabinet 32, the loads 28 comprise first and second groups or strings 28a, 28b of LEDs, the driver circuit 26 is coupled to the first module 20, and power delivered to the first module 20 by the driver circuit 26 is transferred to the second module 22 by the conductor 24. The electric power delivered to the modules 20, 22 is, in turn transferred by the modules 20, 22 to the strings of LEDs 28a, 28b, respectively.
The module 20 will be described in detail as including elements identified by hyphenated reference numerals in conjunction with the main reference numeral 20, it being understood that the module 22 includes like elements. Because the modules 20, 22 are substantially identical to one another only the module 20 will be described herein.
As illustrated in
In an example implementation as shown in
In an example implementation as shown in
In the illustrated example implementation as shown in
The illustrations depict example individual stamped cable socket contacts 66 (
Of course, a cable 40 is not required inasmuch as the standardized male and female connectors can be directly connected together, if increased power distribution capacity is required or desirable.
The use of standardized male and female connectors standardizes interconnection of the various elements of the power distribution system and reduces the required part count and inventory for an installer to keep on hand. Specifically, the installer need only maintain stocks of modules and various lengths of cables (preferably only standardized lengths thereof).
Referring next to
In like fashion, as seen in
If desired, the PCB 46 can be replaced by any other suitable interconnection member or members, such as discrete wires, or a combination of wires and one or more PCBs.
Referring next to
The bottom side 20-7 of the housing 20-1 may further include one or more input ports, such as input ports 70e, 72e, and 74c. Each input port 70e, 72e, 74c, for example the input port 72e, includes two connection pins 100, 102 disposed adjacent a support platform 104. Each input port 70e, 72e, 74c is shaped to receive a suitable mating connector 110 having female receptacles adapted to receive the connection pins 100, 102. The female receptacles of the mating connector 110 are coupled electrically to a power source that supplies power, such as a driver circuit.
The connection pins of the ports 70a-70e, 72a-72e, and 74a-74c are electrically interconnected to the traces 48a, 48b to permit electrical interconnection between the main connectors 20-2 and 20-3 and the ports 70, 72, and 74. Specifically, power may be supplied through either of the main connectors 20-2 or 20-3 to the output ports 70a-70d, and/or to the output ports 72a-72d, and/or to the output ports 74a and/or 74b. Also, power may be transferred in either direction between the main connectors 20-2 and 20-3, or between either or both of the main connectors 20-2 and 20-3 and one or more of the input ports 70e, 72e, and/or 74c. Still further, power may be transferred from one or more of the input ports 70e, 72e, and/or 74c to one or more of the output ports 70a-70d, 72a-72d, and 74a and/or 74b.
In summary, a power distribution module provides low resistance stamped contacts that are designed such that, in a specific embodiment, the contact makes electrical connection with a PCB via a standard solder through hole. The contact design utilizes a special stamped shape/geometry that employs a precise mechanical interference to establish two distinct points of contact at the barbs 58, 60 that generate a consistent amount of contact pressure that is tolerant of connector misalignment, thereby contributing to minimization of overall resistance of the power distribution system. The electrical contact points are made on the edges 62, 64 of the stamped contacts. The housing 20-1 provides electrical spacing sufficient for the application and also provides a touch-safe design based on UL 2238 requirements.
Also, to prevent a connector from being inserted incorrectly, the connector has keying features that interact with the mating connector such that the connector can only be plugged in one way. This makes it impossible for installers to mis-wire the system.
In addition, the contact design will incorporate a wire termination section that will accommodate ultra-sonic welding for further, least-resistance type of wire termination(s).
Furthermore, this disclosure contemplates embodiments having alternative loads other than groups or strings of LEDs. The electric power distribution system and the electric power distribution module(s) 20, 22 may provide power to can openers, mobile device chargers, audio equipment, fans, other kitchen appliances, other low voltage applications, or any combination of the aforementioned loads.
All references, including publications, patent applications, and patents, cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.
The use of the terms “a” and “an” and “the” and similar references in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the disclosure and does not pose a limitation on the scope of the disclosure unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the disclosure.
Numerous modifications to the present disclosure will be apparent to those skilled in the art in view of the foregoing description. It should be understood that the illustrated embodiments are exemplary only, and should not be taken as limiting the scope of the disclosure.
This application claims the benefit of U.S. Provisional Patent Application Ser. No. 62/506,611, “ELECTRIC POWER DISTRIBUTION MODULE AND SYSTEM,” filed May 16, 2017, the entire contents of which are hereby incorporated by reference.
Number | Date | Country | |
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62506611 | May 2017 | US |