Patent Application
20140106627
The present disclosure relates generally to a reconfigurable terminal for an electrical receptacle device, and more particularly relates to an apparatus and method for a reconfigurable terminal that can be used with multiple electrical receptacle configurations.
Terminals are components of various electrical devices such as receptacles, switches, lampholders, lighting controls, and the like. In the case of electrical receptacles, terminals are used to connect the electrical supply power to the plug blades of an electrical plug. Terminals may directly receive the blades of electrical plugs, or they may supply power to blades of a plug through other electrical components. There are a number of different receptacle blade configurations/geometries such as those configurations standardized by the National Electrical Manufacturers Association (NEMA), and the configuration or orientation of the terminals in the receptacle may vary depending on the blade configuration of the particular receptacle. In addition, different types of electrical receptacles, including surface-mounted receptacles and flush-mounted receptacles, can be of different depths. Thus, the general configuration of a terminal for a specific application may vary as to geometry, orientation and/or size of the terminals in the receptacle in dependence upon the geometry, size and/or depth requirements of the receptacle.
It is not uncommon that different types and/or models of receptacles have different or unique terminal component parts to account for the varying sizes and/or blade configurations. In addition, even one receptacle can include a number of unique terminal component parts to account for the different blade configurations within the one receptacle. These unique terminal component parts that vary by size and/or configuration increase manufacturing complexity and costs.
Therefore, it would desirable to have a universal/reconfigurable terminal that can be used in various types of receptacle devices, where the devices may be of different depths and/or require different blade configurations. It would also be desirable to have a universal/reconfigurable terminal capable of multiple configurations so that multiples of one type of terminal can be used in a single receptacle where multiple terminal configurations are required. A universal/reconfigurable terminal would decrease the number of unique parts required for manufacturing receptacle devices, which would reduce manufacturing complexity and costs, including inventory costs, labor costs, molding costs, etc.
An electrical receptacle terminal for receiving an electrical plug blade including: a contact portion having a tabbed end including a plurality of tabs and a plug blade end configured to receive said electrical plug blade; a clamp having an aperture and a first notch, wherein the notch is arranged and configured to engage any one of the plurality of tabs of the contact portion; and, a fastener having a surface that is adapted and configured for selectively and securingly engaging the aperture of the clamp. The terminal is capable of being configured into a plurality of configurations depending on which one of the plurality of tabs that the first notch engages.
An electrical receptacle, which includes a plurality of the terminals described above, is disclosed. The receptacle includes a cover plate or cover portion having an opening for one or more sockets with a plurality of apertures to receive an electrical plug, and a base portion that receives the cover plate or cover portion and has a plurality of openings that are each configured to receive one of the terminals. Each of the plurality of terminals is in a terminal configuration position that aligns with one of the apertures in the socket and one of the openings in the base portion.
A method for assembling an electrical receptacle terminal is disclosed. The method includes engaging one of the plurality of tabs of the contact portion with a notch in a clamp, wherein any one of the plurality of tabs engages with the notch according to a desired or predetermined orientation. The method may also include inserting a fastener into an aperture of the clamp, wherein the fastener has a surface that is configured for selectively and securingly engaging the aperture in the clamp.
A method of assembling an electrical receptacle for receiving an electrical plug having a plurality of plug blades with predetermined plug blade orientations is disclosed. The method includes assembling a plurality of terminals having terminal orientations corresponding to the plurality of plug blades, respectively, wherein each terminal assembly includes the steps described above. The method also includes inserting each of the plurality of terminals into one of a plurality of openings in a base portion according to the desired or predetermined orientation.
One or more aspects of the present invention are particularly pointed out and distinctly claimed as examples in the claims at the conclusion of the specification. The foregoing and other objects, features, and advantages of the present invention may be more readily understood by one skilled in the art with reference being had to the following detailed description of several embodiments thereof, taken in conjunction with the accompanying drawings wherein like elements are designated by identical reference numerals throughout the several views, and in which:
The present disclosure describes a terminal for a wiring device such as an electrical receptacle, wherein the electrical receptacle receives plug blades of an electrical plug. Embodiments will be described below while referencing the accompanying figures. The accompanying figures are merely examples and are not intended to limit the scope of the present disclosure. The terminal can be employed on any suitable wiring device such as but not limited to receptacles, switches, lighting/fan speed controls, dimmers, HVAC equipment/controllers, and the like.
Contact portion 20 has a second end 22 that includes two jaws 23, 24. Jaws 23, 24 are configured to receive a plug blade from an electrical plug (not shown). The ends of the jaws 23, 24 are outwardly directed, as shown in
Contact portion 20 may be composed of any suitable metal or combination of metals, including but not limited to, brass, copper, tin, plated brass, plated copper, any suitable alloy/combination thereof, etc. The plating material may be any suitable material such as, but not limited to, tin. For example, by tin plating the contact, the contact can be made to be compatible with aluminum conductors, thus allowing the requirements of Underwriters Laboratories (UL) standards to be met. The contact portion can be produced from a sheet of metal that is shaped and/or bent into the geometry and/or size of the requirements for the contact portion. In addition, the contact portion can be assembled using a mold and/or by using multiple component pieces of metal, or by any other suitable means or method now known or hereafter developed to those skilled in the art.
As depicted in
In the exemplary embodiment, first wall 36 and second wall 37 are sloped and angled inward towards third wall 31. However, it should be understood that the walls of clamp 30 need not necessarily be sloped and/or angled, may have slopes of differing angles, may include compound slopes/angles, etc. The length of the walls, angles, and/or wall slopes of the clamp walls may also be the reverse of what is illustrated in the exemplary embodiment. For example, the third wall 31 that includes the notch may be longer than the fourth wall 33 that includes the aperture, the angle between the first wall 36 and the fourth wall 33 may be wider or equal to the angle between the first wall 36 and third wall 31, etc. In addition, it should be understood that the clamp need not necessarily include defined walls. For example, the clamp may be a cylindrical clasp or ring-shaped, include a portion that is cylindrical shaped and a portion that is a wall(s), etc.
First wall 36 and/or second wall 37 may include at least part of first notch 32. In the exemplary embodiment, first wall 36 and second wall 37 each include a portion of the notch 32. However, it should be understood by those skilled in the art that only one of the first and second walls may include at least part of the notch.
First notch 32 is configured to engage tab 21b of contact portion 20. When tab 21b (or 21a, 21c) is engaged with notch 32, X and Y are substantially perpendicular to one another (see
The space between the first wall 36 and the second wall 37 preferably forms a channel 38 for receiving a wire/conductor. The channel 38 allows for a conductor to be received between the first wall 36 and the second wall 37. Preferably, the narrowest part of the channel 38 is wider than the widest conductor that may be received into the channel 38. In some embodiments, fastener 40 is in contact, or interferes with, first wall 36 and/or second wall 37.
Clamp 30 may be composed of any suitable metal, including but not limited to, a steel-plated material, a zinc-plated material, etc. One advantage of using a zinc-plated material is to provide corrosion resistance. Thus, zinc-plating the clamp 30 alleviates the potential issue of corrosion and/or a galvanic reaction due to a contact portion 20 composed of a brass-type material in contact with the clamp 30 composed of a steel-type material. Using a steel-plated material reduces deformation or buckling of the clamp 30 when engaged with the contact portion 20.
Aperture 35 may include “thread-like” features, and fastener 40 may thread into aperture 35 of clamp 30. In addition to or in alternative to the threads in the aperture, first wall 36 and/or second wall 37 may include “thread-like” features which may engage the threads of fastener 40. In other words, the threads in first wall 36 and second wall 37 may form threads which engage at least a portion of fastener 40, even though they may not totally encircle fastener 40. In addition, the walls of the clamp may include “thread-like” features even if the walls are not angled/sloped and even if the clamp is another shape, including, but not limited to ring-shaped, cylindrical, etc.
Fastener 40 may be, but is not limited to, a set screw, a self-tapping screw, clasp, pin, stud, rod, bolt, etc. In addition, fastener 40 may be configured to be driven by any suitable drive configuration, such as, but not limited to, an allen/hex drive, slotted/straight blade drive, Phillips/cross drive, 6-point star/torx drive, square/Robertson drive, or the like. In addition, fastener 40 may have any suitable type of head, or it may be headless as in the case of a set screw. A screw driver or other suitable tool (not shown) may engage groove 45 of the fastener 40. The selection of the drive type for fastener 40 may depend on the intended application and torque requirements of fastener 40. For example, there may be a predefined torque range for a given terminal or application. For example, a minimum amount of torque may be required to ensure a low resistance electrical connection that is also mechanically secure. Conversely, the torque should not exceed a maximum value in order to avoid undesirable deformation. The use of a slotted drive may ensure that sufficient torque is applied while preventing excessive torque. Similarly, a Phillips drive may also be used to prevent excessive torque. One inherent feature of a Phillips drive is that the Phillips bit will cam out of the drive recess above a certain torque. This cam out behavior can be used to ensure excessive torque is not applied.
There are several advantages to the contact portion 20 being positioned substantially perpendicular to the clamp 30, as opposed to a conventional terminal where the contact portion is stacked in line with the clamp. One advantage is that the height of the terminals in the disclosed invention may be less than the height of a conventional terminal. Thus, the same terminal can be used in different types of electrical receptacles that have varying depth restrictions, including but not limited to, flush-mount receptacles, surface-mount receptacles, etc. Advantages of reducing the number of unique terminal parts required among different types of receptacles include automating production as well as cutting manufacturing costs, complexity, inventory, etc.
Another advantage of the clamp 30 being in a substantially perpendicular position to the contact portion 20 (and the contact portion 20 having a plurality of tabs) is that the same components of terminal 10 can be assembled in a variety of different configurations. Thus, if an electrical receptacle (see
The configuration of the terminal is dependent on which one of the plurality of tabs 21a, 21b, 21c is engaged in the first notch 32 of clamp 30. That is, when one of the plurality of tabs 21a, 21b, 21c is engaged with the notch 32, there is a different configuration position than when any other one of the plurality of tabs 21a, 21b, 21c is engaged with notch 32. For example, in the exemplary embodiment, when a first tab 21b is engaged with notch 32, the terminal is in a first terminal configuration position (as shown in
The ability to configure the terminal in a plurality of different configuration positions allows for one or more terminals in an electrical receptacle to each have the same components (i.e. contact portion 20, clamp 30, and fastener 40) because each terminal can be assembled in a configuration position that would match the configuration of each plug blade aperture in the socket (not shown).
Tabs 21a, 21b, and 21c provide structural joint support when they are engaged with first notch 32 of clamp 30. Torque ratings of the disclosed invention maintains or exceeds torque ratings in conventional terminals for a two-piece device.
As shown in the exemplary embodiment of
In another embodiment, the terminal may be a ground terminal. For ground terminals, the clamp component may be the same clamp component as the exemplary embodiment in
The contact portion of ground terminals may differ from the contact portion of the terminals in the exemplary embodiments in
The method of assembling an electrical receptacle terminal 10 for receiving an electrical plug blade includes engaging one of a plurality of tabs 21a, 21b, 21c of a contact portion 20 with first notch 32 of clamp 30, wherein the clamp includes a first notch 32 and an aperture 35; and inserting a fastener into aperture 35 of clamp 30. When assembled, contact portion 20 is substantially perpendicular to clamp 30. Any one of the plurality of tabs 21a, 21b, 21c of the contact portion 20 may engage notch 32 of clamp 30. The one of the plurality of tabs 21a, 21b, 21c chosen to engage with notch 32 depends on the desired or predetermined orientation (i.e. first terminal configuration position, second terminal configuration position, third terminal configuration position) of terminal 10.
In the method of assembling a terminal, the terminal may be a ground terminal, which includes a ground contact portion configured to receive a ground pin. The ground contact portion may, but not necessarily, have the same geometry as contact portions 20, but may have a wider spacing between the jaws to receive a ground pin. The clamp used in the ground terminal may be the same as the clamp 30 used in terminal 10, and the fastener may be the same as the fastener 40 used in terminal 10.
Terminals 90a, 90b, 90c, 130 are each assembled and positioned in accordance with their function and the plug/receptacle configuration. Each of the respective terminals 90a, 90b, 90c (non-ground terminals), may, but not necessarily, include substantially identical components. These components of the respective terminals 90a, 90b, 90c include: a contact portion 120a, 120b, 120c; a clamp 100a, 100b, 100c; and a fastener 110a, 110b, 110c. However, the configurations of these components may vary by terminal 90a, 90b, 90c. Clamp 100d of ground terminal 130 may, but not necessarily, be substantially identical to clamps 100a, 100b, 100c; and, fastener 110d of ground terminal 130 may, but not necessarily, be substantially identical to fasteners 110a, 110b, 110c.
Contact portions 120a, 120b, 120c of terminals 90a, 90b, 90c each include a first end with a plurality of tabs. In this embodiment, the geometry and number of the tabs of the contact portions 120a, 120b, 120c are similar to the geometry described and shown in the exemplary embodiments in
Clamps 100a, 100b, 100c (and 100d) may each be substantially identical and are similar to the geometry and features described and shown in the embodiments of
Fasteners 110a, 110b, 110c, 110d may, but not necessarily, be substantially identical to one another and are similar to the features described and shown in the embodiments of
When each of the terminals 90a, 90b, 90c, 130 are assembled, each of the contact portions 120a, 120b, 120c, 140 are substantially perpendicular to each of the respective clamps 100a, 100b, 100c, 100d. The configuration position of the terminals 90a, 90b, 90c, 130 is dependent on which one of the plurality of tabs of the contact portion 120a, 120b, 120c, 140 engages with the notches in the clamps 100a, 100b, 100c, 100d, respectively.
A difference between the plurality of terminals 90a, 90b, 90c may be the configurations of the components. The configurations of the components in each terminal 90a, 90b, 90c may differ according to the respective configuration of each the plurality of apertures 86a, 86b, 86c in socket 85 and/or openings 70a, 70b, 70c in base portion 70. In other words, contact portions 120a, 120b, 120c may, but not necessarily, be each substantially identical; clamps 100a, 100b, 100c may, but not necessarily, be each substantially identical; and, fasteners 110a, 110b, 110c may, but not necessarily, be each substantially identical. But the way each respective contact portion 120a, 120b, 120c is coupled to each respective clamp 100a, 100b, 100c may differ to obtain the required configuration needed to align with the apertures 86a, 86b, 86c in socket 85 and the openings 71a, 71b, 71c in base portion 70. In order for clamp 100a of terminal 90a to align with opening 71a of base portion 70, and for contact portion 120a of terminal 90a to align with aperture 86a of socket 85, the terminal 90a is assembled in a first terminal configuration position (see
Ground terminal 130 is configured to receive the ground pin of an electrical plug. Ground terminal 130 has a clamp 100d, which may, but not necessarily, be substantially identical to the clamps 100a, 100b, 100c of the other terminals 90a, 90b, 90c. In addition, ground terminal 130 has a fastener 110d, which may, but not necessarily, be substantially identical to the fasteners 110a, 110b, 110c of the other terminals 90a, 90b, 90c. A difference between the components of the ground terminal 130 and the components of the other terminals 90a, 90b, 90c is the contact portion. Ground contact portion 140 may, but not necessarily, have the same geometry as the other contact portions 90a, 90b, 90c; however, ground contact portion 140 may differ from the other contact portions 90a, 90b, 90c in that the spacing or width between the jaws in the ground contact portion 140 is wider than the spacing or width between the jaws in the other contact portions 90a, 90b, 90c. The wider spacing between the jaws in the ground contact portion 140 accounts for the difference in sizing of the ground pin.
Base portion 70 includes a plurality of openings 71a, 71b, 71c, 71d. Each of these openings 71a, 71b, 71c, 71d are configured to receive a terminal 90a, 90b, 90c, 130. More specifically, opening 71a receives terminal 90a, opening 71b receives 90b, opening 71c receives terminal 90c, and opening 71d receives ground terminal 130. When terminals 71a, 71b, 71c, 71d are inserted into base portion 70, the outer edges of fasteners 110a, 110b, 110c, 110d are exposed to the external environment due to the openings 71a, 71b, 71c, 71d of the base portion 70. This exposure allows fasteners 110a, 110b, 110c, 110d to be loosened and tightened accordingly when the receptacle 60 is in an assembled position.
The electrical receptacle shown in
Socket 85 includes a plurality of apertures 86a, 86b, 86c, 86d so that plug blades of an appropriate electrical plug (not shown) can be inserted through the apertures 86a, 86b, 86c, 86d and into engagement with the contact portions 120a, 120b, 120c, 140 of terminals 90a, 90b, 90c, 130. In this exemplary embodiment, one of the apertures 86d in socket 85 is configured to receive a ground pin (not shown). Ground terminal 130 is configured to align with the ground aperture 86d in socket 85. The embodiment in
The method of assembling an electrical receptacle 60, which receives a plurality of plug blades includes assembling a plurality of terminals 90a, 90b, 90c, 130, and aligning each of the plurality of terminals 90a, 90b, 90c, 130 with one of a plurality of openings 71a, 71b, 71c, 71d in a base portion 70. Each of terminals 90a, 90b, 90c, 130 are assembled according to the method described in detail above, and then inserted into base portion 70 according to their function, desired or predetermined orientation, etc. As discussed above, assembling each of the plurality of terminals 90a, 90b, 90c, 130 includes engaging one of a plurality of tabs of a contact portion 120a, 120b, 120c, 140 with the notch of a respective clamp 100a, 100b, 100c, 100d, respectively. Each of the terminals 90a, 90b, 90c, 130 include an end with a plurality of tabs, and each of the clamps 100a, 100b, 100c, 100d includes a notch on one end and an aperture on the opposite end. Each of the contact portions 120a, 120b, 120c, 140 engages with each respective clamp 100a, 100b, 100c, 100d resulting in each of the contact portions 120a, 120b, 120c, 140 being in a substantially perpendicular position to each of the respective clamps 100a, 100b, 100c, 100d. Any one of the plurality of tabs on the contact portion 120a, 120b, 120c, 140 may engage the notch of the respective clamp 100a, 100b, 100c, 100d, the tab chosen being the one that allows the terminal 90a, 90b, 90c, 130 to align with the desired or predetermined orientation required to align with the respective openings 71a, 71b, 71c, 71d of base portion 70 and/or the plurality of apertures 86a, 86b, 86c, 86d in socket 85. Fasteners 100a, 100b, 100c, 100d are then inserted into each of the apertures of clamp 100a, 100b, 100c, 100d.
In the method of assembling the electrical receptacle, one of the terminals may be a ground terminal 130, which includes a ground contact portion 140 configured to receive a ground pin. The ground contact portion 140 may have the same geometry as the other contact portions 120a, 120b, 120c, but has a wider spacing between the jaws to account for a ground pin. The clamp 100d and the fastener 110d may be the same clamp and fastener used in the other terminals 90a, 90b, 90c.
According to the method of assembling the electrical receptacle, the plurality of terminals 90a, 90b, 90c, 130 are each aligned with one of a plurality of openings 71a, 71b, 71c, 71d in the base portion according to the desired or predetermined orientation, and each of the plurality of terminals 90a, 90b, 90c, 130 is inserted into the base portion 70. For example, opening 71a of base portion 70 is positioned in such a way that a terminal in the first terminal configuration position (see
After inserting fasteners 110a, 110b, 110c, 110d into the respective clamp 100a, 100b, 100c, 100d, each of the terminals 90a, 90b, 90c, 130 may be inserted into base portion 70 so that the head of the fasteners 110a, 110b, 110c, 110d are positioned outward, towards, or into each of the openings 71a, 71b, 71c, 71d of base portion 70. The sequence of inserting the terminals 90a, 90b, 90c, 130 into base portion 70 is for illustrative purposes, and the terminals may be inserted into the base portion in any desired order.
The method of assembling the electrical receptacle may further include positioning an end (i.e. bared end) of a conductor in the channel of one or more of the clamps 100a, 100b, 100c, 100d, and tightening each of the respective fasteners 110a, 110b, 110c, 110d to hold the conductor against the tab of the contact portion 120a, 120b, 120c, 140 that is engaged with the respective notch of clamp 100a, 100b, 100c, 100d. As the fastener 110a, 110b, 110c, 110d is tightened, the fastener forces the bared end of the conductor against the tab of the contact portion that is engaged with the respective notch. Thus, the conductor is retained in the channel of the clamp. Further, the method of assembling the electrical receptacle 60 may further include engaging socket 85 with cover plate or cover portion 80, and engaging cover plate or cover portion 80 with base portion 70.
With the exception of the ground terminals, the terminals used among the different NEMA configurations shown in
It should be understood that the embodiments in
Terminal 190b includes contact portion 220b, clamp 200b, and fastener 210b. Contact portion 220b includes a plurality of tabs 222a, 222b, 222c. Tab 222b engages a notch on clamp 200b, and fastener 210b extends through an aperture on clamp 200b. Terminal 190b is in a first terminal configuration position (as shown in
In the exemplary embodiment in
While certain embodiments of the disclosure have been described herein, it is not intended that the disclosure be limited thereto, as it is intended that the disclosure be as broad in scope as the art will allow and that the specification be read likewise. Therefore, the above description should not be construed as limiting, but merely as exemplifications of particular embodiments. Those skilled in the art will envision additional modifications, features, and advantages within the scope and spirit of the claims appended hereto.
