Patent Grant
11843203
The field of the invention relates generally to a locking electrical outlet assembly to secure a plug and power cord connection thereto, and more specifically to a locking outlet assembly for electrical outlets operable interchangeably with a combination of different types of mating plug connectors in an industrial power distribution unit.
Computer data center applications typically include a plurality of computer servers arranged in server racks or cabinets. Power distribution units (PDUs) are known to include a number of power outlets distributed along a chassis of the PDU for respective connection to components and equipment arranged on the server rack. The respective PDUs receive input power from the same power source or different power sources, and distribute output power to the power outlets provided. Power cords of equipment in the server racks or cabinets may be plugged in to the PDU. State of the art PDUs also intelligently facilitate remote management of power distribution to critical equipment, power metering and monitoring features both local and remote from the PDU, on/off power outlet switching and local and remote controls, alarm features detecting and alerting of certain operating conditions, and other sophisticated features allowing adaptation of the PDU for particular power system applications distributing power to specific electrical components and equipment.
A variety of different types of plug connectors for power cords are known for use with different devices in the server rack or cabinet that are desirably served by industrial power distribution units. As such, PDUs including so-called combination outlets have recently been introduced wherein the same power outlets in the PDU may be interchangeably used with different types of power cord plug connectors in different arrangements. Conventional combination outlets for PDUs are disadvantaged in some aspects, however, and further improvements are desired to more completely meet the needs of the marketplace.
Non-limiting and non-exhaustive embodiments are described with reference to the following Figures, wherein like reference numerals refer to like parts throughout the various views unless otherwise specified.
In order to understand the inventive concepts described below to their fullest extent, set forth below is a discussion of the state of the art and certain longstanding problems pertaining to industrial power distribution units (PDUs), followed by descriptions of exemplary inventive embodiments of PDU devices, systems and methods addressing longstanding problems in the art.
In general, an industrial PDU typically includes an elongated chassis with a large number of power outlets (e.g., 36 outlets) arranged along an axial length of the chassis, in combination with sophisticated power monitoring and power management components. The PDU may define a portion of a rather complex redundant power system in certain applications. For example, in a data center application, two power input paths may connect to respective sets of main power panels, transfer switches, backup generators, power panels, Maintenance Bypass Panels (MBP), uninterruptible power supplies, and branch protection circuit breakers feeding electrical power to the respective PDUs that in turn feed electrical power to information technology (IT) equipment and achieve multiple and redundant power supply operation of the IT equipment via the PDUs provided.
Each PDU in the data center application may be provided with “intelligent” features such as power metering, power control, environmental sensing, etc. of the PDU in use. A management module, sometimes referred to as a network management module, is therefore typically provided in the PDU that includes a simple computer or controller in communication with a network interface to realize bi-directional communication with a remote computer or computing network for purposes of monitoring and managing the power system in the data center. A number of different communication ports may be provided in a network interface including a Universal Serial Bus (USB) port, an Ethernet port, Rs485 ports, and sensor ports that may in turn interface with compatible power cord cables and mating connectors in a known manner.
The management module in a conventional PDU may include a display that is local to the management module to show data and setup information at the PDU to the end user or installer, as well as responsible persons for overseeing the data center. The display in the management module may include a liquid crystal display (LCD) display screen, a light emitting diode (LED) display screen, and LCD/LED display screen, an organic light emitting diode (oLED) display screen, or another known type of display screen. The local display may be a single color display or multiple color display, may be provided with or without backlighting, and may be factory set to show critical power and setup information to the end user, installer or overseer as well as to display desired data and information after setup.
By virtue of the features described above, industrial PDUs are relatively large, sophisticated devices and therefore relatively expensive devices possessing vast functionality that so-called “power strip” devices cannot and will not provide. Power-strips are instead multi-outlet devices which, by design, are smaller, lighter, portable, and relatively inexpensive for powering non-critical electrical components for general business or residential use that do not require the power monitoring, power management, and data communication capabilities of an industrial PDU.
The various power outlets provided in a PDU may distribute electrical power from a common power supply input to a respective electrical component, electrical device, electrical appliance or electrical equipment via removable power cords. Each power cord has a plug connector on one end that interfaces with one of the outlets on the PDU and a second end that connects to the electrical device, electrical appliance or electrical equipment. Such PDUs and power cords are prolifically used for respective power connection to IT components and equipment arranged on the server rack in a computer data center.
A number of different types of plug connectors exist for power cords in the computer data center equipment realm. The plug connectors typically include terminals located inside an open-ended housing that may in turn be received over an outlet in a PDU in a safe and effective manner. The terminals of the plug connector pass through apertures in the outlet of the PDU and are received in mating terminals of the outlet to establish the desired electrical connection to the PDU while the housing of the plug connector extends over and receives the exterior surface of the PDU outlet. As such, conventional plug connectors and PDU outlets each have mating housing features and mating terminal features.
In contrast to a PDU, a conventional power strip device is designed for use with a standard plug having terminals projecting from an exterior of the plug housing that are mated with plug-in connection to internal terminals of an outlet, without positive engagement of the plug connector housing to any housing feature of the socket. The outlets in the power strip receive the terminals of a plug but the plug connector housing itself is not received in the outlets to establish the desired electrical connection. The power strip device that is generally designed for residential or business use is designed to operate with respect to standard plugs having standard terminals that are in turn universally used with a standard wall outlet in a modern residence or commercial building.
For instance, in the United States the standard wall outlet is a NEMA 5-15R, 15A outlet. The standard plug in the United States is either a NEMA 1-15P plug or a NEMA 5-15P plug. NEMA 1-15P and NEMA 5-15P plugs each include parallel and straight terminal blades, while the NEMA 5-15 plug further includes a terminal ground pin. The NEMA 1-15P and NEMA 5-15P plugs are commonly referred to in layman terms as a “two prong” plug or a “three prong” plug that are prolifically found in power cords and extension cords of a typical consumer electrical device or appliance. In general, any power cord including the standard plug can be plugged into the standard wall outlet and can alternatively be plugged in to the power strip device, whereas the plug connectors of certain types of data center equipment are entirely incompatible with the standard wall outlet due to the terminals being interior to the plug housing and due to interfering features of the plug connector housing and the standard wall outlet, and for the same reasons are incompatible with the standard outlets in a power strip device. From this perspective, and unlike the power strip device, the industrial PDU requires special purpose outlets rather than standard outlets in order to make the needed connections to IT equipment or other devices via power cords having special purpose plug connectors with incompatible housing and terminal features to the standard outlet design.
Different types of special purpose plug connectors are likewise known that include different plug connector housing shapes and different orientations of terminals inside the plug connector housing. Accordingly, different types of special outlets are known for PDUs that are specifically configured to connect to different types of special purpose connector plugs via compatible outlet shapes and terminal apertures with one of the different types of plug connectors available. Such different types of special purpose outlets have been used in conventional PDUs to connect with specific plug connector types in a one-to-one correlation. That is, each of the different types of special purpose outlets is generally configured to specifically connect to a different one of the particular and different types of plug connectors available. In other words, a plurality of different outlets have conventionally been provided in a PDU to correspondingly mate with different types of plug connectors, wherein a first type of outlet is provided to mate with a first type of plug connector, a second type of outlet is provided to mate with a second type of plug connector, etc.
Providing such different types of special purpose outlets in a conventional PDU to mate with different plug connector types is undesirable from the manufacturing perspective. Increasing the number of outlets in the PDU to provide a greater variety of power outlets having specific configuration to mate with power cords having different plug connector types requires a larger PDU and therefore increased material costs and assembly costs in the manufacturing of a PDU. While this may be acceptable to customers that can use the outlets provided in about the same number to that provided in the PDU, in other cases such a PDU would be a poor fit for a customer that has no need for some of the outlets provided in the PDU. A possible solution would be to offer a number of stock keeping units (SKUs) of PDUs having different numbers of outlets and different combinations of outlets to more specifically meet the specific needs of a given installation, but increasing SKUs complicates the supply chain and requires additional costs to maintain an adequate inventory of PDUs to meet the needs of different customers.
Alternatively, customized PDU manufacturing is possible to meet the needs of customers specifically. Such customization of PDUs is undesirable in some aspects from each of the manufacturer's perspective and customer perspective. While customization of PDUs can be accommodated with some appeal to certain customers, it increases manufacturing costs and corresponding purchase prices. Different PDUs having the various different types of power outlets in different numbers for individual installations also entails a relatively complicated order process and opportunity for human error and mistake in the ordering and in the execution of the order by the manufacturer. Manufacturing delay and delivery delay for customized PDUs may also result in uneven timing of orders and inefficiencies of manufacturing customized PDUs.
From the purchaser's perspective, customization of PDUs can nonetheless undesirably result in a sub-optimal number of outlets for connection to the specific types of plug connectors for a particular end use either because the purchaser miscalculated the number of desired outlets of each type that is actually needed or because the needs changed due to unanticipated changes in the components being connected to the PDU or to unexpected types of power cords provided or on hand to make the desired connections. Considering that the connected plugs and IT equipment receiving power from the PDU may change over time in a data center, an otherwise acceptable PDU at the time of initial purchase and installation could suddenly become obsolete as the need to connect to different types of plug connectors changes.
Recently, PDUs have been introduced that include so-called combination outlets that are designed to facilitate electrical connections to different types of special purpose plug connectors in the same outlet. That is, by virtue of such combination outlets, different types of plug connectors having different plug housings and/or different terminal configurations can be interchangeably connected to the same outlet. This provides desired flexibility to make connections to various different types of plug connectors in a smaller number of outlets to reduce the size and expense of a PDU while affording greater flexibility from the installation perspective. Known combination outlets, however, can nonetheless be impractical in some aspects, undesirably limited in some aspects, undesirably complicated and expensive to manufacture, and/or subject to certain reliability issues in use. Improvements are accordingly desired.
Practical, simple, reliable and more economically manufactured combination outlet assemblies and power distribution units including combination outlet assemblies are described hereinbelow that address the shortcomings above. Method aspects will be in part apparent and in part explicitly discussed from the following description. While combination outlet assemblies and industrial PDUs including the same are described in the exemplary context of power distribution in computer data centers and data center equipment including IT equipment, such description is exemplary only and the embodiments of the invention are not necessarily limited thereto. Rather, the benefits of the inventive embodiments of combination outlet assemblies and PDUs accrue more generally to any end use or application presenting similar problems and in which at least some of the same benefits may be realized via the inventive concepts described herein.
Referring now to
The combination outlet assembly 100 includes a housing 102 that in an exemplary embodiment is a single piece integrally formed housing including the features shown and described below. Specifically, in a contemplated embodiment the housing 102 may be formed and fabricated in a single piece construction via a molded, heavy duty plastic material. As compared to combination outlets including multiple piece housings that must be separately manufactured and subsequently assembled to one another, the single piece housing is advantageous from the manufacturing perspective to lower costs, while also avoiding reliability issues of separately fabricated housing parts detaching from one another in use and handling when attached to a PDU.
In the example embodiment shown the single piece housing 102 is defined by a pair of longitudinal side walls 104, 106 having respective first and second end edges, a pair of end walls 108, 110 extending orthogonally to the pair of longitudinal side walls 104, 106 and respectively interconnecting the first and second edges of the pair of longitudinal side walls 104, 106. A bottom wall 112 interconnects the pair of longitudinal side walls 104, 106 and the pair of end walls 108, 110. The side walls 104, 106, end walls 108, 110 and bottom wall 112 define a generally rectangular or box-like housing. As shown in
As shown in
As shown in
In the illustrated example, the dividing wall 118 is slightly off-centered in the lengthwise dimension L of the single piece integrally formed housing 102. That is, the dividing wall 118 is slightly closer to one of the pair of end walls 108, 110 than to the other as shown in the top view of
As shown in
In the example shown, the outer shape and profile of the first and second outlet cores 114, 116 further extend as mirror images of one another in the lengthwise dimension L. In other words, and as shown in top view in
As shown in
Unlike the space 134, the space 136 that surrounds the outlet core 116 does not match the outer shape and profile of the outlet core 116. While the outlet core 116 has six walls 120, 122, 124, 126, 128 and 130 as shown, the housing internal walls surrounding the outlet core 116 include only four walls defining a generally rounded rectangular shape. As such, the space 136 has an inner boundary corresponding to the outer perimeter of the walls 120, 122, 124, 126, 128 and 130 of the outlet core 116 and an outer boundary that is nearly square. The outer boundary of the space 136 is therefore both larger than the inner boundary and differently shaped from the inner boundary. The area of the space 136 on the bottom wall 112 of the housing is considerably larger than the area of the space 134 as shown.
The receptacle space 134 surrounding the first outlet core 114 is compatible with a first power cord 200 (
As shown in
The second plug connector housing 222 also includes three terminal blades 224, two of which extend in a generally coplanar relationship and third extending in a spaced apart but parallel plane to the other two of the terminal blades 224. As such, each of the terminal blades 224 of the plug connector housing 222 inside the plug connector housing 222 extend at a 90° angle relative to the terminals 204 of the plug connector housing 202 of the power cord 200 (
The three terminal blades 224 in the plug connector housing 222 correspond to a line terminal, a neutral terminal, and a ground terminal connecting to respective conductors in cable 226 of the power cord 220. The terminal and housing configuration of the power cord plug shown in
In the illustrated embodiments, the outlet cores 114, 116 are respectively provided with the same sets of terminals 150, 152, 154. It is recognized, however, that the sets of terminals need not be the same in the outlet cores 114, 116 in another embodiment. Specifically, the outlet core 114 may be provided with simpler shaped terminals than those shown in
It is also recognized that by virtue of the grooves 132 in each outlet core 114, 116, each of the outlet cores may also accept an IEC C16 plug that is similar to housing 202 of the power cord 200 and has similar terminals to the terminals 204, but further includes an internal protrusion that fits into the groove 132 in each outlet core. The outlet core 114 may therefore accept a CI6 plug and a C14 plug but reject a C20 plug, while the outlet core 116 may accept a C14 plug, a C16 plug and a C20 plug. As such, the outlet core 114 may accept two different types of plugs while the outlet core 116 may accept three different types of plugs. The combination outlet assembly including only two outlet cores 114, 116 may therefore accept six combinations of mating plugs of different types. While exemplary plug types are described and illustrated having different housing structure and/or different terminal structure, such plug types are exemplary only and alternative types of plugs having plug connector housings of alternative geometry are possible having the same or different terminal structure of the IEC plug connectors described above in further and/or alternative embodiments.
As shown in
While an exemplary location and geometry has been described and illustrated for the projections 170, 172 the projections may be located elsewhere and may have different geometry in another embodiment. Also, a greater or fewer number of projections of the same or different shape and geometry may be utilized for similar purposes to the projections 170, 172 and to realize the benefits thereof to varying degrees.
As shown in
A resilient spring element 184 (
A similar opening to the latch opening 182 is provided in the end wall 110 of the housing 102 in the example shown, but the end wall 110 in the illustrated embodiment does not include a deflectable latch portion to assist with locking and unlocking of a power cord. The end wall 110 can still interface with a lock protrusion of a power cord, but requires a lock protrusion in the power cord that can be selectively positioned relative to the power cord housing to secure and release the lock protrusion with the lock opening in the end wall 110. The deflectable and non-deflectable latch openings in the housing 102 on the end walls 108, 110 provides additional flexibility in the combination outlet assembly to be used with different types of latch protrusions on power cords.
Instead of providing different latching features on each side of the housing 102, in further embodiments both of the housing end walls 108, 110 may be provided with a deflectable latch portion or a non-deflectable latch opening if desired. While the deflectable and non-deflectable latch features are illustrated on the end walls 108, 110 of the housing, in another embodiment the deflectable latch portion and the non-deflectable latch opening could be located on the longitudinal side walls 104, 106. Of course, in some embodiments wherein latching of power cords is not desired or needed, the latch features described could be omitted in the housing construction.
The combination outlet assembly 100 further includes, as shown in
In the illustrated embodiment, the conductor bus element 190 is an asymmetrical J-shaped element having a long leg and a short leg extending parallel thereto and a perpendicular leg interconnecting ends of the long and short legs. The opposing ends of the conductor bus element 190 include sections of enlarged areas to complete mechanical and electrical connection to the terminals 154. The conductor bus element 192 in the example shown is a generally symmetrical element having opposing parallel legs offset from one another with an angled section in between, and out of plane tabs at the distal ends thereof for connection to the terminals 152. The conductor bus element 194 in the example shown is an asymmetrical element having an open rectangular shape with parallel distal ends for connection to the terminals 150. Each conductor bus element 190, 192, 194 also includes out of plane fastener tabs to fix the elements 190, 192, 194 in the desired orientation in the assembly and to complete electrical connection to corresponding bus structure in the chassis of a PDU. The conductor bus elements 190, 192, 194 and sets of terminals in each outlet core 114, 116 are mechanically and electrically connected to corresponding bus conductors in the PDU to complete respective line connections, neutral connections, and ground connections for power distribution to the power outlets provided in the PDU.
As best shown in
In certain contemplated embodiments, the conductor bus elements 190, 192, 194 may be omitted in favor of connecting wires to establish electrical connections to external circuitry through the terminals 150, 152, 154 or in favor of a circuit board including circuitry to which the terminals 150, 152, 154 may be connected in a PDU. Variations and adaptations are possible in this regard to make the electrical connections in the combination outlet assembly 100 to line, neutral and ground circuits in a power system whether through a PDU or as a stand-alone outlet device mounted to another support structure (e.g., a wall, a cabinet, or other support structure).
Also, in certain contemplated embodiments less than the three conductor bus elements 190, 192, 194 shown may be provided. For example, only two the conductor bus elements shown may be provided to respectively interconnect the neutral terminal and the ground terminal of each outlet core 114, 116, while the line connections may be made separately to each line terminal in the outlet cores 114, 116 to desirably facilitate switched outlet capability in the outlets provided. As such, and because the line terminals in each outlet core 114, 116 are not connected by a conductor bus in such an embodiment, they may be selectively turned on or off from via connection or disconnection to the same or different power inputs as desired. For example, the line terminals in each outlet core 114, 116 may be connected to a circuit board and controls to selectively energize or de-energize the outlets either independently or in combination in a known manner. Alternatively, switching elements may be provided that are not implemented through a circuit board if desired.
In the illustrated example wherein all three of the conductor bus elements 190, 192, 194 are provided, however, the outlets are connected to the same power input and desired power metering is facilitated in a simpler manner at reduced cost albeit with more basic functionality than the aforementioned switched power arrangement involving only two of the three conductor bus elements described.
As shown in
Groups of three ganged combination outlet assemblies 100 are shown in
The six groups of three combination outlets 100 in the PDU 300 shown in
The management module 306 in the PDU 300 may include a display presenting power information and setup information to a PDU installer or data center overseer. The PDU 300 may include switches, sensors and other components to provide desired power management and metering functionality that can be accessed locally on the PDU via the management module 306 or communicated to or made accessible from the network interface 308. While the PDU shows an exemplary arrangement of outlets via the combination outlet assemblies 100 provided relative to the management module 308, other arrangements are possible in another embodiment. Also, while the PDU includes only combination outlets via the combination outlet assembly 100, still other types of outlets could be provided in addition to the combination outlets in the combination outlet assembly 100. Varying numbers of combination outlet assemblies 100 may be provided in different embodiments.
The combination outlet assembly 100 including the single piece housing 102 including the features described avoids more complicated multi-piece housing components to provide a combination outlet. Specifically, separately provided adapter pieces fitted to the outlet cores to configure them to accept or reject certain types of plug connectors are obviated by the single piece construction described and illustrated herein. As such adapter pieces are eliminated, any possibility for them to be lost or mislaid, or inadvertently broken or detached is avoided together with reliability issues or negative experiences by purchasers and installers who are frustrated by such issues.
The combination outlet assembly 100 including single piece housings 102 can provided in a modular form and easily be ganged together to scale a PDU to have as many combination outlets desired in an economical manner that generally avoids customization including custom fabricated housings and the like to provide different numbers of power outlets. Considerable variation in PDUs is therefore possible while using a small number of component parts to provide the combination outlet assembly 100. Of course, while the single piece housing 102 in the combination outlet described has considerable benefits, in alternative embodiments the housing 102 may be fabricated from more than one housing piece if desired while still realizing some of the other benefits described. Additionally, combination outlets having more than two outlets are possible in alternative embodiments having single piece or multi-piece housing constructions. Variations and adaptations are possible in this regard.
The latch or locking assembly 400 includes a receptacle insert 404 and a power cord clamp 406. The insert 404 includes a planar rim 408 having a center opening therein with complementary shape to the outer shape and profile of the outlet cores 114, 116 in the combination outlet assembly 100. As such, the rim 408 may be inserted into the receptacle space 134 or 136 and be fitted around the outlet core 114 or 116 adjacent the bottom wall 112. The rim 408 may abut the protrusions 170, 172 in the bottom wall 112 of the housing 102 and therefore be gripped and retained in place in the housing 102 once installed.
A thin and rectangular locking tab 410 extends upwardly and generally perpendicularly from the rim 408, and the locking tab 410 includes a lock protrusion 412 that may be received in the lock opening of the housing end wall 108 or 110 described above. The thin locking tab 410 extends along the interior wall of the outlet core 114 or 116 without obstructing a power cord plug connector in the receptacle space 134 or 136. An elongated tether element 414 extends upwardly from the locking tab 410 and exterior to the receptacle space 134, 136. The tether element 414 includes a series of latch grooves 416 that may be gripped in an interlocking fashion to the power cord clamp 406.
As shown in
In use, with the latch element 422 of the clamp 406 engaged to the tether element 414 and with a portion of the power cord 402 in the clamp opening 428 the distal end of the power cord grip 426 can be deflected and received in the latch housing 432 by a desired amount to engage the tooth 436 of the finger tab 438 to one of the teeth 430 on the power cord grip 426. As the power cord grip 426 is deflected, the opening 428 is decreased and clamps the portion of the power cord 402 therein. If desired the distal end of the power cord grip 426 can be passed entirely though the latch housing 432 via an opening 434 to restrict the opening 428 even further. The opening 434 can be adjusted in size as needed to be clamped around a portion of the power cord plug housing or around a portion of the power cord cable. The locking insert 404 and the clamp 406 when engaged therefore provide positive locking of a power cord that does not include a lock protrusion while still preventing the power cord from dislodging.
When desired, the finger tab 438 of the clamp 406 can be used to deflect the locking tooth 436 outwardly in order to release the distal end of the power cord grip 426 to enlarge the opening 428 to the degree required to remove the power cord 402. The power cord 402 can therefore be removed while the power cord clamp 406 remains attached to the tether element 414 of the insert 404 and while the insert 404 remains in place in the housing 102. The adjustable power cord clamp 406 can be universally used with power cord having plugs of different types. While exemplary shapes and geometries of locking insert 404 and power cord grip 426 are shown and described, alternative geometry could be utilized in other embodiments to realize otherwise similar locking features. The insert 404 and clamp 406 may be fabricated from plastic materials in contemplated embodiments at relatively low cost. The insert 404 and clamp 406 provide event further flexibility to the combination outlet assembly 100 to be used with power cords having integral locking features and power cords without integral locking features while ensuring that connections to the power outlets are reliably secured maintained.
While the latch or locking assembly 400 with the receptacle insert 404 and power cord clamp 406 is described in combination with the combination outlet assembly 100, it is recognized that that latch or locking assembly 400 does not require the combination outlet assembly 100 and instead can be used apart from the combination outlet assembly 100 if desired. As such, the latch or locking assembly 400 may be used with power outlets other than those specifically described herein, whether or not configured as combination outlets that may be interchangeably connected to different power cords having different plug connector types. The rim 408 of the insert can be shaped to complement alternative outlet shapes to the outlet cores 114, 116 and different versions of inserts having different rims 408 can be provided to provide similar locking benefits to various different types of outlets to provide power cord locking features to power cord features that do not have integral locking features.
The power cord locking assembly 520 includes a pair of buttons 522a, 522b that are independently operable with respect to each outlet core 114, 116 to lock or unlock respective power cords 200 and 220 to the electrical outlet assembly 500 as shown in
In the example shown, the buttons 522a, 522b are held to the housing 502 via a locking collar 524 that is attached to the upper surface of the housing 502. The locking collar 524 spans the length dimension of the housing 502 and therefore spans each of the buttons 522a, 522b and locates them adjacent each outlet core 114, 116 in a spaced apart but side-by-side relation along the length dimension L (
The buttons 522a, 522b project from the upper surface of the housing 502 and through the locking collar 524, and may be depressed with a person's finger (or perhaps with a tool) to operate the locking and unlocking operation of the assembly 520 for the respective power cords 200 or 220. The example shown includes a concave finger cradle at the top of each button 522a, 522b for convenient engagement by a person's finger, although the finger cradle may be considered optional in some embodiments and need not be provided.
Each button 522a, 522b is biased by a coil spring 526a, 526b (
As best shown in
The front side of the actuating sections 532a, 532b in each button 522a, 522b is further shown with a cylindrical extension in its outer surface which accommodates the respective bias springs 526a, 526b on the interior of the actuating sections 532, 532b. Such cylindrical extensions are needed because of the reduced width of the actuating sections 532a, 532b but in another embodiment could be considered optional in another embodiment where the width of the actuating sections 532a, 532b was increased or in another embodiment with a different orientation of the bias springs 526a, 526b or other alternative biasing features.
The base sections 530a, 530b of each button 522a, 522b extend interior to the housing 502 beneath the locking collar 524 and each base section 530a, 530b includes a generally flat and planar engagement surface 534a, 534b extending parallel to the plug insertion axis A. The flat and planar engagement surface 534a, 534b of each button frictionally engages and secures an abutting flat and planar surface of a mated plug connector housing over a relatively large area on the side of each outlet core 114, 116. In the view of
In contemplated embodiments, the flat and planar engagement surfaces 534a, 534b may optionally include a surface treatment to increase the frictional grip of the engagement surfaces 534a, 534b in use. Such surface treatment may include, as non-limiting examples, a roughened surface, a coating, or an adhesively bonded material familiar to those in the art to further enhance the grip of the engagement surfaces 534a, 534b when engaged to a power cord plug connector.
The actuating section 532a, 532b of each button 522a, 522b extends above the locking collar 524 and above the housing 502. As such, the actuating sections 532a, 532b are accessible from above to manually displace the base section 530a, 530b and the associated engagement surfaces 534a, 534b to the unlocked position when needed. In the unlocked position, the engagement surface 534a or 534b in each button is disengaged from the mated plug connector housing so that it may be easily removed in an unobstructed manner. Disengagement of the engagement surface 534a or 534b defeats the frictional grip of the buttons 522a or 522b such that removal of the plug connector housings will no longer be opposed.
Each of the buttons 522a, 522b in the example shown also include a pair of sloped guide ledges 536a and 536b with each guide ledge respectively projecting from each opposing lateral side of the base section 530a, 530b. The sloped guide ledges 536a, 536b extend as elongated, linear elements that are angled obliquely with respect to a plug insertion axis A (
While an exemplary shape and geometry of the buttons 522a, 522b is shown and described, variations are of course possible while realizing similar benefits and effects in the operation of the locking assembly 520.
The housing 502 is formed with dual pairs of lower sloped guide surfaces 540a, 540b, 540c, 540d extending at the same angle relative to the plug insertion axis A as the sloped guide ledges 536a, 536b of the buttons 522a, 522b. The locking collar 524 is likewise formed with dual pairs of upper sloped guide surfaces 550a, 550b, 550c, 550d (only two of which are visible in
The sloped guide ledges 536a, 536b of the buttons 522a, 522b are fitted between the upper and lower sloped guide surfaces in the assembly as best seen in the sectional view of
When the buttons 522a, 522b are supported on the sloped guide edges 536a, 536b in the assembly any depressing of the buttons 522a, 522b toward the housing 502 imparts both vertical and horizontal motion of the buttons 522a, 522b relative to the housing 502 and the locking collar 524. As the buttons 522a, 522b ascend vertically on the sloped guide surfaces they also move laterally toward the outlet cores 114 or 116, and as the buttons 522a, 522b descend on the sloped guide surfaces they also move laterally away from the outlet cores 114 or 116.
In between the fully extended and fully retracted position shown in
When desired, the buttons 522a, 522b can be depressed to move them to unlocked positions where the engagement surfaces 534a, 534b are disengaged from the plug connector housings so that they can be freely removed. Depending on which type of plug connector housing is being used, the buttons 522a, 522b may or may not need to be fully retracted to reach the unlocked positions where the plug connector housings are be released. For certain types of plug connector housings, the insertion of the plug connector housing may retract the button associated with an outlet core until it clears the plug connector housing, and thereafter the spring-loaded button will automatically assume the locked position because the bias of the spring will always urge the engagement surfaces 534a, 534b to move to a locked position engaging the mated plug connector housing. It is understood, however, that the buttons 522a, 522b may be depressed by a user prior to inserting the plug connector housings and thereafter released by the user once the plug connector housings are engaged.
The buttons 522a, 522b and the locking collar 524 may be fabricated economically from suitable plastic materials known in the art and rather easily assembled in the power cord locking assembly 520 with a high degree of reliability. The power cord locking assembly 520 does not depend on integral locking features such as locking protrusions in the power cords to operate, and does not require lock openings that are to be engaged and disengaged. Further, the power cord locking assembly 520 does not require hardened materials that bite into the surface of a plug connector housing and are simpler and easier to use and re-use in a more or less universal manner with plug connector housings of many types. The operation of the power cord locking assembly 520 is also intuitive and user-friendly relative to other types of locks and latches in the art that are less intuitive and may therefore require some inspection and trial and error to decipher how to properly engage and disengage them.
The electrical outlet assemblies 500 may be used in lieu of the combination outlet assemblies 100 in a PDU assembly to realize significant benefits when assembled to one another using the ganging features included and when fastened to a chassis of a PDU as shown as described in relation to
The benefits of the inventive concepts herein are now believed to have been amply illustrated in relation to the exemplary embodiments disclosed.
An embodiment of an electrical outlet assembly has been disclosed including a housing having a bottom wall and an upper surface. At least one outlet core projects from the bottom wall and is accessible from the upper surface for mating connection with a power cord including a plug connector housing. A plurality of terminals are accessible through a plurality of apertures in the at least one outlet core for mating engagement with respective terminals of the plug connector housing when the plug connector housing is mated to the outlet core along a plug insertion axis extending perpendicular to the bottom wall. A power cord locking assembly includes at least one button projecting from the upper surface of the housing alongside the at least one outlet core, wherein the at least one button is selectively positionable relative to the housing between a locked position and an unlocked position in a direction obliquely oriented to the plug insertion axis. The locked position engages and secures the plug connector housing in the mated position on the outlet core, and the unlocked position disengages from the plug connector housing for removal of the mated plug connector housing from the at least one outlet core.
Optionally, the at least one button may include a planar engagement surface oriented parallel to the plug insertion axis, the planar engagement surface frictionally engaging and retaining an abutting planar surface of the plug connector housing in the locked position. A coil spring may bias the at least one button toward the locked position. The housing may define a first sloped guide surface, wherein a portion of the at least one button is slidably movable upon the first sloped guide surface between the locked position and the unlocked position. A locking collar may be attached to the upper surface of the housing, and the locking collar may define a second sloped guide surface extending parallel to but spaced from the first sloped guide surface. The at least one button may include a body and at least one sloped guide ledge projecting from the body, with the sloped guide ledge being fitted between the first and second sloped guide surfaces and being constrained to slidably move along a predetermined guide path defined by the first and second sloped guide surfaces. The predetermined guide path may be a linear guide path.
Also optionally, a locking collar may span a portion of the upper surface, and the at least one button may protrude from the locking collar. The locking collar may define a guide surface constraining movement of the button along a predetermined guide path, which may be a linear guide path. The at least one button may assume different locking positions engaging different types of plug connectors. The at least one button may include a base section having a first width and an actuating section having a second width less than the first width, the base section engaging and securing the mated plug connector housing in the locked position and the actuating section being manually displaceable to move the base section to the unlocked position.
The at least one outlet core may optionally include a first outlet core and a second outlet core, and the at least one button may include a first button operable with respect to the first outlet core and a second button operable with respect to the second outlet core, and the power cord locking assembly further including a locking collar spanning each of the first button and the second button. The first and second buttons may be independently operable from one another. The housing may include a pair of longitudinal side walls having respective first and second ends and a pair of end walls extending orthogonally to the pair of longitudinal side walls, the longitudinal side walls respectively interconnecting the first and second ends of the pair of longitudinal side walls, and wherein the first and second buttons extend side-by-side adjacent one of the longitudinal side walls of the housing. The first and second outlet cores respectively may have a similar outer shape and profile but differently shaped sets of three terminal apertures, and the electrical outlet assembly may include three terminals associated with each respective set of three terminal apertures in the first outlet core and the second outlet core. The housing may also include a dividing wall extending between the first and second outlet cores, with the dividing wall being off-centered in the housing. An outer shape and profile of the first and second outlet cores may respectively extend as mirror images of one another on opposing sides of the dividing wall, and wherein the first outlet core is misaligned with the second outlet core.
As still further options, a respective space may surround each of the first and second outlet core in the housing, with the respective space that surrounds the first outlet core being shaped to complement the outer shape and profile and the respective space that surrounds the second outlet core being shaped to mismatch the outer shape and profile. The respective space surrounding the first outlet core may accept a first housing of a first plug connector type but may reject a second housing of a second plug connector type, wherein the second housing of the second plug connector type is differently shaped from the first housing of the first plug connector type, and wherein the respective space surrounding the second outlet core accepts the first housing of the first connector type and also accepts the second housing of the second connector type. The first plug connector type may include three terminal blades extending at a common first angular orientation inside the first housing, and wherein the second plug connector type includes three terminal blades extending at a second angular orientation that is 90° from the first angular orientation. The shaped sets of three terminal apertures of the second outlet core may accept each of the three terminal blades of the first plug connector type and also may accept each of the three terminal blades of the second plug connector type.
The electrical outlet assembly may be provided in combination with a power distribution unit having a chassis and a management module, with the electrical outlet assembly being fastened to the chassis. A plurality of electrical outlet assemblies may be ganged side-by-side in the power distribution unit. Each of the ganged outlet assemblies may accept six combinations of mating plugs of different types.
This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.
This application is a continuation-in-part application of U.S. application Ser. No. 17/070,336 filed Oct. 14, 2020, the complete disclosure of which is hereby incorporated by reference in its entirety.
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| Number | Date | Country | |
|---|---|---|---|
| 20220115823 A1 | Apr 2022 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 17070336 | Oct 2020 | US |
| Child | 17499309 | US |
