Electrical plug
11387614 ยท 2022-07-12
Assignee
Inventors
Cpc classification
H01R27/00
ELECTRICITY
International classification
H01R13/58
ELECTRICITY
H01R27/00
ELECTRICITY
Abstract
An electrical plug accommodates many different angular configurations of electrical contacts, has a modular design, and is sturdy and robust. In one embodiment, a reconfigurable power cord assembly includes an electrical plug having a plug body having a plurality of cavities, each cavity for receiving a single electrical contact, at least one cavity configured to allow the respective electrical contact to be positioned in one of the plurality of cavities, at one of a plurality of angular positions, each electrical contact being supported within its cavity by a contact retainer that mounts within the plug body to secure respective electrical contacts within the plug body in a predetermined orientation, wherein the plug body is configured to accommodate a plurality of electrical contact orientations, the contact retainer being removably and rotatably attached to the interior of the plug body.
Claims
1. A configurable electrical plug assembly comprising: power cord having a plurality of conductors, each individual conductor having a respective electrical contact conductively attached thereto; a plug body; a first body piece having a plurality of cavities, each cavity for receiving a single electrical contact, at least one cavity configured to allow the respective electrical contact to be positioned at one of a plurality of distinct angular positions, each electrical contact being supported within its cavity by a contact retainer that mounts within the first body piece to secure respective electrical contacts within the first body piece in a predetermined orientation, the respective contact retainers being removably and rotatably attached to the interior of the first body piece; and a first faceplate that couples with the first body piece, the first faceplate having one or more apertures configured to allow one or more of the electrical contacts to be locked in a first configuration at their respective predetermined cavities and angular orientations.
2. The configurable electrical plug of claim 1 wherein the first body piece and the first faceplate are configured such that the first faceplate can be decoupled from the first body piece to allow at least one electrical contact to be re-positioned, wherein re-positioning the at least one electrical contact includes one or more of: moving the at least one electrical contact from a first distinct angular position in a first distinct cavity to a second distinct angular position in the first distinct cavity; moving the at least one electrical contact from a first distinct angular position in a first distinct cavity to the first distinct angular position in a second distinct cavity; and moving the at least one electrical contact from a first distinct angular position in a first distinct cavity to a second distinct angular position in a second distinct cavity; and further wherein when a second faceplate is coupled with the first body piece, the second faceplate is utilized to lock the plurality of electrical contacts into a second configuration, the second configuration being distinct from the first configuration.
3. The configurable electrical plug of claim 1 wherein the first body piece and the first faceplate are configured such that the first faceplate can be decoupled from the first body piece to allow at least one electrical contact, when viewed end-on at a distal end of the electrical contact, to be re-positioned within one of the plurality of cavities from a first distinct angular position to a second distinct angular position, wherein when a second faceplate is coupled with the first body piece, the second faceplate is utilized to lock the plurality of electrical contacts into a second configuration, the second configuration being distinct from the first configuration.
4. The configurable electrical plug of claim 1 wherein the first body piece and the first faceplate are configured such that the first faceplate can be decoupled from the first body piece to allow at least one electrical contact, when viewed end-on at a distal end of the electrical contact, to be re-positioned within one of the plurality of cavities up to 90 degrees along its longest axis from a first distinct angular position to a second distinct angular position, wherein when a second faceplate is coupled with the first body piece, the second faceplate is utilized to lock the plurality of electrical contacts into a second configuration, the second configuration being distinct from the first configuration.
5. The configurable electrical plug of claim 1 wherein the first body piece and the first faceplate are configured such that the first faceplate can be decoupled from the first body piece to allow at least one electrical contact, when viewed end-on at a distal end of the electrical contact, to be re-positioned within one of the plurality of cavities 90 degrees along its longest axis from a first distinct angular position to a second distinct angular position, wherein when a second faceplate is coupled with the first body piece, the second faceplate is utilized to lock the plurality of electrical contacts into a second configuration, the second configuration being distinct from the first configuration.
6. The configurable electrical plug of claim 1 wherein the first body piece and the first faceplate are configured such that the first faceplate can be decoupled from the first body piece to allow at least one electrical contact, when viewed end-on at a distal end of the electrical contact with respect to the plug body, to be re-positioned within one of the plurality of cavities at least 45 degrees along its longest axis from a first distinct angular position to a second distinct angular position, wherein when a second faceplate is coupled with the first body piece, the second faceplate is utilized to lock the plurality of electrical contacts into a second configuration, the second configuration being distinct from the first configuration.
7. The configurable electrical plug of claim 1 wherein the first body piece, the first faceplate, and the second faceplate are configured to allow a fixed number of electrical contacts to be positioned within one of a number of cavities at one of a plurality of distinct angular positions.
8. The configurable electrical plug of claim 1 wherein the first faceplate that locks the contacts in the first configuration has apertures that are one or more of differently shaped, differently sized, and differently positioned than the apertures of the second faceplate that locks the contacts in the second configuration.
9. The configurable electrical plug of claim 1 wherein when the electrical plug is fully assembled into a given configuration, a faceplate secures the contacts to prevent movement of the contact retainers and the electrical contacts with respect to the plug body.
10. The configurable electrical plug of claim 1 wherein in a given configuration, each electrical contact of the given configuration is secured within a contact retainer which itself is removably secured within a cavity of the first body piece, the contact retainer being prevented from rotation within the cavity when the contact retainer is locked in an operational position.
11. A method for assembling and configuring a configurable electrical plug comprising: inserting two or more electrical contacts into respective contact retainers, thereby forming two or more respective contact combinations; for each contact combination, inserting the contact combination within a first body piece of an electrical plug, the first body piece of the electrical plug having a plurality of cavities, wherein: each cavity of the plurality of cavities is configured to receive a single contact combination; at least one of the plurality of cavities is configured to allow the contact combination to be positioned at one of a plurality of distinct angular positions; and the electrical contact combinations are removably and rotatably attached to the interior of the first body piece of the electrical plug; coupling a first faceplate to the first body piece of the electrical plug, the first faceplate having one or more apertures configured to enable one or more of the contact combinations to be locked in a first configuration in their respective cavities and angular positions; determining a second configuration comprising a second distinct position for at least one of the contact combinations; decoupling the first faceplate from the first body piece; at least partially removing, from the first body piece, at least one contact combination having a first distinct angular position within a first distinct cavity; re-positioning the at least one contact combination having the first distinct angular position within the first distinct cavity; and coupling a second faceplate to the first body piece of the electrical plug, the second faceplate having one or more apertures configured to allow one or more of the contact combinations to be locked into the second configuration in their respective cavities and angular positions.
12. The method of claim 11 wherein re-positioning the at least one contact combination includes one or more of: moving the at least one contact combination from a first distinct angular position in a first distinct cavity to a second distinct angular position in the first distinct cavity; moving the at least one contact combination from a first distinct angular position in a first distinct cavity to the first distinct angular position in a second distinct cavity; and moving the at least one contact combination from a first distinct angular position in a first distinct cavity to a second distinct angular position in a second distinct cavity; and further wherein when a second faceplate is coupled with the first body piece, the second faceplate is utilized to lock one or more of the contact combinations into a second configuration, the second configuration being distinct from the first configuration.
13. The method of claim 11 wherein, when the first faceplate is decoupled from the first body piece, at least one electrical contact, when viewed end-on at a distal end of the electrical contact, is re-positioned within one of the plurality of cavities from a first distinct angular position to a second distinct angular position and further wherein, when a second faceplate is coupled with the first body piece, the second faceplate is utilized to lock one or more of the contact combinations into a second configuration, the second configuration being distinct from the first configuration.
14. The method of claim 11 wherein when the first faceplate is uncoupled from the first body piece, at least one electrical contact, when viewed end-on at a distal end of the electrical contact, is re-positioned within one of the plurality of cavities up to 90 degrees along its longest axis from a first distinct angular position to a second distinct angular position and further wherein, when a second faceplate is coupled with the first body piece, the second faceplate may be utilized to lock one or more of the contact combinations into a second configuration, the second configuration being distinct from the first configuration.
15. The method of claim 11 wherein, when the first faceplate is uncoupled from the first body piece, at least one electrical contact, when viewed end-on at a distal end of the electrical contact, is re-positioned within one of the plurality of cavities 90 degrees along its longest axis from a first distinct angular position to a second distinct angular position and further wherein, when a second faceplate is coupled with the first body piece, the second faceplate may be utilized to lock one or more of the contact combinations into a second configuration, the second configuration being distinct from the first configuration.
16. The method of claim 11 wherein, when the first faceplate is decoupled from the first body piece, at least one electrical contact, when viewed end-on at a distal end of the electrical contact with respect to the plug body, is re-positioned within one of the plurality of cavities at least 45 degrees along its longest axis from a first distinct angular position to a second distinct angular position and further wherein, when a second faceplate is coupled with the first body piece, the second faceplate is utilized to lock one or more of the contact combinations into a second configuration, the second configuration being distinct from the first configuration.
17. The method of claim 11 wherein the first faceplate that locks the contact combinations in the first configuration has apertures that are one or more of differently shaped, differently sized, and differently positioned than the apertures of the second faceplate that locks the contact combinations in the second configuration.
18. The method of claim 11 wherein, when the configurable electrical plug is fully assembled, a faceplate prevents each of the one or more contact combinations from pulling out of its respective cavity, and further secures each contact combination against rotation once a given contact combination is fully seated into its respective body cavity.
19. The method of claim 11 wherein each electrical contact of a given contact combination configuration is secured within a contact retainer which itself is removably secured within one of the plurality of cavities of the first body piece, each contact retainer being prevented from rotation within the cavity when the contact retainer is locked in an operational position.
20. A configurable electrical plug assembly comprising: one or more electrical contacts inserted into respective contact retainers, thereby forming one or more contact combinations; a first body piece of an electrical plug body having a plurality of cavities, each cavity configured to receive a single contact combination, at least one cavity configured to allow the respective contact combination to be positioned in one of a plurality of cavities at one of a plurality of angular positions, the respective contact combinations being removably and rotatably attached to the interior of the first body piece; and one or more faceplates that couple with the first body piece, the faceplates having one or more apertures configured to allow one or more of the contact combinations to be locked into one of a plurality of distinct configurations.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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(13) Common reference numerals are used throughout the figures and the detailed description to indicate like elements. One skilled in the art will readily recognize that the above figures are examples and that other architectures, modes of operation, orders of operation and elements/functions can be provided and implemented without departing from the characteristics and features of the invention, as set forth in the claims.
DETAILED DESCRIPTION
(14) Embodiments will now be discussed with reference to the accompanying figures, which depict one or more exemplary embodiments. Embodiments may be implemented in many different forms and should not be construed as limited to the embodiments set forth herein, shown in the figures, and/or described below. Rather, these exemplary embodiments are provided to allow a complete disclosure that conveys the principles of the invention, as set forth in the claims, to those of skill in the art.
(15) In this disclosure, the embodiments are exemplary, and individual features from one or more of the exemplary embodiments are contemplated to work together and may be combined into collections of features that may differ from the particular features of exemplary embodiments discussed herein. However, those combinations are well within the scope of the inventions discussed herein.
(16) Embodiments herein include an electrical plug that has electrical contacts that can rotate to fit multiple configurations of female ends that are on the market today. Further, various pieces of the electrical plug are configured to accommodate various embodiments having different numbers of electrical contacts, such as two electrical contacts, three electrical contacts, or four electrical contacts, with up to seven different locations for the electrical contacts available in the first body piece, depending on a given design of an implementation of the features discussed herein. Further, the types of electrical contacts may also be varied. For example, some electrical contacts are long and flat, and are presented as a blade. Others, have an arcuate shape, L shape, a U shape, or other shape, depending on what the interfacing female socket or receptacle is configured for. Further, the possible angular orientations of the various numbers of electrical contacts are controllable by the design of a particular implementation of the claimed invention. Thus, several different embodiments having different possible angular orientations and different numbers of electrical contacts at the various different possible angular orientations may be accommodated in various designs according to the principles discussed herein.
(17) In addition to being configured for electrical contact rotation, the electrical plug is also a modular system in order to accommodate spacing and prong style differences that rotation alone cannot achieve. In one embodiment, replacing a flat electrical contact with an L shape electrical contact is enabled by the modular characteristics discussed herein. The inventions discussed herein make switching configurations easy and quick, and are safe to reconfigure.
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(19) Referring to
(20) In one embodiment, electrical contacts 102 are formed of a conductive rigid metal alloy that includes one or more metals and/or one or more nonmetals of appropriate conductivity and other characteristics well known to those of ordinary skill.
(21) In one embodiment, first body piece 104 couples with second body piece 106 through threads 108 on the exterior of a portion the first body piece interfacing with thread channels (not shown) on the interior of second body piece 106. During assembly, when assembling the electrical plug body to lock electrical contacts 102 into place within electrical plug 100 at predetermined angles, the first body piece and the second body piece are rotated in relation to one another, causing threads 108 on first body piece 104 to engage with thread channels on second body piece 106, the rotation continuing until first body piece 104 and second body piece 106 are snugly fit together, putting pressure on contact combinations within the plug body and locking electrical contacts 102 into place within first body piece 104.
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(23) Referring to
(24) Each contact retainer, such as contact combinations 202a, 202b, and 202c, is shown with a raised contact retainer component discussed below which helps secure contact combinations in the cavities at desired angular configurations.
(25) In one embodiment, a given cavity is keyed with a given contact retainer/contact combination so that only particular contact combinations are able to be inserted into the given cavity.
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(27) Referring to
(28) In one embodiment, a portion of bottom area 310 of contact combination 300 is hollowed out as a contact retainer cavity (see
(29) Locking portion 318 of contact retainer 301 is a hollowed out area having a matching bump on electrical contact 303 to be permanently installed into contact retainer 301. When electrical contact 303 is pushed into slotted area 322 of contact retainer 301, a blade of electrical contact 303 (or other shape as discussed herein) passes through slotted area 322 which is slotted through so that the blade of electrical contact 303 passes through contact retainer 301 until a base of electrical contact 303 engages the contact retainer cavity. Because the base of the electrical contact largely fills the contact retainer cavity, the bump on electrical contact 303 temporarily deforms the cavity in the area of the bump, as the bump passes through the area towards the locking portion 318. As electrical contact reaches its final position within contact retainer 301, the bump on electrical contact 303 fits snugly into locking portion 318 of contact retainer 301.
(30) Also provided as an optional feature of contact retainer 301 is an alignment point 320 which is an indented area of contact retainer 301 which serves to support electrical contact 303 as it is being seated within contact retainer 301.
(31) To recap, when a base end of an electrical contact, such as an electrical contact 303, is attached to a conductor of a power cable, the distal end of the electrical contact first passes through bottom area 310 of contact retainer 301 and into a bottom end of slot 312 up through the top end 312 of the slot (see
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(33) Referring to
(34) Persons of ordinary skill having the benefit of this disclosure will readily recognize that whatever angles are desired that the electrical contacts be able to be secured in are governed by the receiving cavity for a given contact, and what angles the given cavity is designed to receive.
(35) Of note, channel 412 of cavity 402 allows for rotation within the channel with partial disassembly of a completed electrical plug, with the amount of possible rotation being governed by the number of degrees of the corresponding area the channel is formed over. Here, the channel is depicted as being formed over 90 degrees, thus allowing rotation after partial disassembly of a given associated contact combination, of 90 degrees. Other degree measures of the channel are possible, and contemplated. For example, the channel can be formed around 45 degrees, 135 degrees, or any other degree measure, as desired by a designer of a particular implementation of the inventive features discussed herein.
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(37) Referring to
(38) This cord lock design has several advantages over currently existing designs. Firstly, the cord lock design depicted herein it does not require screws. Screws can strip out and make the rest of the plug useless. Secondly, since the sliding pieces won't be able to fall off, it will help keep the entire device together when prongs are being changed. Lastly, a hose clamp used to tighten the sliders on the cord is quicker and easier than using screws.
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(40) Referring to
(41) At operation 604, the two or more electrical contacts are each inserted into respective contact retainers which are separate pieces that are normally installed within the electrical plug prior to operation, forming contact combinations.
(42) At operation 606, each respective contact combination is inserted into individual electrical plug cavities so that the respective electrical contact is positioned at a respective individual predetermined angle. Each electrical contact may be positioned at a different angle, depending on the needs of a particular situation.
(43) At operation 608, the body of the electrical plug is assembled, to lock the contact combinations into place within the electrical plug body at the predetermined angles. Using the embodiments of
(44) In one embodiment, assembly of the electrical plug includes securing the power cable to the plug. In one embodiment, a second end of second body piece is where the power cable exits the second body piece, passing between two rails which provide support to a clasping mechanism which secures the power cable rigidly within the electrical plug. A hose clamp or other clamping mechanism positioned around the outside circumference may serve to retain the slides in a clamped configuration, securing a power cable between them.
(45) At operation 610, the process optionally includes a determination that one or more of the electrical contacts need to be rotated, to achieve a new configuration.
(46) At operation 612, the electrical plug is partially disassembled, mostly to remove the pressure from the contact combinations so that one or more of those contact combinations can be rotated, at operation 614, to one or more new angles.
(47) The electrical plug is then reassembled by performing one or more of operations 606 and 608 again at operation 616.
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(52) The embodiment of
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(54) As discussed in detail above with respect to
(55) In one embodiment, re-positioning the at least one electrical contact includes one or more of moving the at least one electrical contact from a first distinct angular position in a first distinct cavity to a second distinct angular position in the first distinct cavity, moving the at least one electrical contact from a first distinct angular position in a first distinct cavity to the first distinct angular position in a second distinct cavity, and moving the at least one electrical contact from a first distinct angular position in a first distinct cavity to a second distinct angular position in a second distinct cavity.
(56) As shown in
(57) Referring back to
(58) In one embodiment, one-way screw slot 709a of faceplate 706 and corresponding one-way screw slot 709b of first body piece 704 allow for the first faceplate 706 to be coupled to first body piece 704. In one embodiment, screw slots 707a of faceplate 706 and corresponding screw slots 707b of first body piece 704 allow for one or more contact combinations 701 to be secured to first body piece 704 of electrical plug 700, and also allow faceplate 706 to be secured to first body piece 704 of electrical plug 700. Screw slots 707a and 707b function to secure the one or more contact combinations 701 to first body piece 704 of electrical plug 700 in order to protect conductively attached wires (not shown). In one embodiment, the screws that secure the one or more contact combinations 701 to first body piece 704 also help to secure faceplate 706. It should be noted here that the above described coupling mechanisms are given for illustrative purposes only and are not intended to limit the scope of the invention as disclosed herein, and as claimed below.
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(61) Referring to
(62) In one embodiment, once two or more respective contact combinations are formed at 804, process flow proceeds to 806. In one embodiment, at 806, each respective contact combination is inserted within a first body piece of an electrical plug, wherein the first body piece of the electrical plug has a plurality of cavities. In one embodiment, each respective contact combination is inserted into the electrical plug cavities so that the respective electrical contact is positioned at one of a plurality of distinct angular positions. Each electrical contact combination may be positioned at a different angle, depending on the needs of a particular situation.
(63) In one embodiment, once each contact combination is inserted into an electrical cavity at 806, process flow proceeds to 810. In one embodiment, at 810, a first faceplate is coupled to the first body piece of the electrical plug, to lock the contact combinations in a first configuration within cavities of the electrical plug body at their respective positions and angles. Using the embodiments of
(64) In one embodiment, once the first faceplate is coupled to the first body piece of the electrical plug at 810, process flow proceeds to 812. In one embodiment, at 812, the process optionally includes a determination that one or more of the electrical contacts needs to be rotated and/or repositioned, to achieve a new, second configuration.
(65) In one embodiment, upon determination of a desired second configuration at 812, process flow proceeds to 814. In one embodiment, at 814, the electrical plug is partially disassembled, to decouple the first faceplate from the first body piece of the electrical plug such that one or more of the contact combinations can be rotated to one or more new angles, or moved to one or more new positions.
(66) In one embodiment, once the first faceplate is decoupled from the first body piece at 814, process flow proceeds to 816. In one embodiment, at 816, at least one contact combination having a first distinct angular position within a first distinct cavity is at least partially removed from its respective cavity in the first body piece of the electrical plug.
(67) In one embodiment, once the at least one contact combination is at least partially removed from its respective cavity at 816, process flow proceeds to 818. In one embodiment, at 818, the at least one contact combination is re-positioned within the first distinct cavity.
(68) In one embodiment, re-positioning the contact combination includes one or more of moving the at least one contact combination from a first distinct angular position in a first distinct cavity to a second distinct angular position in the first distinct cavity, moving the at least one contact combination from a first distinct angular position in a first distinct cavity to the first distinct angular position in a second distinct cavity, moving the at least one contact combination from a first distinct angular position in a first distinct cavity to a second distinct angular position in a second distinct cavity.
(69) In one embodiment, once the at least one contact combination is re-inserted within the first body piece at 818, process flow proceeds to 820. In one embodiment, at 820, the electrical plug is then reassembled by coupling a second faceplate to the first body piece of the electrical plug, the second faceplate having one or more apertures configured to allow one or more of the contact combinations to be locked into the second configuration in their respective cavities and angular positions. In one embodiment, the first faceplate that locks the contact combinations in the first configuration has apertures that are differently shaped, differently sized, and/or differently positioned than the apertures on the second faceplate that locks the contact combinations in the second configuration. In various embodiments, operations 812 through 820 may be repeated as many times as desired. In one embodiment, once a desired configuration has been achieved, the faceplate may be permanently coupled to the first body piece of the electrical plug to prevent further reconfiguration.
(70) In one embodiment, once the second faceplate is coupled to the first body piece at 820, process flow proceeds to EXIT 822 and the process 800 for assembling and configuring an electrical plug is exited.
(71) In the discussion above, certain aspects of one embodiment include a component of manufacture, process steps and/or operations and/or instructions described herein for illustrative purposes. However, the particular order and/or grouping shown and discussed herein are illustrative only and not limiting. Those of skill in the art will recognize that other orders and/or groupings are possible and, in some embodiments, one or more of the process steps and/or operations and/or instructions discussed above can be combined and/or deleted. In addition, portions of one or more of the process steps and/or operations and/or instructions can be re-grouped as portions of one or more other of the process steps and/or operations and/or instructions discussed herein. Consequently, the particular order and/or grouping of the process steps and/or operations and/or instructions discussed herein do not limit the scope of the invention as claimed below.
(72) As discussed in more detail above, using the above embodiments, with little or no modification and/or input, there is considerable flexibility, adaptability, and opportunity for customization to meet the specific needs of various parties under numerous circumstances.
(73) The present invention has been described in particular detail with respect to specific possible embodiments. Those of skill in the art will appreciate that the invention may be practiced in other embodiments. Also, particular divisions of functionality between the various components described herein are merely exemplary, and not mandatory or significant. Consequently, functions performed by a single component may, in other embodiments, be performed by multiple components, and functions performed by multiple components may, in other embodiments, be performed by a single component.
(74) It should also be noted that the language used in the specification has been principally selected for readability, clarity and instructional purposes, and may not have been selected to delineate or circumscribe the inventive subject matter. Accordingly, the disclosure of the present invention is intended to be illustrative, but not limiting, of the scope of the invention, which is set forth in the claims below.
(75) In addition, the operations shown in the figures, or as discussed herein, are identified using a particular nomenclature for ease of description and understanding, but other nomenclature is often used in the art to identify equivalent operations.
(76) Therefore, numerous variations, whether explicitly provided for by the specification or implied by the specification or not, may be implemented by one of skill in the art in view of this disclosure.