Low profile electrical terminal assembly

Abstract

An electrical terminal assembly is provided for use in a low-profile electrical raceway or the like. The terminal assembly includes first and second conductive bodies and an insulator disposed between them. The first body has at least two branches including respective electrical terminals extending outwardly from a main or central portion, with the terminals positioned in a terminal plane. The second body also has at least two branches including respective electrical terminals extending outwardly from a main or central portion, with the terminals positioned in the same terminal plane as the terminals of the first body. The terminals of the second body are positioned next to respective terminals of the first body. The central portions of the first and second bodies are stacked atop one another and therefore lie in different planes, at least one of which is different from the terminal plane.

Claims

1. An electrical terminal assembly for use in a low-profile electrical raceway, said electrical terminal assembly comprising: a first conductive body including a first main body portion, at least two first electrical terminals spaced outwardly from said first main body portion, and respective first conductor arms electrically coupling said first electrical terminals to said first main body portion, wherein said first main body portion is located in a first plane and said first electrical terminals are positioned in a terminal plane; a second conductive body including a second main body portion, at least two second electrical terminals spaced outwardly from said second main body portion, and respective second conductor arms electrically coupling said second electrical terminals to said second main body portion, wherein said second main body portion is located in a second plane spaced below said first plane, and said second electrical terminals are positioned in said terminal plane; wherein said terminal plane is non-coplanar with at least one of said first and second planes, and wherein each of said first electrical terminals is positioned adjacent a respective one of said second electrical terminals.

2. The electrical terminal assembly of claim 1, further comprising an insulative body disposed between said first main body portion and said second main body portion.

3. The electrical terminal assembly of claim 1, wherein said first plane is substantially parallel to said second plane and said terminal plane.

4. The electrical terminal assembly of claim 1, wherein said first and second electrical terminals each comprise respective base portions and upwardly-extending portions, and wherein said base portions are positioned in said terminal plane and said upwardly-extending portions are positioned above said terminal plane.

5. The electrical terminal assembly of claim 1, wherein at least one of said first conductor arms includes a middle region disposed between said first main body portion and a respective one of said first electrical terminals, at least one of said second conductor arms includes a middle region disposed between said second main body portion and a respective one of said second electrical terminals, and wherein said middle regions are coplanar with one another and are non-coplanar with said terminal plane.

6. The electrical terminal assembly of claim 5, further comprising a third conductive body including a third main body portion, at least two third electrical terminals spaced outwardly from said third main body portion, and respective third conductor arms electrically coupling said third electrical terminals to said third main body portion, wherein said third main body portion is located in a third plane spaced below said second plane, and said third electrical terminals are positioned in said terminal plane, wherein at least one of said third conductor arms includes a middle region disposed between said third main body portion and a respective one of said third electrical terminals, and wherein said middle region of said at least one of said third conductor arms is coplanar with said middle regions of said first and second conductor arms.

7. An electrical terminal assembly for use in a low-profile electrical raceway, said electrical terminal assembly comprising: a first conductive body including a first main body portion, at least two first electrical terminals spaced outwardly from said first main body portion, and respective first conductor arms electrically coupling said first electrical terminals to said first main body portion, wherein said first main body portion is located in a first plane and said first electrical terminals are positioned in a terminal plane; a second conductive body including a second main body portion, at least two second electrical terminals spaced outwardly from said second main body portion, and respective second conductor arms electrically coupling said second electrical terminals to said second main body portion, wherein said second main body portion is located in a second plane spaced below said first plane, and said second electrical terminals are positioned in said terminal plane; a third conductive body including a third main body portion, at least two third electrical terminals spaced outwardly from said third main body portion, and respective third conductor arms electrically coupling said third electrical terminals to said third main body portion, wherein said third main body portion is located in a third plane spaced below said second plane, and said third electrical terminals are positioned in said terminal plane; a first insulative body disposed between said first and second main body portions; and a second insulative body disposed between said second and third main body portions; wherein each of said first electrical terminals is positioned adjacent a respective one of said second electrical terminals, and each of said second electrical terminals is positioned adjacent a respective one of said third electrical terminals.

8. The electrical terminal assembly of claim 7, wherein said first conductor arms extend outwardly in different respective directions from said first main body portion, said second conductor arms extend outwardly in different respective directions from said second main body portion, said third conductor arms extend outwardly in different respective directions from said third main body portion, and wherein the different respective directions of said first conductor arms correspond to the different respective directions of said second and third conductor arms.

9. The electrical terminal assembly of claim 8, wherein the different respective directions of said first, second and third conductor arms are oriented at about 90 degrees apart.

10. The electrical terminal assembly of claim 8, wherein the different respective directions of said first, second and third conductor arms are oriented at about 180 degrees apart.

11. The electrical terminal assembly of claim 7, wherein said first electrical terminals are configured to electrically and mechanically engage respective line polarity electrical conductors, said second electrical terminals are configured to electrically and mechanically engage respective ground polarity electrical conductors, and said third electrical terminals are configured to electrically and mechanically engage respective neutral polarity electrical conductors.

12. The electrical terminal assembly of claim 11, wherein at least one of said first electrical terminals is configured to electrically and mechanically engage a line polarity blade or bus bar, at least one of said second electrical terminals is configured to electrically and mechanically engage a ground polarity blade or bus bar, and at least one of said third electrical terminals is configured to electrically and mechanically engage a neutral polarity blade or bus bar.

13. The electrical terminal assembly of claim 7, wherein said first conductive body includes at least three of said first electrical terminals and at least three of said first conductor arms, said second conductive body includes at least three of said second electrical terminals and at least three of said second conductor arms, and said third conductive body includes at least three third electrical terminals and at least three of said third conductor arms.

14. The electrical terminal assembly of claim 13, wherein all of said first, second, and third electrical terminals are positioned in said terminal plane.

15. The electrical terminal assembly of claim 13, wherein said first conductive body includes at least four of said first electrical terminals and at least four of said first conductor arms, said second conductive body includes at least four of said second electrical terminals and at least four of said second conductor arms, and said third conductive body includes at least four third electrical terminals and at least four of said third conductor arms.

16. The electrical terminal assembly of claim 15, wherein all of said first, second, and third electrical terminals are positioned in said terminal plane.

17. The electrical terminal assembly of claim 16, wherein each of said conductor arms of each of said conductive bodies is oriented at either about 90 degrees or about 180 degrees relative to each other of said conductor arms of each of said conductive bodies.

18. The electrical terminal assembly of claim 7, wherein at least one each of said first, second, and third electrical terminals is configured to electrically and mechanically engage respective blade terminals or bus bars that are aligned substantially perpendicularly to said terminal plane.

19. The electrical terminal assembly of claim 7, wherein said first, second, and third planes are substantially parallel to one another.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a top perspective view of a low profile electrical terminal assembly in accordance with the present invention;

(2) FIG. 2 is a top perspective view of the an electrical raceway and raceway junction incorporating the low profile electrical terminal assembly of FIG. 1, with an upper portion of the junction cut away to show part of the electrical terminal assembly;

(3) FIG. 3 is an exploded perspective view of the electrical terminal assembly of FIG. 1;

(4) FIG. 4 is a side elevation of the three conductive bodies of the electrical terminal assembly of FIG. 1, shown in a vertically spaced arrangement;

(5) FIG. 5 is another side elevation of the conductive bodies of FIG. 4, shown in their assembled configuration;

(6) FIG. 6 is a top perspective view of the middle conductive body of FIGS. 4 and 5, shown overlying a lower insulator piece, and with an upper insulator piece spaced above and being lowered onto the middle conductive body for attachment to the lower insulator piece;

(7) FIG. 7 is a top perspective view of the low profile raceway and raceway junction of FIG. 2; and

(8) FIGS. 8A and 8B are side sectional elevations of the raceway junction of FIG. 7, and depicting the insertion of a male plug connector into the respective electrical terminals of the electrical terminal assembly.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

(9) Referring now to the drawings and the illustrative embodiments depicted therein, a low profile electrical terminal assembly 10 is configured for mounting in a raceway junction 12, such as shown in FIGS. 1, 2 and 7-8B. Raceway junction 12 receives or conveys electrical power from electrical conductors 14 that are routed through a raceway 16, which is coupled to raceway junction 12. In the illustrative embodiment of FIGS. 2 and 7, raceway junction 12 includes three electrical receptacles 18 corresponding to three sets of electrical terminals of electrical terminal assembly 10, as will be described below. The configuration of low profile electrical terminal assembly 10 permits two or more conductive bodies to be positioned in a thinly stacked arrangement, which facilitates a thin or low profile construction for raceway junction 12, which may be used to route electrical power in different directions and to different locations within a region such as work area.

(10) In the illustrated embodiment, low profile electrical terminal assembly 10 includes three electrically conductive bodies or elements including a hot or line body 20, a ground body 22, and a neutral body 24, such as shown in FIGS. 3 and 4. Each electrically conductive body 20, 22, 24 has a respective main or central body portion 20a, 22a, 24a and also three conductor arms or branches 20b, 22b, 24b, that radiate or extend outwardly from the respective central body portions 20a, 22a, 24a. In addition, each of the conductor bodies includes a respective crimp terminal 20c, 22c, 24c for engaging a respective one of the electrical conductors 14. Each arm or branch 20b, 22b, 24b has an electrical terminal 26 at its distal end. In the illustrated embodiment, electrical terminals 26 are each configured to establish six or more points of contact with a male blade terminal, bus bar, or the like, such as described in commonly-owned U.S. patent application Ser. No. 15/054,708, filed Feb. 26, 2016, entitled ELECTRICAL CONTACT RECEPTACLE FOR BUS BARS AND BLADE TERMINALS, which is hereby incorporated herein by reference in its entirety. It will be appreciated that the precise style or configuration of electrical terminals may be varied according to the needs of a particular application, and is not necessarily limited to the style of electrical terminals 26 disclosed herein. However, the disclosed electrical terminals 26 are capable of establishing significant contact surface area with a blade terminal or the like, and thus are suitable for low profile applications such as described herein.

(11) In the illustrated embodiment, each main or central body portion 20a, 22a, 24a is generally square in shape when viewed from above, and defines a central opening 27, such as for material and weight savings. Line body 20 has its arms or branches 20b extending off of three sides of the generally square main body portion 20a, each branch being generally arranged as an extension of a respective leg forming the square main body portion 20a. Similarly, crimp terminal 20c extends radially outwardly off of a fourth side of main body portion 20a. The neutral body's arms or branches 22b extend radially outwardly from respective sides of the generally square main body portion 22a, but branches 22b extend outwardly from a middle or central region of each leg of the square main body portion 22a. For purposes of the present application, it will be appreciated that the term radially is used to refer to any outwardly-extending direction.

(12) Similarly to branches 22b, crimped terminal 22c extends radially outwardly from the central region of the fourth side of the square main body portion 22a. The neutral body's arms or branches 24b are arranged similarly to those of line body 20, except that arms 24b are extensions of opposite legs of each side of the generally square main body portion 24a. It will be appreciated that line body 20, ground body 22, and neutral body 24 may each be unitarily formed from a single planar sheet of electrically conductive material in a stamping process such as a multi-stage stamping process in which the general plan shape is initially cut out, followed by bending or stamping operations in which the final shapes of the branches 20b, 22b, 24b are formed, along with the forming of crimped terminals 20c, 22c, 24c and electrical terminals 26.

(13) With this arrangement of branches for each conductive body, when the bodies are stacked together such as shown in FIG. 1, the neutral body's branches 24b are spaced well apart from the line body's branches 20b, with ground body's branches 22b positioned between branches 20b and branches 24b. Similarly, crimped terminal 22c is disposed between the crimped terminals 20c and 24c. The resulting electrical terminal assembly 10 permits branching in up to three different directions while providing electrical continuity for a line conductor 14a, a neutral conductor 14b, and a ground conductor 14c (FIGS. 1 and 7). However, it is envisioned that more or fewer directions of branching are possible by using different shapes or arrangements of branches. For example, triangular main bodies would readily accommodate branching in two directions, and pentagonal main bodies would readily accommodate branching in four directions.

(14) Each main body portion 20a, 22a, 24a lies in a respective plane P1, P2, P3 so that main body portions 20a, 22a, 24a are sufficiently spaced apart in the region where the respective bodies 20, 22, 24 overlap or overlie one another, such as shown in FIG. 5. It will further be appreciated that the plane P3 in which neutral main body portion 24a lies is the same as a terminal plane P4 in which lower or base surfaces or portions of each terminal 26 lie. Thus, the terminal plane P4 is coplanar with the neutral main body portion 24a, which is spaced below the plane P2 of the ground main body portion 22a, which is spaced below the plane P1 of line main body portion 20a. In the illustrated embodiment, each terminal 26 also includes an upwardly-extending portion that extends above the base portion and, therefore, above terminal plane P4.

(15) Each electrical terminal 26 has its base or bottom portion lying in terminal plane P4 due to the shapes of the corresponding arms or branches 20b, 22b, 24b, such as shown in FIG. 4. Because the neutral body's main body portion 24a is coplanar with terminal plane P4, neutral branches 24b need not change their elevation between neutral main body portion 24a and the corresponding electrical terminals 26. However, if clearance is needed for another component, such as in raceway junction 12, branch 24b may include an optional rise 28a, followed by an elevated region 28b (which may lie in the plane P2 of ground main body portion 22a), and a drop 28c back down to an end region 28d at the level of terminal plane P4 and the plane P3 of neutral main body portion 24a, such as shown in FIG. 4. Because ground main body portion 22a lies in plane P2 spaced above terminal plane P4, ground branches 22b include a drop 30a down to a lowered portion 30b that lies in terminal plane P4. Line main body portion 20a lies in the highest elevation plane P1 and, therefore, line branches 20b drop the furthest distance down to terminal plane P4. Line branches 20b include a first drop region 32a, followed by a first lowered region 32b, followed by a second drop region 32c, followed by a second lower region 32d that lies in terminal plane P4.

(16) As will be apparent with reference to FIGS. 1 and 5, when electrical terminal assembly 10 is assembled, first lowered region 32b of line branch 20b lies in the same plane as ground body 22a and a proximal region of ground branch 22b, which also is the same plane in which elevated region 28b of neutral branch 24b lies, so that all of these regions generally lie in the same plane P2 as ground main body portion 22a. The branches associated with crimp terminals 20c, 22c, 24c may also be shaped in a similar manner as branches 20b, 22b, 24b, so that the distal ends (crimp portions) of crimp terminals 20c, 22c, 24c lie in the same plane as one another, such as terminal plane P4.

(17) To ensure that line main body portion 20a does not contact or electrically arc with ground main body portion 22a, and to ensure that ground main body portion 22a does not contact or arc with neutral main body portion 24a, a pair of insulative bodies including a first insulator 34 and a second insulator 36 are positioned between the respective main body portions 20a, 22a, 24a. As best shown in FIG. 3, first insulator 34 is disposed between the line main body portion 20a and ground main body portion 22a, and second insulator 36 is disposed between ground main body portion 22a and neutral main body portion 24a. Not only do insulators 34, 36 ensure sufficient separation of the respective main body portions 20a, 22a, 24a during installation and operation, but they also limit or substantially prevent electrical shorts due to compressive loads atop the main body portions. This is particularly useful for applications in which the low profile electrical terminal assembly 10 is mounted along a floor surface, such as in raceway junction 12, in which case insulators 34, 36 ensure separation of the main body portions 20a, 22a, 24a even if significant compressive weight or force is applied above the main body portions. Such loads may be imparted, for example, by a person standing on that region, or by a piece of equipment or furniture resting along (or rolling over) the junction 12 above main body portions 20a, 22a, 24a. Even if the junction 12 were crushed by an overload condition, it is envisioned that electrical terminal assembly 10 would be likely to maintain sufficient separation of the various conductive surfaces to avoid an electrical short, owing to the presence of insulators 34, 36 and the offset arrangement of branches 20b, 22b, 24b and crimp terminals 20c, 22c, 24c,

(18) Each of the insulators 34, 36 is generally square in shape when viewed from above or in plan view, and includes a generally square opening 38 that substantially aligns with the respective openings 27 formed in the main body portions 20a, 22a, 24a. In the illustrated embodiment, the insulators 34, 36 are configured to snap together from either side of ground main body portion 22a, so that the insulators may be assembled to ground conductive body 22 prior to final assembly of electrical terminal assembly 10. To facilitate alignment of first insulator 34 relative to second insulator 36, first insulator 34 includes a pair of downwardly-extending projections 40 at diagonally-opposite corners, and a pair of notches 42 at the other diagonally-opposite corners, such as shown in FIG. 3. Similarly, second insulator 36 includes a pair of upwardly-extending projections 44 at diagonally-opposite corners corresponding to notches 42 of first insulator 34, and notches 46 at the other diagonally-opposite corners corresponding downwardly projections 40 of first insulator 34. As best shown in FIG. 1, notches 42 receive upward projections 44, and notches 46 receive downward projections 40. In addition, both of the insulators 34, 36 include four resilient latch tabs 48 that engage respective receiving regions 50 of the other insulator. Thus, latch tabs 48 cooperate with receiving regions 50 to allow the insulators 34, 36 to snap together, with ground main body portion 22a sandwiched between the respective inwardly-directed surfaces of the insulators 34, 36. If necessary, first insulator 34 may be separated from second insulator 36 by prying the insulators apart to release latch tabs 48 from the respective receiving regions 50. It is envisioned that insulators 34, 36 may be made from substantially any electrically insulating and compression-resistant material, such as injection molded resinous plastic. In addition, the positioning of latch tabs 48 and receiving regions 50 permit the first insulator 34 to be an identical component to second insulator 36, so that two identical insulators or insulative bodies are interchangeable and may be coupled to one another simply by rotating one insulator by 90-degrees relative to the other insulator, such as shown in FIGS. 3 and 6. Optionally, the insulative bodies may be unitarily formed and joined together by a flexible living hinge.

(19) Referring to FIGS. 2 and 7-8B, low profile electrical terminal assembly 10 is positioned between an upper housing surface 54 and a lower housing surface 56 of raceway junction 12, with each set of three electrical terminals 26 aligned with a corresponding electrical receptacle region 18, in which openings 58 formed in upper housing surface 54 permit access to the respective electrical terminals 26 by respective prongs 60 of male plug 52, such as shown in FIGS. 2, 8A, and 8B. When the prongs 60 of respective male plugs 52 are engaged with the corresponding electrical terminals 26 of electrical terminal assembly 10, the prongs 60 establish electrical connections with the respective electrical conductors 14 that are routed along raceway 16. This allows electrical power to be routed through electrical conductors 62 associated with each male plug 52 to another location, such as shown in FIG. 7. Power may be supplied to electrical conductors 14 via crimped terminals 64 (FIG. 7), or substantially any other type of electrical connection or direct-wiring arrangement. It will further be appreciated that electrical power could be supplied to low profile electrical terminal assembly 10 via any one of male plugs 52 and its corresponding electrical conductors 62, although in that case female receptacles would typically be substituted for male plugs 52 and male plugs would be substitutes for receptacles 26.

(20) Accordingly, the assembled low profile electrical terminal assembly 10 has a thin overall height, such as shown in FIG. 5, while providing positive insulation between the overlying conductive components or surfaces. Branch conductors of different polarities are laterally separated from one another, and are shaped so that the corresponding electrical terminals 26 all lie in substantially the same common terminal plane P4, and providing significant electrical contact areas for receiving the respective terminals of another electrical connector, such as a three-pronged male plug 52 (FIGS. 2 and 7-8B). Although the illustrated embodiment has its terminal plane P4 located coplanar with the plane P3 of neutral main body portion 24a, it will be appreciated that the electrical terminals 26 may be positioned substantially any desired elevation by changing the degree to which the respective branches change elevation along their length.

(21) Changes and modifications in the specifically-described embodiments may be carried out without departing from the principles of the present invention, which is intended to be limited only by the scope of the appended claims as interpreted according to the principles of patent law including the doctrine of equivalents.