AU2016101472B4

AU2016101472B4 - Power charger

Info

Publication number: AU2016101472B4
Application number: AU2016101472A
Authority: AU
Inventors: Grant Coe
Original assignee: Legrand Australia Pty Ltd
Current assignee: Legrand Australia Pty Ltd
Priority date: 2013-12-23
Filing date: 2016-08-18
Publication date: 2017-03-02
Anticipated expiration: 2022-08-29
Also published as: AU2014218469A1; AU2018206804A1; AU2016203455B2; AU2016203455A1; NZ703329A; AU2016101472A4

Abstract

An Universal Serial Bus power supply unit comprising a Universal Serial Bus connector configured to be inserted 5 in a receptacle in a power plate and retained in the receptacle by an attachment mechanism; and a transformer for converting mains power to a power output for the Universal Serial Bus connector and having an input arranged to be connected to a mains power supply and an 10 output connected to connector, wherein the power connector is remote from the transformer. 80367671 (GHMatters) P94418.AU.5 18/08/16

Description

1 2016101472 09 Feb 2017

POWER CHARGER

The present invention relates to a power charger and, in particular, to a Universal Serial Bus power supply unit. 5 The invention has particular application as a power charger for a mobile device. The invention also relates to a method of installing a Universal Serial Bus power supply in a power plate. 10 Recently, mobile devices have increasingly used Universal Serial Bus (USB) connections to connect to power supplies for charging and powering purposes. USB is particularly attractive for mobile devices since the connector includes power contacts, to charge and power the device, and also 15 data contacts, to transfer data between the mobile device and the unit to which it is connected, for example a laptop computer.

There are two main types of USB ports for charging or 20 powering devices via USB. The first of these is a Charging Downstream Port (CDP). CDP supports data transfer as well as carrying power. In order not to interfere with high speed data transfer, typically, CDPs limit the current on the power contacts to around 900mA 25 during data transfer. The second type of USB charging port is a Dedicated Charging Port (DCP). Dedicated Charging Ports only provide power and do not carry data. DCPs can provide larger current across the power contacts due to the fact that no data is being transferred and so 30 interference is not a problem. DCPs can provide current of up to 2000mA. Higher current allows the batteries of the device to charge more quickly.

With mobile devices continually including more power 35 hungry applications, access to charging points and speed of charging is becoming important. Long recharge periods may be acceptable to consumers in certain situations, for 8036767_1 18/08/2016 2 2016101472 09 Feb 2017 example where the device can recharge overnight, but if a consumer needs to recharge a device during the day he will require the recharge to take place quickly. Consequently, higher current is becoming increasingly import and DCPs 5 are becoming more attractive for recharge purposes.

Summary of the Invention

In accordance with an aspect of the present invention, there is provided a Universal Serial Bus power supply unit 10 comprising: a Universal Serial Bus connector configured to be inserted in a receptacle in a power plate and retained in the receptacle by an attachment mechanism; a transformer for converting mains power to a power output for the Universal Serial Bus connector, the transformer 15 being housed within a transformer housing that is separate to the power plate and having an input adapted to be connected to mains wiring and an output for providing power to the Universal Serial Bus connector, the Universal Serial Bus connector being remote from the transformer; 20 and a cable electrically connecting the transformer to the Universal Serial Bus connector to provide the output power from the transformer to the Universal Serial Bus connector . 25 Preferably, the transformer is suitable for converting power from mains power specifications to a power specification suitable for charging a mobile device.

Preferably, the connector is adapted to be connected into 30 a standard size receptacle in the power plate.

Preferably, the transformer input includes wiring adapted to be connected to the mains wiring at the power plate. 35 Preferably the power plate is a general power output (GPO) plate, switch plate, lighting plate or an electrical accessory plate. 8036767_1 18/08/2016 3 2016101472 09 Feb 2017

Preferably the attachment mechanism is a clipping mechanism. 5 In a second aspect, the invention provides a method of installing a Universal Serial Bus power supply in a power plate comprising; providing a Universal Serial Bus power supply unit comprising a Universal Serial Bus connector; a transformer for converting mains power to a power output 10 for the Universal Serial Bus connector, the transformer being housed within a transformer housing that is separate to the power plate and the Universal Serial Bus connector being remote from the transformer; and a cable electrically connecting the transformer to the Universal 15 Serial Bus connector to provide the output power from the transformer to the Universal Serial Bus connector; inserting the Universal Serial Bus connector in a receptacle in the power plate; retaining the Universal Serial Bus connector in the receptacle by an attachment 20 mechanism; and connecting input wiring of the transformer to mains power supply.

The power plate may be a general power output (GPO) plate, switch plate, lighting plate or an electrical accessory 25 plate. In one form, the power plate is for a general purpose outlet and the method comprises connecting the input wiring of the transformer to mains power supply at the power plate. 30 Preferably the power plate is surface mounted. In one form, the transformer is adapted to be positioned within a wall cavity.

Preferably the Universal Serial Bus connector is adapted 35 to be connected into a standard size receptacle in the power plate. 8036767_1 18/08/2016 4 2016101472 09 Feb 2017

Preferably the attachment mechanism is a clipping mechanism.

Description of the Drawings 5 The present invention will now been described, by way of example only, with reference to the accompanying drawings, in which:

Figure 1 is a first embodiment of a twin USB power supply unit in accordance with an embodiment of the present 10 invention;

Figure 2 is a face view of the connector of the power supply unit showing the twin USB receptacles;

Figure 3 shows the face of a double power socket incorporating a connector having twin USB receptacle in 15 accordance with an embodiment of the present invention; Figure 4 shows the USB power supply unit installed and connected to a device for charging; and

Figure 5 shows the components of a USB power supply unit in accordance with an embodiment of the present invention. 20 Figure 6 shows connections to a general power output wall plate .

Figure 7 shows connections to a general power output wall plate . 25 Description

Referring to the drawings, there is shown a terminating unit 10 for connection to a mains power supply. The mains power supply may be the power supply installed in a residence or office and, typically, will be provided with 30 a live, neutral and earth connection within standard rating cabling. The terminating block 10 houses a transformer to convert the voltage and current of the mains supply to that suitable for charging mobile device via USB. Transformer 20 (shown in Figure 5) is housed 35 within the terminating block 10. The terminating block 10 includes a wiring connection block 30 to facilitate connection from the mains wiring to the transformer. 8036767_1 18/08/2016 5 2016101472 09 Feb 2017

The terminating unit has a power output 40 for providing power to USB connector 60 via cable 50 to provide a USB power supply unit. The power leads contained within cable 5 50 are connected to the output of the transformer 20. In the illustrated form, the USB connector 60 is a twin USB connector 60. The twin USB connector includes two USB receptacles 62 and 64 shown in Figure 2. 10 The terminating unit is preferably made from heat resistant plastic in order to safely manage and contain heat generated by the transformer.

The terminating unit is designed with a suitable form 15 factor to allow connection onto a surface or to be contained within a wall cavity. For example, embodiments may include receptacles for fastening means, for example screws, to provide attachment of the terminating unit to a surface . 20

In further embodiments, the terminating connections 30 may be contained within the terminating unit in order that the connections between the mains cabling and the transformer are contained within the terminating unit. Such 25 embodiments are particularly advantageous because no wiring is left exposed which increases the safety of the unit.

The output from the transformer can be selected in 30 dependence on the power delivery requirements for various devices. Preferably, in order to provide power for devices through a USB the power output from the transformer is provided in the form of a 5 volt output and a current of 2000mA. In the embodiment of Figure 1, the 35 power output from the transformer is split to provide two USB power connections via USB receptacles 62 and 64 within connection unit 60. 8036767_1 18/08/2016 6 2016101472 09 Feb 2017

The form factor of USB connector 60 is suitable to be incorporated into a power socket plate. Figure 3 shows a standard power socket plate 310 incorporating twin USB 5 receptacles.

In the embodiment of Figure 3, the plate is configured to simultaneously receive two separate power plugs at power connections 320, 310 along with two separate USB plugs USB 10 connector 360. On the reverse side of the plate, the USB connector 360 does not interfere with the wiring into the power connectors 320, 310 due to its small form factor. Instead, simply USB connector 360 and USB cabling 50 protrudes from the rear side of the plate to the larger 15 terminating unit including the transformer. This configuration enables the terminating unit and transformer to be located sufficiently far from the plate so as not to interfere with any of the cabling or connections to the plate itself. 20

The embodiments of the invention facilitate easy and safe installation since there is no exposed wiring at the reverse side of the plate for the USB power charger and no electrical connections are made to the power plate for the 25 USB connections, these are made within the USB connector and completed before presenting the connector to the plate. Instead the connector is simply fitted into the plate. All electrical connections to the USB receptacles are pre-connected and housed within the USB connector. 30

Additionally, the terminating unit contains any heat generated from the transformer so as not to interfere with any other components or wiring for the power plate. 35 Figure 4 shows a representative example of an embodiment of the USB power charger installed into a wall cavity and connected to a power plate. The transformer is correctly 8036767_1 18/08/2016 7 2016101472 09 Feb 2017 configured to convert mains power specifications to USB power specifications. In installation, the engineer can pull the mains power lead 405 through wall cavity 420 and connect the mains power cables to the terminating block 5 housing the transformer. Preferably, terminating unit 410 and transformer are pre-connected to the USB connector 440. Once the connection between the mains and the transformer are made, the USB connector 440 is fixed into the power plate 430. The terminating unit 410 is then fed 10 through the wall cavity 420 and fixed in position using attachments. Power plate is fixed over the wall cavity as usual.

As shown in Figure 4, devices can be connected to the USB 15 connectors on the power plate. It is clear from Figure 4 that the terminating unit is located remotely from USB connector. Since the terminating unit is remote from the USB connector it does not interfere structurally with any power plate wiring. Instead, the USB connector connects 20 directly to the power plate.

In typical embodiments of the invention the cabling 50 has sufficient length to enable the transformer to be placed away from the power plate and attached to a surface. 25 Typical lengths for cables are around 30 cm.

Figure 6 shows a further embodiment of a USB connector connected to a power plate. In Figure 6 the USB connector is connected to double general power output (GPO) plate 30 600. The GPO includes a receptacle 610 for receiving USB connector 620. In Figure 6b USB connector 620 is inserted into the receptacle of power plate 600. In the embodiment of figure 6b USB connector 620 includes a clipping mechanism to retain USB connector in the receptacle. 35 Alternatively, other attachment mechanisms could be used for attaching the USB connector to double GPO plate 600. 8036767_1 18/08/2016 δ 2016101472 09 Feb 2017

Figure 6c shows the power connections in and out of the double GPO plate 600. Mains wiring 630 is terminated onto terminals 602 604 602 on the rear side of double GPO plate 600. Power to USB transformer 640, housed within housing 5 640, is provided from double GPO plate 600. The Active (live) wire 632 from mains wiring is connected to Active terminal 602 on the rear side of double GPO plate 600.

The Neutral wire 634 from mains wiring is connected to Neutral terminal 604 on the rear side of the double GPO 10 plate 600. The Earth wire 636 from the mains wiring is connected to the Earth terminal 606 on the rear side of double GPO plate 600. USB transformer is housed within housing 640. USB 15 transformer includes active input provided by active wire 642 and a neutral input provided by neutral wire 644. The active wire 642 and neutral wire 644 are contained within cabling 660. In the embodiment of Figure 6, the active wire 642 and neutral wire 644 are terminated to the 20 transformer within transformer housing 640.

To provide mains power input to the transformer active wire 642 is connected to active terminal 602 on the double GPO plate 600 and neutral wire 644 is connected to neutral 25 terminal 604 on the double GPO plate 600. Mains power at 230 V is routed from the double GPO plate terminals 602 604 to the transformer and converted to deliver 2.1 mA at 5V to each USB receptacle contained within USB connector 620 . 30

As discussed above, by positioning transformer away from double GPO plate 600, any heat dissipation in the transformer is located away from the double GPO plate. Additionally, by positioning the transformer away from the 35 double GPO plate there are fewer restrictions on the physical size of the transformer. Larger transformers can be utilised to deliver larger power outputs. 8036767_1 18/08/2016 9 2016101472 09 Feb 2017

Cable tie 650 attached to transformer housing 640 is attached to mains wiring 630 after electrical connections to the terminals of the double GPO plate 600 have been 5 completed. Cable tie 650 is plastic but may also be manufactured from any other suitable material. Alternatively the cable tie may be in the form of a clip or hook or any other form suitable for attaching the transformer housing to mains wiring 630. 10

The cable of mains wiring 630 is thermoplastic sheathed cable (TPS cable) which is typically thicker and stiffer than USB cabling 660. By attaching transformer housing 640 to the mains wiring 630 the mains wiring supports the 15 weight of the transformer without providing undue strain on the electrical connections to double GPO plate 600.

During installation mains wiring 630 is pulled through the wall 670 to facilitate connection of the mains active 20 neutral and earth wires 632 634 636 and transformer power wires 642 644 onto double GPO plate 600.

In alternative embodiments the transformer housing 640 is attached to the inside of wall 670 or positioned elsewhere 25 within the wall cavity. Screws or other suitable attachment means can be used to attach transformer housing 640 to the wall.

After power connections to and from terminals 602 604 606 30 of double GPO plate 600 are complete and USB connector 620 is inserted into double GPO plate 600, transformer housing 640 is fed into the wall cavity and double GPO plate 600 is surface mounted to wall 670 using screws or other attachment means as shown in Figure 6e. 35

Transformer housing 640 is sized within the dimensions of double GPO plate 600 to allow it to pass into the all 8036767_1 18/08/2016 10 2016101472 09 Feb 2017 cavity. After installation transformer 640 hangs in the wall cavity behind wall 670 supported by cable tie 650 and mains wiring as shown in Figure 8. Transformer is positioned away from double GPO plate 600 to prevent heat 5 dissipation from the transformer in the vicinity of the double GPO plate.

In further embodiments the USB connector and USB receptacles are integral with double GPO plate 600. In 10 such embodiments the connections to and from the USB transformer is prewired to double GPO plate terminals 602 604 and the USB connector 620. Such embodiments remove the requirement for the USB connector to be manually inserted into the double GPO plate 600 during 15 installation. Additionally, there is no need to connect the USB transformer wires 642 644 to the terminals 602 604 of the double GPO plate 600 during installation. Such embodiments have similar cable lengths to the separate system to provide heat dissipation within the transformer 20 away from the front plate.

Figure 7 shows an alternative embodiment of installation of the USB transformer. In the embodiment of Figure 7 mains wiring 710 carrying power at mains specifications, 25 typically at 230 Volts is split at 715. One leg of the split mains wiring is routed to USB transformer within transformer housing 720. USB transformer converts the power input from mains power to 2.1 A at 5 V for connection to twin USB receptacles in connector 730. 30 Output 725 from USB transformer is routed to USB connector 730 on double GPO plate 740. Transformer housing 720 is designed to contain heat dissipated from the transformer, as discussed above. USB connector 730 is inserted into double GPO plate 740. 35

The second leg 745 of the split mains wiring is routed directly to double GPO plate 740. Second leg 745 provides 18/08/2016 8036767_1 11 2016101472 09 Feb 2017 power at mains specifications to two three pin power outputs of double GPO plate 740.

In the embodiments above, the power plates are double 5 General Power Output (GPO) plates. However, further embodiments include any electrical accessory plate to which mains wiring is terminated and into which USB receptacles are provided. For example, in further embodiments the power plate is a lighting plate 10 incorporating a switch for controlling lighting units. In a further embodiment the power plate is a designated USB plate including USB receptacles.

The mains wiring is wiring installed within a premises and 15 maintained within the walls, ceilings and floors of the premises. Typically mains wiring is connected to the rear side of surface mounted electrical devices including power plates including GPO plates, lighting plates, switch plates or other electrical devices. Mains wiring carries 20 power at mains power specifications, typically 220 - 240 Volts or 110 to 130 Volts depending on location.

It will be clear to those skilled in the art that the configuration of embodiments of the present invention provides versatility in terms of the performance and 25 rating of the transformer, the type of USB connectors, and heat and power ratings of the materials. For example, if power capabilities of USB sockets were to increase, further embodiments of the invention could incorporate different transformers or, indeed, different connection 30 receptacles. Additionally, embodiments of the invention provide good control over the materials used in the terminating unit in order to manage different levels of heat or standard requirements of different safety requirements. The cabling between the terminating unit 35 and the USB connector can also be selected as suitable for the installation needs and safety rating requirements of the building. Additionally, the flexibility of the 8036767_1 18/08/2016 12 2016101472 09 Feb 2017 cabling can be selected in order to meet the requirements of the installation.

It will be clear to those skilled in the art that 5 embodiments of the present invention are not limited to use in USB charging systems. Different connectors for different devices can be incorporated into the connection unit. 10 Many power plates are now produced with a standard size receptacle to receive power connectors or, indeed, to be blocked off. Embodiments of the present invention may include single USB receptacles, twin USB receptacles or any other type of USB receptacle or other power connector. 15 A further advantage provided by embodiments of the present invention is that the transformer is remote from the connector. This moves the generation of heat from the vicinity of the power plate and USB receptacle which 20 increases the safety of the power plate. By removing the large transformer from the locality of the power plate, embodiments of the invention also removes size restrictions and wiring restrictions from the power plate. This makes installation more straightforward at the plate 25 and also removes any physical interference between the transformer itself and other wiring.

Modifications and variations as would be apparent to a skilled addressee are deemed to be within the scope of the 30 present invention. 8036767_1 18/08/2016

Claims

Claims :

1. A Universal Serial Bus power supply unit comprising: a Universal Serial Bus connector configured to be inserted in a receptacle in a power plate and retained in the receptacle by an attachment mechanism; a transformer for converting mains power to a power output for the Universal Serial Bus connector, the transformer being housed within a transformer housing that is separate to the power plate and having an input adapted to be connected to mains wiring and an output for providing power to the Universal Serial Bus connector, the Universal Serial Bus connector being remote from the transformer; and a cable electrically connecting the transformer to the Universal Serial Bus connector to provide the output power from the transformer to the Universal Serial Bus connector .
2. An electrical power supply according to claim 1 wherein the connector is adapted to be connected into a standard size receptacle in the power plate.
3. An electrical power supply according to either claim 1 or 2 wherein the transformer input includes wiring adapted to be connected to the mains wiring at the power plate .
4. A method of installing a Universal Serial Bus power supply in a power plate comprising; providing a Universal Serial Bus power supply unit comprising a Universal Serial Bus connector; a transformer for converting mains power to a power output for the Universal Serial Bus connector, the transformer being housed within a transformer housing that is separate to the power plate and the Universal Serial Bus connector being remote from the transformer; and a cable electrically connecting the transformer to the Universal Serial Bus connector to provide the output power from the transformer to the Universal Serial Bus connector; inserting the Universal Serial Bus connector in a receptacle in the power plate; retaining the Universal Serial Bus connector in the receptacle by an attachment mechanism; and connecting input wiring of the transformer to mains power supply.
5. A method according to claim 4, wherein the power plate is for a general purpose outlet and the method comprises connecting the input wiring of the transformer to mains power supply at the power plate.