FIELD OF THE INVENTION
The present invention relates to electrical power systems for use in work areas and, more particularly, to electrical terminals for use in modular electrical systems.
BACKGROUND OF THE INVENTION
Modular electrical power systems are typically used in office areas and other work areas or places where access to electrical power is desirable, and particularly in flexible areas that are designed to be reconfigurable to suit changing needs, such as with movable partition walls and other furnishings. In some cases, it is desirable to set up electrical power systems in exposed locations, such as along floors or walls, in which case it may be particularly desirable to use electrical conduits and connectors that have very low overall thickness, especially when used in walking areas.
SUMMARY OF THE INVENTION
The present invention provides a low profile electrical terminal assembly, such as for use in a junction of a modular electrical system, in which a plurality of electrical terminals are arranged in generally the same plane (i.e., arranged between two substantially parallel planes that are in close proximity), and that permit the establishment of electrical connections. The low profile electrical terminal assembly is particularly well adapted for routing power in different directions from a junction point in a modular electrical system, and has a very thin or minimally intrusive thickness. The assembly includes at least two conductive main bodies that are stacked one on top of the other at close spacing, optionally with an insulating body disposed in between. Each conductive body has respective conductor arms or branches that radiate or extend outwardly from a central main body region, and the arms or branches terminate with respective electrical terminals located outboard of the main body. The branches or arms of at least one conductive body are bent or otherwise formed to position the electrical terminals along a different plane than that of the associated main body. This permits the electrical terminals of each main body to lie in a common plane, while the corresponding main bodies are stacked in different (typically parallel) planes. To avoid inadvertent contact between the arms or branches of one main body, and the arms or branches of another main body, the branches of one body are laterally offset from the branches of the other body or bodies so that, when viewed from above or in plan view, the conductor arms or branches do not overly one another. This arrangement allows for the close-proximity stacking of two or more conductive main bodies, but with the respective electrical terminals all located substantially within the same plane as one another so that the overall thickness of the assembly is minimized.
According to one form of the present invention, an electrical terminal assembly is provided for use in a low profile electrical raceway or the like. The assembly includes first and second conductive bodies, each having at least two electrical terminals extending outwardly therefrom, at the ends of respective conductor arms or branches. The first conductive main body is located in a first plane, with the conductor branches or arms radiating outwardly, and with the respective electrical terminals at the ends of the branches or arms positioned in a terminal plane. The second conductive main body is located in a second plane, spaced below the first plane, and its conductor arms or branches extend substantially radially outwardly so that the respective electrical terminals associated with the second main body are positioned in the same terminal plane as the terminals of the first main body. One of the electrical terminals of the first main body is positioned adjacent a first of the electrical terminals of the second main body, while a second of the electrical terminals of the first main body is positioned adjacent a second of the electrical terminals of the second main body. Optionally, an electrically insulative body is disposed between the first and second main bodies.
In one aspect, the terminal plane is non-coplanar with at least one of the first and second planes of the first and second conductive main bodies.
In another aspect, the electrical terminals at the ends of the conductor arms are female terminals. Optionally, the female terminals are configured to receive male blade terminals or bus bars.
In still another aspect, a third conductive main body is located in a third plane, which is spaced below the second plane of the second conductive main body. The third conductive main body has at least two conductor arms or branches extending radially outwardly therefrom, with respective electrical terminals at the ends of the arms, and the terminals located in the same terminal plane as the electrical terminals of the first and second main bodies. Optionally, an insulative body is positioned between the second and third main bodies.
Thus, the low profile electrical terminal assembly of the present invention allows for close stacking of electrical conductors having different polarities, with conductor arms or branches extending radially outwardly and having respective electrical terminals that are located in a common terminal plane, such as for engaging respective conductors of a corresponding electrical connector. This permits the construction and assembly of low profile electrical raceways and junctions for routing power in different directions throughout a work area or the like, and may even permit the installation of low profile electrical raceways along a floor surface that includes walking areas.
These and other objects, advantages, purposes and features of the present invention will become apparent upon review of the following specification in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top perspective view of a low profile electrical terminal assembly in accordance with the present invention;
FIG. 2 is a top perspective view of the an electrical raceway and raceway junction incorporating the low profile electrical terminal assembly of FIG. 1, with an upper portion of the junction cut away to show part of the electrical terminal assembly;
FIG. 3 is an exploded perspective view of the electrical terminal assembly of FIG. 1;
FIG. 4 is a side elevation of the three conductive bodies of the electrical terminal assembly of FIG. 1, shown in a vertically spaced arrangement;
FIG. 5 is another side elevation of the conductive bodies of FIG. 4, shown in their assembled configuration;
FIG. 6 is a top perspective view of the middle conductive body of FIGS. 4 and 5, shown overlying a lower insulator piece, and with an upper insulator piece spaced above and being lowered onto the middle conductive body for attachment to the lower insulator piece;
FIG. 7 is a top perspective view of the low profile raceway and raceway junction of FIG. 2; and
FIGS. 8A and 8B are side sectional elevations of the raceway junction of FIG. 7, and depicting the insertion of a male plug connector into the respective electrical terminals of the electrical terminal assembly.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings and the illustrative embodiments depicted therein, a low profile electrical terminal assembly 10 is configured for mounting in a raceway junction 12, such as shown in FIGS. 1, 2 and 7-8B. Raceway junction 12 receives or conveys electrical power from electrical conductors 14 that are routed through a raceway 16, which is coupled to raceway junction 12. In the illustrative embodiment of FIGS. 2 and 7, raceway junction 12 includes three electrical receptacles 18 corresponding to three sets of electrical terminals of electrical terminal assembly 10, as will be described below. The configuration of low profile electrical terminal assembly 10 permits two or more conductive bodies to be positioned in a thinly stacked arrangement, which facilitates a thin or low profile construction for raceway junction 12, which may be used to route electrical power in different directions and to different locations within a region such as work area.
In the illustrated embodiment, low profile electrical terminal assembly 10 includes three electrically conductive bodies or elements including a “hot” or line body 20, a ground body 22, and a neutral body 24, such as shown in FIGS. 3 and 4. Each electrically conductive body 20, 22, 24 has a respective main or central body portion 20a, 22a, 24a and also three conductor arms or branches 20b, 22b, 24b, that radiate or extend outwardly from the respective central body portions 20a, 22a, 24a. In addition, each of the conductor bodies includes a respective crimp terminal 20c, 22c, 24c for engaging a respective one of the electrical conductors 14. Each arm or branch 20b, 22b, 24b has an electrical terminal 26 at its distal end. In the illustrated embodiment, electrical terminals 26 are each configured to establish six or more points of contact with a male blade terminal, bus bar, or the like, such as described in commonly-owned U.S. patent application Ser. No. 15/054,708, filed Feb. 26, 2016, entitled ELECTRICAL CONTACT RECEPTACLE FOR BUS BARS AND BLADE TERMINALS, which is hereby incorporated herein by reference in its entirety. It will be appreciated that the precise style or configuration of electrical terminals may be varied according to the needs of a particular application, and is not necessarily limited to the style of electrical terminals 26 disclosed herein. However, the disclosed electrical terminals 26 are capable of establishing significant contact surface area with a blade terminal or the like, and thus are suitable for low profile applications such as described herein.
In the illustrated embodiment, each main or central body portion 20a, 22a, 24a is generally square in shape when viewed from above, and defines a central opening 27, such as for material and weight savings. Line body 20 has its arms or branches 20b extending off of three sides of the generally square main body portion 20a, each branch being generally arranged as an extension of a respective leg forming the square main body portion 20a. Similarly, crimp terminal 20c extends radially outwardly off of a fourth side of main body portion 20a. The neutral body's arms or branches 22b extend radially outwardly from respective sides of the generally square main body portion 22a, but branches 22b extend outwardly from a middle or central region of each leg of the square main body portion 22a. For purposes of the present application, it will be appreciated that the term “radially” is used to refer to any outwardly-extending direction.
Similarly to branches 22b, crimped terminal 22c extends radially outwardly from the central region of the fourth side of the square main body portion 22a. The neutral body's arms or branches 24b are arranged similarly to those of line body 20, except that arms 24b are extensions of opposite legs of each side of the generally square main body portion 24a. It will be appreciated that line body 20, ground body 22, and neutral body 24 may each be unitarily formed from a single planar sheet of electrically conductive material in a stamping process such as a multi-stage stamping process in which the general plan shape is initially cut out, followed by bending or stamping operations in which the final shapes of the branches 20b, 22b, 24b are formed, along with the forming of crimped terminals 20c, 22c, 24c and electrical terminals 26.
With this arrangement of branches for each conductive body, when the bodies are stacked together such as shown in FIG. 1, the neutral body's branches 24b are spaced well apart from the line body's branches 20b, with ground body's branches 22b positioned between branches 20b and branches 24b. Similarly, crimped terminal 22c is disposed between the crimped terminals 20c and 24c. The resulting electrical terminal assembly 10 permits branching in up to three different directions while providing electrical continuity for a line conductor 14a, a neutral conductor 14b, and a ground conductor 14c (FIGS. 1 and 7). However, it is envisioned that more or fewer directions of branching are possible by using different shapes or arrangements of branches. For example, triangular main bodies would readily accommodate branching in two directions, and pentagonal main bodies would readily accommodate branching in four directions.
Each main body portion 20a, 22a, 24a lies in a respective plane P1, P2, P3 so that main body portions 20a, 22a, 24a are sufficiently spaced apart in the region where the respective bodies 20, 22, 24 overlap or overlie one another, such as shown in FIG. 5. It will further be appreciated that the plane P3 in which neutral main body portion 24a lies is the same as a terminal plane P4 in which lower or base surfaces or portions of each terminal 26 lie. Thus, the terminal plane P4 is coplanar with the neutral main body portion 24a, which is spaced below the plane P2 of the ground main body portion 22a, which is spaced below the plane P1 of line main body portion 20a. In the illustrated embodiment, each terminal 26 also includes an upwardly-extending portion that extends above the base portion and, therefore, above terminal plane P4.
Each electrical terminal 26 has its base or bottom portion lying in terminal plane P4 due to the shapes of the corresponding arms or branches 20b, 22b, 24b, such as shown in FIG. 4. Because the neutral body's main body portion 24a is coplanar with terminal plane P4, neutral branches 24b need not change their elevation between neutral main body portion 24a and the corresponding electrical terminals 26. However, if clearance is needed for another component, such as in raceway junction 12, branch 24b may include an optional rise 28a, followed by an elevated region 28b (which may lie in the plane P2 of ground main body portion 22a), and a drop 28c back down to an end region 28d at the level of terminal plane P4 and the plane P3 of neutral main body portion 24a, such as shown in FIG. 4. Because ground main body portion 22a lies in plane P2 spaced above terminal plane P4, ground branches 22b include a drop 30a down to a lowered portion 30b that lies in terminal plane P4. Line main body portion 20a lies in the highest elevation plane P1 and, therefore, line branches 20b drop the furthest distance down to terminal plane P4. Line branches 20b include a first drop region 32a, followed by a first lowered region 32b, followed by a second drop region 32c, followed by a second lower region 32d that lies in terminal plane P4.
As will be apparent with reference to FIGS. 1 and 5, when electrical terminal assembly 10 is assembled, first lowered region 32b of line branch 20b lies in the same plane as ground body 22a and a proximal region of ground branch 22b, which also is the same plane in which elevated region 28b of neutral branch 24b lies, so that all of these regions generally lie in the same plane P2 as ground main body portion 22a. The branches associated with crimp terminals 20c, 22c, 24c may also be shaped in a similar manner as branches 20b, 22b, 24b, so that the distal ends (crimp portions) of crimp terminals 20c, 22c, 24c lie in the same plane as one another, such as terminal plane P4.
To ensure that line main body portion 20a does not contact or electrically arc with ground main body portion 22a, and to ensure that ground main body portion 22a does not contact or arc with neutral main body portion 24a, a pair of insulative bodies including a first insulator 34 and a second insulator 36 are positioned between the respective main body portions 20a, 22a, 24a. As best shown in FIG. 3, first insulator 34 is disposed between the line main body portion 20a and ground main body portion 22a, and second insulator 36 is disposed between ground main body portion 22a and neutral main body portion 24a. Not only do insulators 34, 36 ensure sufficient separation of the respective main body portions 20a, 22a, 24a during installation and operation, but they also limit or substantially prevent electrical shorts due to compressive loads atop the main body portions. This is particularly useful for applications in which the low profile electrical terminal assembly 10 is mounted along a floor surface, such as in raceway junction 12, in which case insulators 34, 36 ensure separation of the main body portions 20a, 22a, 24a even if significant compressive weight or force is applied above the main body portions. Such loads may be imparted, for example, by a person standing on that region, or by a piece of equipment or furniture resting along (or rolling over) the junction 12 above main body portions 20a, 22a, 24a. Even if the junction 12 were crushed by an overload condition, it is envisioned that electrical terminal assembly 10 would be likely to maintain sufficient separation of the various conductive surfaces to avoid an electrical short, owing to the presence of insulators 34, 36 and the offset arrangement of branches 20b, 22b, 24b and crimp terminals 20c, 22c, 24c,
Each of the insulators 34, 36 is generally square in shape when viewed from above or in plan view, and includes a generally square opening 38 that substantially aligns with the respective openings 27 formed in the main body portions 20a, 22a, 24a. In the illustrated embodiment, the insulators 34, 36 are configured to snap together from either side of ground main body portion 22a, so that the insulators may be assembled to ground conductive body 22 prior to final assembly of electrical terminal assembly 10. To facilitate alignment of first insulator 34 relative to second insulator 36, first insulator 34 includes a pair of downwardly-extending projections 40 at diagonally-opposite corners, and a pair of notches 42 at the other diagonally-opposite corners, such as shown in FIG. 3. Similarly, second insulator 36 includes a pair of upwardly-extending projections 44 at diagonally-opposite corners corresponding to notches 42 of first insulator 34, and notches 46 at the other diagonally-opposite corners corresponding downwardly projections 40 of first insulator 34. As best shown in FIG. 1, notches 42 receive upward projections 44, and notches 46 receive downward projections 40. In addition, both of the insulators 34, 36 include four resilient latch tabs 48 that engage respective receiving regions 50 of the other insulator. Thus, latch tabs 48 cooperate with receiving regions 50 to allow the insulators 34, 36 to snap together, with ground main body portion 22a sandwiched between the respective inwardly-directed surfaces of the insulators 34, 36. If necessary, first insulator 34 may be separated from second insulator 36 by prying the insulators apart to release latch tabs 48 from the respective receiving regions 50. It is envisioned that insulators 34, 36 may be made from substantially any electrically insulating and compression-resistant material, such as injection molded resinous plastic. In addition, the positioning of latch tabs 48 and receiving regions 50 permit the first insulator 34 to be an identical component to second insulator 36, so that two identical insulators or insulative bodies are interchangeable and may be coupled to one another simply by rotating one insulator by 90-degrees relative to the other insulator, such as shown in FIGS. 3 and 6. Optionally, the insulative bodies may be unitarily formed and joined together by a flexible living hinge.
Referring to FIGS. 2 and 7-8B, low profile electrical terminal assembly 10 is positioned between an upper housing surface 54 and a lower housing surface 56 of raceway junction 12, with each set of three electrical terminals 26 aligned with a corresponding electrical receptacle region 18, in which openings 58 formed in upper housing surface 54 permit access to the respective electrical terminals 26 by respective prongs 60 of male plug 52, such as shown in FIGS. 2, 8A, and 8B. When the prongs 60 of respective male plugs 52 are engaged with the corresponding electrical terminals 26 of electrical terminal assembly 10, the prongs 60 establish electrical connections with the respective electrical conductors 14 that are routed along raceway 16. This allows electrical power to be routed through electrical conductors 62 associated with each male plug 52 to another location, such as shown in FIG. 7. Power may be supplied to electrical conductors 14 via crimped terminals 64 (FIG. 7), or substantially any other type of electrical connection or direct-wiring arrangement. It will further be appreciated that electrical power could be supplied to low profile electrical terminal assembly 10 via any one of male plugs 52 and its corresponding electrical conductors 62, although in that case female receptacles would typically be substituted for male plugs 52 and male plugs would be substitutes for receptacles 26.
Accordingly, the assembled low profile electrical terminal assembly 10 has a thin overall height, such as shown in FIG. 5, while providing positive insulation between the overlying conductive components or surfaces. Branch conductors of different polarities are laterally separated from one another, and are shaped so that the corresponding electrical terminals 26 all lie in substantially the same common terminal plane P4, and providing significant electrical contact areas for receiving the respective terminals of another electrical connector, such as a three-pronged male plug 52 (FIGS. 2 and 7-8B). Although the illustrated embodiment has its terminal plane P4 located coplanar with the plane P3 of neutral main body portion 24a, it will be appreciated that the electrical terminals 26 may be positioned substantially any desired elevation by changing the degree to which the respective branches change elevation along their length.
Changes and modifications in the specifically-described embodiments may be carried out without departing from the principles of the present invention, which is intended to be limited only by the scope of the appended claims as interpreted according to the principles of patent law including the doctrine of equivalents.
Patent Grant
9595777
