Patent Grant
10164374
The present disclosure relates to electrical connectors, and more particularly to twist-lock connectors.
Twist-lock connectors are used in many electrical applications where robust electrical connections and connector retention is desired. Historically, twist-lock connectors are made by crimping wire into stamped and formed electrical contacts made of brass, phosphor bronze, beryllium copper or other material. The electrical contacts are mounted in a base made of a non-conductive resin, such as Bakelite, or thermosetting plastic, or ceramic or other non-conductive material. The other end of the wires are then attached to a terminal block, connector, direct solder or other method of electrically connecting the wires to the module, lamp or Printed Circuit Board (PCB), which uses the electrical power or data conducted from the plugged-in connector (the connected device). The twist-lock connectors may include one or more female contacts that may electrically couple with corresponding male plug contacts.
Difficulties may arise when manufacturing traditional twist-lock connectors, which may therefore be prone to failure. For example, the stamped and formed contacts may not be perfectly formed so that the contact pressure of female contacts onto corresponding male plug contacts may vary greatly, leading to intermittent electrical connection, contact corrosion or loss of connection due to thermal expansion or contraction, or mechanical stress or vibration. In addition, crimping of the contacts to the wires may be incomplete or may damage the wire being crimped, thus causing failure of the connection. In some instances, the terminal block, connector or solder joint electrically connecting the wires to the module, lamp or Printed Circuit Board (PCB) may be improperly done, or may fail from thermal or mechanical stress or vibration. As a result, the wires may be strain relieved so that the wires will not break off or increase in electrical resistance when the wires are moved during servicing, or mechanical vibration.
Safety concerns may also be present in traditional twist-lock connectors. For example, the wires may become disconnected from either the crimped contact in the twist-lock connector, or the terminal block, receiving connector, solder joint, etc., and then move to make electrical connection with the conductive housing of the connected device, thereby presenting an electrical shock hazard.
In addition, the traditional twist-lock connector may also be relatively expensive to manufacture, with many steps of stamping and forming the contacts, crimping and terminating the wires, and may be difficult or expensive to install during final assembly of the connected device (for example, a luminaire) by requiring the assembler to install the wire ends into a terminal block through inserting a connector or soldering the wires into the connected device.
In some implementations, an electrical receptacle that accepts male twist-lock connectors may connect the corresponding contacts directly to an electronic printed circuit board without the need for stamped and formed contacts crimped to wires. In some implementations, the stamped and formed contacts may be eliminated in favor of either forming plated contacts on a PCB or soldering solid metal contacts to a PCB. In some implementations, crimping the wire and terminating the wire on stamped contacts may be eliminated by using traces on the PCB to connect to the circuitry on the PCB. Tolerances may be very tightly controlled (e.g., +/−0.003 inches) using PCB routing and plating production techniques. Such a PCB and electrical receptacle may be less expensive to produce compared to traditional twist-lock connectors by benefiting from the automatic assembly processes used in PCB fabrication and assembly.
A twist-lock connector that receives a set of male electrical contacts may be summarized as including: a set of female electrical receptacles that correspond to the set of male electrical contacts, the set of female electrical receptacles sized and dimensioned to receive the set of male electrical contacts, and the set of female electrical receptacles are physically engageable with the set of male electrical contacts when each of the male electrical contacts in the set of male electrical contacts are inserted into respective ones of the female electrical receptacles in the set of female electrical receptacles and rotated; a primary printed circuit board that has a first face and an opposing second face, the first face directed towards the female electrical receptacles; and a set of electrical connectors that correspond to the set of male electrical contacts, each of the electrical connectors positioned on respective ones of a set of flexible portions of the primary printed circuit board, each of the flexible portions resiliently deform responsive to one of the male electrical contacts contacting and exerting a force on the electrical connectors positioned on the flexible portion to provide a biasing force that urges the electrical connectors toward the male electrical contact.
The set of female electrical receptacles may include three female electrical receptacles arranged around a central point. The set of electrical connectors are comprised of brass plated with tin. Each of the flexible portions of the primary circuit board may be separated from remaining parts of the primary circuit board on a plurality of sides. Each flexible portion may comprise a proximal end and a distal end, the proximal end attached to the remaining part of the primary circuit board and the distal end separated therefrom. For each of the flexible portions, the electrical connector may be located proximate the distal end. The primary circuit board may include a composite mat that has a matrix, wherein the primary circuit board includes a pattern of elements, and wherein the pattern of elements is rotated by 60 degrees relative to the matrix of the composite mat. The twist-lock connector may further include: a secondary circuit board located on an opposite side of the female receptacles from the primary circuit board, the secondary circuit board includes a plurality of electrical connector pads arranged around a central axis. At least a subset of the plurality of electrical connector pads may provide dimming control for an electrically coupled luminaire. The twist-lock connector may further include: a support that is clamped next to the second face of the primary printed circuit board and biases the set of electrical connectors towards the female electrical receptacles. The twist-lock connector may further include: a screw that is threaded through and physically couples the support, the primary printed circuit board, and a mounting base that includes the set of female receptacles. The set of electrical connectors transitions to a biased position when the set of male electrical contacts may be rotatably engaged with the set of female electrical connections. The electrical connectors may include two opposing portions of the primary printed circuit board separated by a channel, wherein the channel is sized and positioned to engage with a respective one of the male electrical contacts when the male electrical contact is rotatably engaged with a corresponding one of the female electrical receptacles. Each of the respective flexible portions may include an internal tab that includes a fixed end and a free end. 15. At least one of the electrical connectors may include an electrical post.
A twist-lock connector that receives a set of male electrical contacts may be summarized as including a set of female electrical receptacles that correspond to the set of male electrical contacts, the set of female electrical receptacles sized and dimensioned to receive the set of male electrical contacts, and the set of female electrical receptacles are physically engageable with the set of male electrical contacts when each of the male electrical contacts in the set of male electrical contacts are inserted into respective ones of the female electrical receptacles in the set of female electrical receptacles and rotated; a primary printed circuit board that has a first face and an opposing second face, the first face directed towards the female electrical receptacles; and a set of electrical connectors that correspond to the set of male electrical contacts, each of the electrical connectors positioned on respective ones of a set of flexible portions of the primary printed circuit board, each of the flexible portions resiliently deform responsive to one of the male electrical contacts contacting and exerting a force on the electrical connector positioned on the flexible portion to provide a biasing force that urges the electrical connector toward the male electrical contact. The set of female electrical receptacles may include three female electrical receptacles arranged around a central point. The set of electrical connectors may be comprised of brass plated with tin. Each of the flexible portions of the primary circuit board may be separated from remaining parts of the primary circuit board on a plurality of sides. Each flexible portion may include a proximal end and a distal end, the proximal end attached to the remaining part of the primary circuit board and the distal end separated therefrom. For each of the flexible portions, the electrical connector may be located proximate the distal end. The primary circuit board may be comprised of a composite mat that may have a matrix, the primary circuit board may include a pattern of elements, and the pattern of elements may be rotated by a defined amount relative to the matrix of the composite mat. The matrix may include a first axis and a second axis, each flexible portion may extend in a direction from a proximal end to a distal end, and the pattern of elements on the primary printed circuit board may be rotated relative to the matrix of the composite mat such that the respective direction in which each flexible portion extends is parallel to at least one of the first axis and the second axis of the matrix.
The twist-lock connector may further include a secondary circuit board located on an opposite side of the female receptacles from the primary circuit board, the secondary circuit board including a plurality of electrical connector pads arranged around a central axis. At least a subset of the plurality of electrical connector pads may provide dimming control for an electrically coupled luminaire.
The twist-lock connector may further include a support base that is clamped next to the second face of the primary printed circuit board and limits deflection of the flexible portions away from the female electrical receptacles.
The twist-lock connector may further include a mounting base that includes the set of female receptacles, the mounting base located opposite the support base across the primary printed circuit board.
The twist-lock connector may further include a screw that is threaded through and operable to clamp the support base, the primary printed circuit board, and the mounting base, wherein the mounting base is rotatable relative to the screw.
The twist-lock connector may further include a twist-lock plug, the twist-lock plug including the set of male electrical contacts, wherein the twist-lock plug further includes a photo-control component, and the mounting base may be rotatable to selectively position the photo-control component. The flexible portions may transition to a deformed position when the set of male electrical contacts are rotatably engaged with the set of female electrical receptacles. The electrical connectors may be comprised of two opposing portions of the primary printed circuit board separated by a channel, and the channel may be sized and positioned to engage with a respective one of the male electrical contacts when the male electrical contact is rotatably engaged with a corresponding one of the female electrical receptacles. Each of the respective flexible portions may be comprised of an internal tab that includes a fixed end and a free end. At least one of the electrical connectors may be comprised of an electrical post. The electrical post may include a proximal end and an opposing distal end, the proximal end may be located relatively closer to the primary circuit board and the distal end may be located relatively away from the primary circuit board, and the distal end may include a chamfer or tapered portion at an end that may be directed away from the primary circuit board.
A method of physically coupling a twist-lock connector with a twist-lock plug, the twist-lock plug including a plurality of male electrical contacts, the twist-lock connector including a plurality of female electrical receptacles and a primary printed circuit board that includes a set of flexible portions, such flexible portions including an electrical contact and aligning with respective ones of the female electrical receptacles, may be summarized as including inserting each of the male electrical contacts of the twist-lock plug into respective ones of the female electrical receptacles, the female electrical receptacles guide the male electrical contacts towards the electrical contacts on respective ones of the flexible portions; twisting the twist-lock plug with respect to the twist-lock connector, such twisting which securely engages the male electrical contacts with the respective ones of the female electrical receptacles; and deforming at least one of the flexible portions by the male electrical contacts into a deformed position responsive to one of the male electrical contacts contacting and exerting a force on the electrical contact positioned on the flexible portion. Deforming at least one of the flexible portions may include deforming at least one of the flexible portions in which the at least one flexible portion is separated from remaining parts of the primary circuit board on a plurality of sides. Deforming at least one of the flexible portions may include deforming the at least one of the flexible portions in the primary printed circuit board, the at least one of the flexible portions including a proximal end and a distal end, the proximal end attached to the remaining part of the primary circuit board and the distal end separated therefrom. The primary circuit board may be comprised of a composite mat that may have a matrix that includes a first axis and a second axis, and deforming at least one of the flexible portions may include deforming the at least one of the flexible portions of the primary printed circuit board, the primary circuit board including a pattern of elements, and the pattern of elements being rotated by a defined amount relative to the matrix of the composite mat.
The method may further include clamping a support base next to the primary printed circuit board, the support base which limits deflection of the flexible portions away the female electrical receptacles.
The method may further include clamping a mounting base to the primary printed circuit board, the mounting base which includes the plurality of female receptacles, the mounting base which is located opposite the support base across the primary printed circuit board.
The electrical contacts may be comprised of two opposing portions of the primary printed circuit board separated by a channel, and may further include engaging respective ones of the male electrical contacts within corresponding channels when the male electrical contact is rotatably engaged with a corresponding one of the female electrical receptacles.
A method of manufacturing a twist lock connector that includes a mounting base, a support base, and a primary printed circuit board, the mounting base which includes at least one female electrical receptacle, may be summarized as including routing one or more portions of the primary printed circuit board to form one or more cut out sections, each cut out section surrounding a respective flexible portion of the primary printed circuit board in which each respective flexible portion resiliently deforms responsive to a force being applied to the flexible portion; mounting the primary printed circuit board between the mounting base and the support base; and clamping the mounting base, the primary printed circuit board, and the support base such that each of the at least one female electrical receptacles is aligned with respective ones of the flexible portions of the primary printed circuit board. Routing one or more portions of the primary printed circuit board to form one or more cut out sections may include routing at least three portions of the primary printed circuit board to form at least three flexible portions of the primary printed circuit board.
The method may further include electrically coupling a set of electrical connectors to the primary printed circuit board, at least one electrical connector in the set of electrical connectors being electrically coupled to one of the flexible portions of the primary printed circuit board, wherein at least one of the electrical connectors in the set of electrical connectors may be comprised of brass plated with tin.
The primary printed circuit board may be comprised of a composite mat that may have a matrix that includes a first axis and a second axis and the primary printed circuit board may include a pattern of elements, and the method may further include rotating the pattern of elements in the primary printed circuit board a defined amount relative to the matrix of the composite mat. The matrix may include a first axis and a second axis, each flexible portion extending in a direction from a proximal end to a distal end, and rotating the pattern of elements on the primary printed circuit board may include rotating the pattern of elements on the primary printed circuit board such that the respective direction in which each flexible portion extends is parallel to at least one of the first axis and the second axis of the matrix. Clamping the mounting base, the primary printed circuit board, and the support base may further include clamping the support base and the primary printed circuit board to thereby limit an amount of deflection of the flexible portions of the primary printed circuit board away from the female electrical receptacles in response to the force being applied to the flexible portions.
In the drawings, identical reference numbers identify similar elements or acts. The sizes and relative positions of elements in the drawings are not necessarily drawn to scale. For example, the shapes of various elements and angles are not necessarily drawn to scale, and some of these elements may be arbitrarily enlarged and positioned to improve drawing legibility. Further, the particular shapes of the elements as drawn, are not necessarily intended to convey any information regarding the actual shape of the particular elements, and may have been solely selected for ease of recognition in the drawings.
In the following description, certain specific details are set forth in order to provide a thorough understanding of various disclosed implementations. However, one skilled in the relevant art will recognize that implementations may be practiced without one or more of these specific details, or with other methods, components, materials, etc. In other instances, well-known structures associated with computer systems, server computers, and/or communications networks have not been shown or described in detail to avoid unnecessarily obscuring descriptions of the implementations.
Unless the context requires otherwise, throughout the specification and claims that follow, the word “comprising” is synonymous with “including,” and is inclusive or open-ended (i.e., does not exclude additional, unrecited elements or method acts).
Reference throughout this specification to “one implementation” or “an implementation” means that a particular feature, structure or characteristic described in connection with the implementation is included in at least one implementation. Thus, the appearances of the phrases “in one implementation” or “in an implementation” in various places throughout this specification are not necessarily all referring to the same implementation. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more implementations.
As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. It should also be noted that the term “or” is generally employed in its sense including “and/or” unless the context clearly dictates otherwise.
The headings and Abstract of the Disclosure provided herein are for convenience only and do not interpret the scope or meaning of the implementations.
The primary PCB 106 may include a first face 116 and an opposing second face 118 opposed across a thickness 119. The first face 116 and the second face 118 may each be planar, and may be parallel to each other. The primary PCB 106 may be comprised of one or more of a non-conductive resin or composite, such as fiberglass FR4, epoxy/Kevlar fiber or thermosetting plastic, or ceramic, or metal covered with nonconductive coating or film, or other non-conductive material. In some implementations, the primary PCB 106 may be circular in shape and may have a diameter of about 5 inches, although such shapes and dimensions should not be considered limiting. In some implementations, the primary PCB 106 may include a plurality of electrical traces or other electrically conductive pathways for conducting electrical signals. The primary PCB 106 may include one or more apertures (“vias”) that extend between the first face 116 and the second face 118, with such apertures being used to electrically couple electronic components to one or more of the electrical traces or other conductive pathways. Such electrical coupling may be performed, for example, manually through soldering the electronic components, and/or such electrical coupling may be performed, for example, mechanically or automatically using pick-and-place technology. In some implementations, the electronic components and electrical traces and/or pathways may form an electronic circuit that performs one or more defined tasks. For example, in some implementations, such an electronic circuit may be used to control the operation of one or more luminaires, such as, for example, luminaires that provide lighting for roadways, streets, parking lots, and other large spaces.
The primary PCB 106 may include one or more flexible portions 104 that may each support one or more PCB mounted electrical connectors 102. For example, as shown in
In some implementations, the flexible portion 104 may be formed within an interior section of the primary PCB 106 by cutting out, routing, and/or otherwise removing portions of the primary PCB 106. In some implementations, a plurality of sides of the flexible portion 104 may be physically separated from the remaining part of the primary PCB 106. In some implementations, for example, the flexible portion 104 may form an “L” shape within the primary PCB 106 in which only the top part of the “L” is attached to the primary PCB 106. The PCB 106 proximate the remaining sides of the L-shaped flexible portion 104 may be cut out, routed, or otherwise removed, thereby creating a separation or void between the flexible portion 104 and the remaining part of the primary PCB 106 along these remaining sides. Such separation may enable the flexible portion 104 to flex, deform, and move relative to the remaining part of the primary PCB 106.
The PCB mounted electrical connectors 102 may be comprised of conductive components soldered, riveted or otherwise attached to the flexible portions 104 of the primary PCB 106. In some implementations, the PCB mounted electrical connectors 102 may be plated on the flexible portions 104 using standard PCB manufacturing processes. In some implementations, plating may be formed around the edge of the flexible portions 104 to make contact with male electrical contacts that may be inserted into the twist-lock connector 100, and as such, may require that no contacts be soldered and/or crimped to electrical connections from the primary PCB 106. In some implementations, gold, tin, or other highly conductive metals may be plated on the flexible portions 104 to achieve the relatively low resistance and contact corrosion resistance for the PCB mounted electrical connectors 102. In some implementations, the PCB mounted electrical connectors 102 may be cylindrical metal components supplied in tape and reel packaging, and automatically placed on the primary PCB 106 during standard automatic pick and place assembly, along with other components in the twist-lock connector 100. In some implementations, the PCB mounted electrical connectors 102 may include an electrical post with a chamfer or tapered portion at an end that is directed towards the mounting base 110. Such a chamfer or tapered portion may facilitate engagement with other electrical connectors. Physical attachment and electrical connections may be made by reflow soldering with contacts that may be RoHS certified brass plated with tin, for example.
The flexible portion 104 may be resiliently deformable. As such, when a force is applied against the flexible portion 104, as may occur, for example, when male electrical contacts come into contact with the PCB mounted electrical connectors 102, the flexible portion 104 may exert a biasing force in an opposing direction. In some implementations, such an opposing force may be determined according to Hooke's Law of Spring Force that provides a linear relationship of force to distance of compression of the spring. As such, the biasing force applied by the flexible portion 104 may urge the PCB mounted electrical connectors 102 towards the male electrical contacts. A process of routing the primary PCB 106 to form the flexible portions 104 may provide advantages over conventional processing in which contacts are stamped by sequential stamping dies such that the contacts may have poor tolerances caused by die wear or other process variations. The tooling used for sequential stamping may be expensive, especially as compared to the tooling used for PCB fabrication. In addition, the contact force resulting from the flexible portions 104 may be better controlled, with less variation between different flexible portions 104, because of the close dimensional tolerances used in PCB fabrication. In some implementations, one or both of the support base 108 and/or the mounting base 110 may be used to provide additional support for the flexible portions 104.
In some implementations, the primary PCB 106 may include one or more registration apertures 120 that may be used to align the primary PCB 106 with one or more other components in the twist-lock connector 100. For example, the primary PCB 106 includes three major registration apertures 120a and two minor registration apertures 120b that may be aligned with corresponding major registration projections 122a and minor registration projections 122b on the support base 108 to thereby align the primary PCB 106 with the support base 108.
The support base 108 may be comprised of non-conducting material. Such non-conducting material may include, for example, plastic resin, such as ABS resin. In some implementations, the support base 108 may include a threaded portion 124 that may be coupleable to the mounting coupler 114, such as a screw. In some implementations, the support base 108 may include one or more spring guides 126 in which each spring guide 126 may be aligned with at least a part of a respective one of the flexible portions 104 on the primary PCB 106. When the components of the twist-lock connector 100 are clamped together, each of the spring guides 126 may be proximate to or in contact with the part of the respective flexible portion 104 of the primary PCB 106. As such, when the male electrical contacts apply a force against the PCB mounted electrical connectors 102 going towards the support base 108, placing the flexible portions 104 in a deformed position, the spring guides 126 in the support base 108 may exert an opposing force, directed towards the mounting base 110, against the respective flexible portions 104 of the primary PCB 106. Such a force, applied by the spring guides 126 against the flexible portions 104, may result in the position of the flexible portions 104 being maintained with respect to the remaining part of the primary PCB 106 (e.g., at least a portion of the outer surfaces of the flexible portions 104 may be maintained within the planes formed by the first face 116 and the second face 118, respectively).). In some implementations, the spring guides 126 may be used to limit an amount of deflection of the flexible portions 104 when the flexible portions 104 are in a deformed position.
The mounting base 110 may be comprised of non-conducting material. Such non-conducting material may include, for example, plastic resin, such as ABS resin. The mounting base 110 may be positioned between the primary PCB 106 and the secondary PCB 112. The mounting base 110 may include one or more female electrical receptacles 128 that may each be sized and dimensioned to securely receive a corresponding male electrical contact. Such male electrical contacts may be inserted into the respective ones of the female electrical receptacles 128 along a directed axis 130 that runs from the mounting base 110 to the primary PCB 106. The female electrical receptacles 128 may be used to guide each male electrical contact towards one of the PCB mounted electrical connectors 102.
Once inserted into the female electrical receptacles 128, the male electrical contacts may be rotated clockwise and/or counter-clockwise to securely lock the male electrical contacts with the female electrical receptacles. In some implementations, as discussed below for example, the male electrical contacts may be part of a turn-lock plug in which the male electrical contacts have a distal end that includes an offset portion that can be inserted fully into the corresponding female electrical receptacles 128. When turned, the offset portion of the male electrical contacts may engage with a corresponding edge or lip within each respective female electrical receptacle 128 that holds the distal end within the respective female electrical receptacle 128. When locked within the female electrical receptacles 128, the male electrical contacts may be maintained in contact, and thereby be electrically coupled, with the PCB mounted electrical connectors 102. The chamfer or tapered sections of the PCB mounted electrical connectors 102 may thereby facilitate the engagement and electrical coupling with the male electrical contacts. When securely engaged, the male electrical contacts may place the flexible portions 104 in a deformed or deflected position.
The mounting base 110 may include a mounting base surface 132 that faces towards the secondary PCB 112 and a side wall 134 that may extend from the first mounting base surface 132 towards the primary PCB 106. In some implementations, the mounting base surface 132 and the side wall 134 may form a cavity 136 that has an opening that faces towards the primary PCB 106. The cavity 136 may include one or more spring guides (see, e.g.,
The mounting base 110 may include a central aperture 138 that may enable the mounting coupler 114 to pass through from the mounting base surface 132 towards the support base 108. In some implementations, the central aperture 138 may include an enlarged portion 140 that may be used to next an upper portion 142 of the mounting coupler 114 such that the mounting coupler 114 is flush with the mounting base surface 132 when the mounting coupler 114 is engaged with the support base 108 to thereby clamp together the components of the twist-lock connector 100. The female electrical receptacles 128 may be arranged around the central aperture 138.
The secondary PCB 112 may include a first surface 146 and an opposing second surface 148 separated by a thickness 150. The secondary PCB 112 may be annular in shape and may be sized to be received within the recessed portion 144 of the mounting base 110. In some implementations, the secondary PCB 112 may be physically coupled to the mounting base 110 within the recessed portion 144 using silicone or some other adhesive. The mounting coupler 114 may pass through the central open area of the annular region. In some implementations, the secondary PCB 112 may include one or more electrical contact pads 152 that may electrically couple with electrical contacts on other devices mounted on the twist-lock connector 100. The electrical contact pads 152 may be arranged around a central axis 154 that extends through the central portion of the secondary PCB 112. In some implementations, two or four electrical contact pads 152 may be used to provide a five or seven pin NEMA photo-control twist lock socket, respectively. Such electrical contact pads 152 may be used to provide low voltage control of the controllable device. For example, many luminaires have 0 to 10 volt dimming control, where the low voltage signal sets the brightness of the luminaire. Digital Addressable Lighting Interface (DALI) control may use two low voltage control lines, which may be connected via two of the electrical contact pads 152. In some implementations, the electrical contact pads 152 may be plated with corrosion resistant plating such as gold or tin plating. In some implementations, the electrical contact pads 152 may be connected to the primary PCB 106 by a pluggable post and header connector. Such a pluggable post and header connector may thereby physically couple the secondary PCB 112 to the other components of the twist-lock connector 100.
The mounting coupler 114 may extend through one or more components of the twist-lock connector 100 to thereby clamp such components together. In some implementations, the mounting coupler 114 may be a screw with a countersunk head that may be securely received within the enlarged portion 140 of the central aperture 138 of the mounting base 110. The mounting coupler 114 may extend through the central aperture 138 of the mounting base 110, the primary PCB 106 and be coupled with a corresponding coupling device in the support base 108. Such a coupling device may include, for example, a threaded portion that may receive a corresponding threaded cavity of the mounting coupler 114. When so coupled, the mounting coupler 114 may thereby clamp together one or more components of the twist-lock connector 100.
The flexible portions 104 may be formed using cutouts 300 in which a part of the primary PCB 106 adjacent the flexible portions 104 have been removed. Such cutouts 300 may be formed within the primary PCB 106 using a standard PCB routing process to remove part of the primary PCB 106. For example, in some implementations, cutouts 300 may be formed along a plurality of sides of the flexible portion 104. Such a flexible portion 104 may be resiliently deformed when a force is applied against the flexible portion 104, as may occur, for example, when male electrical contacts come into contact with the PCB mounted electrical connectors 102. As a result, the flexible portion 104 that has been deflected may exert a force in an opposing direction. When the original force is removed, the flexible portion 104 may return to a non-deflected state wherein the flexible portion 104 is coplanar with the remainder of the primary PCT 106.
In some implementations, the opposing force provided by a flexible portion 104 that has been deflected may be determined according to Hooke's Law of Spring Force that provides a linear relationship of force to distance of deflection of the spring. As such, the flexible portion 104 may generate a contact force based upon the displacement and/or deformation caused by the male electrical contacts applying a force in the opposite direction against the PCB mounted electrical connectors 102. A process of routing the primary PCB 106 to form the cutouts 300 may provide advantages over conventional processing in which contacts are stamped by sequential stamping dies such that the contacts may have poor tolerances caused by die wear or other process variations. In addition, the contact force resulting from the flexible portions 104 may be better controlled, with less variation between different flexible portions 104, because of the close dimensional tolerances used in PCB fabrication. In some implementations, one or both of the support base 108 and/or the mounting base 110 may be used to provide additional support for the flexible portions 104.
The flexible portion 104 may include multiple portions, as shown in
The support base 108 may include a plurality of spring guides 126, each of which may be aligned with at least part of the flexible portions 104 in the primary PCB 106. In some implementations, at least some of the spring guides 126 may be aligned with at least a part of the flexible portions 104 of the primary PCB 106. For example, as shown in
In some implementations, the spring guides 126 may be used to maintain the position of the flexible portions 104 of the primary PCB 106 with respect to the other portions of the primary PCB 106 (e.g., at least a portion of the outer surfaces of the flexible portions 104 may be maintained within the planes formed by the first face 116 and the second face 118, respectively). In some implementations, the spring guides 126 may be used to limit an amount of deflection of the flexible portions 104 when the flexible portions 104 are in a deflected state. The spring guides 126 may exert a force against the secondary section 312 of the flexible portions 104 in the direction of the mounting base 110 when the flexible portions 104 are in a deflected state. Such spring guides 126 may prevent twisting or other deformations of the flexible portions 104 when the flexible portions 104 are in a deflected state, such as when corresponding male electrical contacts come into contact with the PCB mounted electrical connectors 102.
In some implementations, a curved section 506 of each of the spring guides 500 may extend between the primary part 502 and the secondary part 504 of the spring guide in the mounting base 110. Such a curved section 506 may have a radius of curvature that provides sufficient space for the PCB mounted electrical connectors 102 (
In some implementations, the mounting base 110 may include one or more registration cavities 510 that may engage with one or more corresponding minor registration projections 122b (
In some implementations, the twist-lock plug 700 may include one or more electrical connectors 714 that may be used to electrically couple with the electrical contact pads 152 on the secondary PCB 112. Such electrical connectors 714 and corresponding electrical contact pads 152 may be used for a five or seven pin NEMA photo-control twist-lock socket, respectively, that may provide low voltage control of the controllable device. For example, many luminaires have 0 to 10 volt dimming control, where the low voltage signal sets the brightness of the luminaire. Digital Addressable Lighting Interface (DALI) control may include two low voltage control lines, which may be connected via two sets of the electrical connectors 714 and corresponding electrical contact pads 152.
In some implementations, the twist-lock plug 700 may provide photo-control for a luminaire when engaged and electrically coupled with a corresponding twist-lock connector 100 in the luminaire. In such an implementation, the mounting coupler 114 in the twist-lock connector 100 may be loosened, allowing for the rotation of the remaining components of the twist-lock connector 100 such that the photo-control components in the twist-lock plug 700 may be aligned to a more optically favorable position. Projections 122b engage in recesses 510 to keep the mounting base 110, the primary PCB 106 and/or the support base 108 aligned during rotation. The mounting coupler 114 may then be tightened to clamp together the components of the twist-lock connector 100, thereby maintaining the position of the twist-lock connector 100. The twist-lock plug 700 with the photo-control may then be engaged with and installed in the twist-lock connector 100. Such a rotatable feature may be advantageous in installations where there may be other light sources or light reflectors (such as tree branches) which may cause undesirable operation of the photo-control if not oriented in a particular direction.
The foregoing detailed description has set forth various implementations of the devices and/or processes via the use of block diagrams, schematics, and examples. Insofar as such block diagrams, schematics, and examples contain one or more functions and/or operations, it will be understood by those skilled in the art that each function and/or operation within such block diagrams, flowcharts, or examples can be implemented, individually and/or collectively, by a wide range of hardware, software, firmware, or virtually any combination thereof. In one implementation, the present subject matter may be implemented via Application Specific Integrated Circuits (ASICs). However, those skilled in the art will recognize that the implementations disclosed herein, in whole or in part, can be equivalently implemented in standard integrated circuits, as one or more computer programs running on one or more computers (e.g., as one or more programs running on one or more computer systems), as one or more programs running on one or more controllers (e.g., microcontrollers) as one or more programs running on one or more processors (e.g., microprocessors), as firmware, or as virtually any combination thereof, and that designing the circuitry and/or writing the code for the software and or firmware would be well within the skill of one of ordinary skill in the art in light of this disclosure.
Those of skill in the art will recognize that many of the methods or algorithms set out herein may employ additional acts, may omit some acts, and/or may execute acts in a different order than specified.
In addition, those skilled in the art will appreciate that the mechanisms taught herein are capable of being distributed as a program product in a variety of forms, and that an illustrative implementation applies equally regardless of the particular type of signal bearing media used to actually carry out the distribution. Examples of signal bearing media include, but are not limited to, the following: recordable type media such as floppy disks, hard disk drives, CD ROMs, digital tape, and computer memory.
The various implementations described above can be combined to provide further implementations. To the extent that they are not inconsistent with the specific teachings and definitions herein, all of the U.S. patents, U.S. patent application publications, U.S. patent applications, foreign patents, foreign patent applications and non-patent publications referred to in this specification and/or listed in the Application Data Sheet, including but not limited to U.S. Provisional Patent Application No. 61/052,924, filed May 13, 2008; U.S. Pat. No. 8,926,138, issued Jan. 6, 2015; PCT Publication No. WO2009/140141, published Nov. 19, 2009; U.S. Provisional Patent Application No. 61/051,619, filed May 8, 2008; U.S. Pat. No. 8,118,456, issued Feb. 21, 2012; PCT Publication No. WO2009/137696, published Nov. 12, 2009; U.S. Provisional Patent Application No. 61/088,651, filed Aug. 13, 2008; U.S. Pat. No. 8,334,640, issued Dec. 18, 2012; U.S. Provisional Patent Application No. 61/115,438, filed Nov. 17, 2008; U.S. Provisional Patent Application No. 61/154,619, filed Feb. 23, 2009; U.S. Patent Publication No. 2010/0123403, published May 20, 2010; U.S. Patent Publication No. 2016/0021713, published Jan. 21, 2016; PCT Publication No. WO2010/057115, published May 20, 2010; U.S. Provisional Patent Application No. 61/174,913, filed May 1, 2009; U.S. Pat. No. 8,926,139, issued Jan. 6, 2015; PCT Publication No. WO2010/127138, published Nov. 4, 2010; U.S. Provisional Patent Application No. 61/180,017, filed May 20, 2009; U.S. Pat. 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No. 15/238,129, filed Aug. 16, 2016; U.S. Provisional Patent Application No. 62/264,694, filed Dec. 8, 2015; U.S. Non-provisional patent application Ser. No. 15/369,559, filed Dec. 5, 2016; U.S. Provisional Patent Application No. 62/397,709, filed Sep. 21, 2016; U.S. Non-provisional patent application Ser. No. 15/709,022, filed Sep. 19, 2017; U.S. Provisional Patent Application No. 62/397,713, filed Sep. 21, 2016; U.S. Non-provisional patent application Ser. No. 15/709,028, filed Sep. 19, 2017; U.S. Provisional Patent Application No. 62/327,939, filed Apr. 26, 2016; U.S. Non-provisional patent application Ser. No. 15/496,985, filed Apr. 25, 2017; U.S. Provisional Patent Application No. 62/379,037, filed Aug. 24, 2016; U.S. Non-provisional patent application Ser. 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These and other changes can be made to the implementations in light of the above-detailed description. In general, in the following claims, the terms used should not be construed to limit the claims to the specific implementations disclosed in the specification and the claims, but should be construed to include all possible implementations along with the full scope of equivalents to which such claims are entitled. Accordingly, the claims are not limited by the disclosure.
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