Patent Application
20110256748
The subject matter herein relates generally to appliances, and more particularly, to power connector systems for appliances.
Appliances, such as dryers, are powered by a power cord being terminated to a terminal block on a back side of the appliance. Typically, the power cord is plugged into a wall socket, and includes multiple wires with terminals at the ends thereof that are affixed to the terminal block. In some known systems, the terminals are ring terminals that are affixed to the terminal block using fasteners, such as bolts. Such systems are not without disadvantages. For instance, the terminals must be individually connected to the terminal block, which is time consuming. Such systems require a degree of know-how to safely and correctly attach the power cord to the appliance. Such systems require the use of tools to complete assembly and are prone to safety malfunctions if not properly installed.
A need remains for a power connector system that allows for safe connection of the power cord to the appliance. A need remains for a power connector system that allows for connection without tools or special knowledge.
In one embodiment, a power connector system is provided for an appliance that includes a cable assembly comprising a plug having plug contacts terminated to discrete wires of the cable assembly. The power connector system also includes a receptacle assembly having a receptacle housing having a cavity that receives the plug. The receptacle housing is configured to be received in a cutout of a bezel of the appliance such that the cavity is accessible from an exterior of the appliance. The receptacle housing holds receptacle contacts that are mated to the plug contacts when the plug is received in the cavity.
In another embodiment, a power connector for an appliance is provided including a receptacle housing having a front and a rear. The receptacle housing has a cavity open at the front that is configured to receive a plug. The receptacle housing has contact channels extending between the cavity and the rear, and the receptacle housing has a latching feature configured to engage a bezel of the appliance to secure the receptacle housing to the bezel such that the cavity is accessible from an exterior of the appliance. Receptacle contacts are received in the contact channels. The receptacle contacts have mating ends within the cavity that are mated to corresponding plug contacts when the plug is received in the cavity.
The electronic device includes a bezel 102, which is the only part of the electronic device illustrated in the Figures. The bezel 102 defines a mounting location for the power connector system 100 and may form part of, or be attached to, a wall or outer casing of the electronic device. In the illustrated embodiment, the bezel 102 is a metal plate having a cutout 104. The cutout 104 provides an opening between an exterior and an interior of the electronic device. Electrical components of the electronic device may be housed in the interior, and power is supplied to the electrical components through the bezel 102 using the power connector system 100.
The power connector system 100 includes a cable assembly 106 and a receptacle assembly 108. The receptacle assembly 108 is coupled to the bezel 102 and is part of the electronic device. The receptacle assembly 108 defines a socket connector configured to receive a portion of the cable assembly 106.
The cable assembly 106 is mated with the receptacle assembly 108 to supply power to the electronic device. The cable assembly 106 includes a plug 110 at an end of a cable 112. The cable 112 includes discrete wires 114 being terminated to individual plug contacts 116 (shown in
The plug 110 includes a body 118 that holds the plug contacts 116 such that the plug contacts 116 may be simultaneously mated with the receptacle assembly 108 as a unit. The plug 110 and plug contacts 116 define a separable interface that may be mated and unmated quickly and easily by inserting the plug 110 into the receptacle assembly 108 and removing the plug 110 from the receptacle assembly 108. The body 118 may be manufactured from a rigid material, such as a plastic material. The body 118 includes a base 120 and a cap 122 at an end of the base 120. The wires 114 enter the body 118 at an edge of the cap 122 such that the wires 114 extend generally perpendicular to a central axis 124 of the plug 110. When mated with the receptacle assembly 108, the wires 114 extend generally along the bezel 102, as opposed to away from the bezel 102. As such, the cable assembly 106 has a low profile, which may allow the electronic device to sit flush with a wall or against another object without the cable 112 interfering with the positioning of the electronic device.
The base 120 is at least partially received in the receptacle assembly 108 when mated thereto. In an exemplary embodiment, the base 120 includes a keying feature 126 for keyed mating with the receptacle assembly 108. In the illustrated embodiment, the keying feature 126 is represented by a chamfered corner. Other embodiments may include a slot, a groove, a protrusion, a tab a particular shape of the body 118, and the like.
The receptacle assembly 108 includes a receptacle housing 130. The receptacle housing 130 is coupled to the bezel 102 such that the receptacle housing 130 is aligned with the cutout 104. Optionally, the receptacle housing 130 may be substantially flush with the bezel 102. In the illustrated embodiment, the receptacle housing 130 may be positioned behind the bezel 102. A portion of the receptacle housing 130 may extend through the cutout 104. Optionally, a seal (not shown) may be provided between the receptacle housing 130 and the bezel 102. The seal may prevent moisture from leaking into the interior of the electronic device through the cutout 104.
The receptacle housing 130 has a cavity 132 that receives the plug 110. The cavity 132 may be sized and shaped similar to the base 120 such that the base 120 may be received in the cavity 132. When the plug 110 is mated with the receptacle assembly 108, the cap 122 remains external to the cavity 132. Optionally, the cap 122 may sit flush against a front 134 of the receptacle housing 130.
In an exemplary embodiment, the receptacle assembly 108 includes a locking feature 136. The locking feature 136 engages the plug 110 to securely couple the plug 110 to the receptacle assembly 108. In the illustrated embodiment, the locking feature 136 is represented by locking tabs that extend forward from the front 134. The locking tabs are formed integral with the receptacle housing 130. The locking tabs engage the cap 122 to resist removal of the plug 110 from the cavity 132. Alternative types of locking features may be provided in alternative embodiments, such as a separate plate or cover that is coupled to the receptacle housing 130 and/or the bezel 102 such that the plate or cover is provided outward of the plug 110 to hold the plug 110 in the cavity 132. The plate or cover may be coupled using fasteners, latches or other fastening means.
In the illustrated embodiment, one of the towers 150 is shorter than the others. The shorter tower 150 allows one of the receptacle contacts to extend further into the cavity 132. Such receptacle contact may define a ground contact configured to mate prior to the other receptacle contacts 146, which may constitute power contacts. As such, the receptacle assembly 108 has a sequenced mating interface. The towers 150 hold the receptacle contacts 146 in different quadrants within the hub 142 and cavity 132.
The base 140 includes one or more latching features 152. The latching features 152 engage and interact with the bezel 102 to securely couple the receptacle housing 130 to the bezel 102. The bezel 102 includes corresponding latching features 154 that interact with the latching features 152 to secure the receptacle housing 130 to the bezel 102. The bezel 102 includes rails 156 that guide and position the receptacle housing 130 with respect to the bezel 102 and the cutout 104. The rails 156 engage a rear of the base 140 to hold the receptacle housing 130 against the bezel 102. The base 140 is generally planar and the front 134 abuts a rear of the bezel 102. In an exemplary embodiment, the receptacle housing 130 is slid into position against the rear of the bezel 102 to a final position. For example, the receptacle housing 130 may be slid in a mating direction represented by arrow 158 to a locked position. The latching features 152 engage the latching features 154 to securely couple the receptacle housing 130 to the bezel 102. The latching features 152, 154 may be any type of latching features including latches, tabs, windows, catches, and the like.
The receptacle contacts 146 include mating ends 160 and terminating ends 162. The mating ends 160 are configured to be mated to the plug contacts 116 (shown in
In the illustrated embodiment, one of the receptacle contacts 146 extends further into the cavity 132 to define a ground contact, which mates with the corresponding plug contact 116 prior to other receptacle contacts 146 mating to corresponding plug contacts 116. The tower 150 corresponding to the ground contact is shorter than the other tower 150. Because the receptacle contacts 146 are identical to one another, having one of the towers 150 shorter than the other towers 150 allows one of the receptacle contacts 146 to extend further into the cavity 132 to define the ground contact and a sequenced mating interface. Alternatively, rather than having all of the receptacle contacts 146 identical to one another, the receptacle contacts 146 may be differently sized. For example, one of the receptacle contacts 146 may be longer than the other contacts to define a ground contact and extend further into the cavity 132. In other alternative embodiments, each of the receptacle contacts 146 may extend into the cavity 132 by the same amount. Optionally, the plug contacts 116 may define a sequenced mating interface in addition to, or instead of, the receptacle contacts 146.
The latching features 152 engage the latching features 154. For example, one of the latching features 152 (on the left side of
The base 140 of the receptacle housing 130 is received in the rail 156, which restricts movement of the receptacle housing 130 away from the bezel 102. The rail 156 supports the receptacle housing 130. The locking feature 136 extends forward from the base 140 through the cutout 104.
The receptacle assembly 208 includes a receptacle housing 230. The receptacle housing 230 has a cavity 232 that receives a plug, such as the plug 110 (shown in
In an exemplary embodiment, the receptacle assembly 208 includes a locking feature 238. The locking feature 238 is represented by slots that are configured to receive a cover or other element that surrounds the plug to hold the plug in the cavity 232. Alternatively, the locking feature 238 may be represented by locking tabs similar to those illustrated in
The receptacle housing 230 includes a base 240 and a hub 242 extending rearward from the base 240. The base 240 is configured to be secured to the bezel 202. The front and rear flanges 234, 236 are proved at the base 240. The base 240 and/or the hub 242 surround the cavity 232. The hub 242 includes a plurality of contact channels 244 that receive receptacle contacts 246. The contact channels 244 isolate the receptacle contacts 246 from one another and may entirely surround the receptacle contacts 246. The contact channels 244 extend between a rear 248 of the receptacle housing 230 and the cavity 232. The receptacle contacts 246 may be loaded into the contact channels 244 through the rear 248 such that portions of the receptacle contacts 246 are exposed within the cavity 232.
In an exemplary embodiment, the receptacle assembly 208 includes a cover 250 at a rear of the receptacle housing 230. The cover 250 is coupled to the receptacle housing 230.
When coupled to the receptacle housing 230, the cover 250 covers a rear end 260 of the contact channels 244. As such, the cover 250 restricts rearward movement of the receptacle contacts 246 in the contact channels 244. For example, during mating with plug contacts, the receptacle contacts 246 may be forced rearward. The cover 250 blocks rearward movement of the receptacle contacts 246. Optionally, a seal (not shown) may be provided between the cover 250 and the receptacle housing 230. The seal may prevent moisture from leaking into the contact channels 244 to damage and/or corrode the wires 258 and/or the receptacle contacts 246.
The receptacle housing 230 includes one or more latching features 262. The latching features 262 engage and interact with the bezel 202 to securely couple the receptacle housing 230 to the bezel 202. The bezel 202 includes corresponding latching features 264 (shown in
The receptacle contact 246 may be stamped and formed from a blank of material into the shape shown. For example, edges 274, 276 of the receptacle contact 246 may be rolled inward toward one another to create a contact having the shape illustrated in
In an exemplary embodiment, the receptacle contact 246 may include a flange 278 extending outward therefrom. As described in further detail below, the flange 278 may control a loading depth of the receptacle contact 246 into the contact channel 244. In the illustrated embodiment, the flange 278 extends from a top of the receptacle contact 246. The flange 278 is provided at one of the edges 274, however may be provided remote from the edge 274 or may be provided at both edges 274, 276 in alternative embodiments.
The receptacle contact 246 includes one or more tabs 280 extending therefrom. As described in further detail below, the tabs 280 may engage the contact channels 244 to provide a friction fit with the contact channels 244. In the illustrated embodiment, a single tab is provided on a bottom of the receptacle contact 246, however any number of tabs 280 and any location of tabs 280 may be utilized on alternative receptacle contacts.
The receptacle contact 246 includes a conductor crimp 290 that crimps the stripped wire. The receptacle contact 246 includes an insulation crimp 292 that crimps the insulation of the wire. The receptacle contact 246 includes legs 294 at the terminating end that are un-crimped. The legs 294 are used to provide a fixed surface that the cover 250 (shown in
In the illustrated embodiment, one of the receptacle contacts 246 extends further into the cavity 232 to define a ground contact, which mates with the corresponding plug contact prior to other receptacle contacts 246 mating to corresponding plug contacts. The receptacle contacts 246 are loaded into the contact channels 244 until the flanges 278 engage corresponding shoulders 282 in the contact channels 244. The flanges 278 define a loading depth of the receptacle contacts 246 into the contact channels 244. The tabs 280 engage the contact channels 244 to hold the receptacle contacts 246 in the contact channels 244. The cover 250 is provided behind the contact channels 244. Optionally, the cover 250 may function as a backstop to stop rearward movement of the receptacle contacts 246 out of the contact channels 244. For example, if the terminating ends 272 engage the cover 250, then the cover 250 prevents further rearward movement of the receptacle contacts 246.
A locking feature 284 is illustrated in
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, sixth paragraph, unless and until such claim limitations expressly use the phrase “means for” followed by a statement of function void of further structure.
