AU2019204172A1 - Face plate with frame and method of manufacture - Google Patents

Abstract

Disclosed is a face plate arrangement for an electrical unit, and method of manufacture. A frame of the face plate is made from an extruded material, and is connected to a face plate body to provide the face plate. The face plate may be connected to a base plate such as a grid of the electrical unit. Also disclosed is an electrical unit formed from the base plate and the face plate. 124' 121 123' 123'3 124' Figure 3B 123" 122' 126 123"'. 124"'. 125'12 126' 123' 124' Figure 3B

Description

FACE PLATE WITH FRAME AND METHOD OF MANUFACTURE

TECHNICAL FIELD [0001] The present application relates to face plates for electrical switch units and outlets.

INCORPORATION BY REFERENCE [0002] This application refers to the following Australian Patent Applications:

- Australian Patent No 2011334615 entitled “USB Outlet Charger”

- Australian Patent Application No. 2015221512 entitled “Electrical Outlet and Support for Electrical Device”

- Australian Patent Application No. 2015275225 entitled “Electrical System, Apparatus and Method”

- Australian Patent Application No. 2016235020 entitled “Connectors for Electrical System”

- Co-pending Australian Provisional Patent Application entitled “Electrical Outlet and Support for Electrical Device” fded on 14 June 2018 [0003] The entire content of each of these applications is hereby incorporated by reference.

BACKGROUND [0004] Wired electrical units such as wall mounted switch units, and power outlets are generally made of a base plate such as a grid plate or a switch plate, to which one or more electrical sockets and/or electrical switch mechanisms are mounted, and connected to a source of electrical power, and a face plate, which provides an outer covering and provides an aesthetic and/or enhanced functionality to the electric unit.

[0005] Face plates are generally moulded from plastic, which requires special tooling to be constructed for each new face plate design or configuration. It would be advantageous to provide an alternative construction method to simplify manufacture, or at least provide a useful alternative.

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SUMMARY [0006] According to a first aspect, there is provided a face plate for connection to a base plate of an electrical unit, wherein at least a portion of the face plate is extruded.

[0007] In some embodiments, the at least a portion of the face plate that is extruded is a face plate frame.

[0008] In some embodiments, the face plate further comprises a face plate body connected to the face plate frame.

[0009] In some embodiments, an end of the face plate is closed by an end cap.

[0010] In some embodiments, the end cap provides some retention of the face plate body to the face plate frame.

[0011] In some embodiments, the face plate body provides some retention of the face plate body to the frame.

[0012] In some embodiments, the face plate body provides reinforcement to the face plate frame.

[0013] In some embodiments, the face plate body supports one or more switch actuators.

[0014] In some embodiments, the face plate body comprises connectors for connecting the face plate to the base plate.

[0015] According to a second aspect, there is provided a face plate body for use in the face plate of the first aspect, the face plate body comprising: at least one aperture for receiving a switch element or providing access to a socket; and at least one face plate frame engager for engaging with the face plate frame.

[0016] In some embodiments, the face plate body further comprises at least one face plate frame locator for locating within a part of the face plate frame to reduce movement of the face plate body within the face plate frame.

[0017] In some embodiments, the face plate body further comprises at least one end cap engagement region for engaging with an end cap inserted into an end of the face plate.

2019204172 14 Jun 2019 [0018] In some embodiments, the face plate body further comprises an end cap locator for locating with an end cap inserted into the face plate.

[0019] According to a third aspect, there is provided an end cap for insertion into an end of a face plate frame, the end cap comprising: an end face for providing a closed face to the end of the face plate frame when inserted into the end of the face plate frame; and an end cap face plate frame connector for connecting the end cap to the face plate frame when the end cap is inserted into the end of the face plate frame.

[0020] In some embodiments, the end cap further comprises a face plate body engager for engaging with a face plate body.

[0021] In some embodiments, in use, the face plate body engager serves to retain the face plate body to the face plate frame when the end cap is inserted into the end of the face plate frame.

[0022] In some embodiments, the end cap further comprises an end cap face plate body locator for locating with the face plate body.

[0023] According to a fourth aspect, there is provided an electrical unit comprising a base plate mounted to a surface and a face plate according to the first aspect.

[0024] According to a fifth aspect, there is provided a method of producing a face plate, the method comprising: extruding a length of material to provide a face plate frame; forming one or more face plate frame apertures; inserting a face plate body into the face plate frame such that at least a portion of the face plate body is located within the one or more face plate frame apertures; and inserting at least one end cap into an end of the face plate frame.

[0025] According to a sixth aspect, there is provided a face plate comprising: a face plate frame comprising at least one face plate frame aperture; and a face plate body connected to the face plate frame and at least partially located within the at least one face plate frame aperture, the face plate body comprising: at least one face plate body aperture for receiving a switch actuator or for providing access to a socket.

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BRIEF DESCRIPTION OF DRAWINGS [0026] Embodiments of the various aspects described herein will be detailed with reference to the accompanying drawings in which:

[0027] Figure 1A - shows a perspective view of an extrudate of indefinite length for forming a face plate or face plate frame;

[0028] Figure IB - shows an end view of the extrudate of Figure 1A;

[0029] Figure 1C - shows a side view the extrudate of Figure 1A;

[0030] Figure 2A - shows as a front perspective view of an extrudate with an aperture formed therein to form a face plate frame;

[0031] Figure 2B - shows a rear perspective view of the extrudate of Figure 2A;

[0032] Figure 3A - shows a front perspective view of a face plate body;

[0033] Figure 3B - shows a rear perspective view of the face plate body of Figure 3 A;

[0034] Figure 4A - shows a rear perspective view of a face plate formed from combining the face plate frame and the face plate body;

[0035] Figure 4B - shows an end detail of the face plate body frame engager engaging with the face plate frame;

[0036] Figure 4C - shows a front perspective view of the face plate of Figure 4A;

[0037] Figure 5A - shows a bottom perspective view of an end cap;

[0038] Figure 5B - shows a top perspective view of the end cap of Figure 5A;

[0039] Figure 6 - shows a rear perspective view of a face plate with end caps inserted;

[0040] Figure 7A - shows a front perspective view of the face plate of Figure 6 with a switch actuator;

[0041] Figure 7B - shows a rear perspective view of the face plate of Figure 7A;

[0042] Figure 8 A - shows another embodiment of a face plate frame;

2019204172 14 Jun 2019 [0043] Figure 8B - shows another embodiment of a face plate body for use with the face plate frame of Figure 8A;

[0044] Figure 8C - shows a face plate formed from the combination of the face plate frame and face plate body of Figures 8 A and 8B;

[0045] Figure 9 - shows another embodiment of a face plate;

[0046] Figure 10 - shows another embodiment of a face plate;

[0047] Figure 11 - shows another embodiment of a face plate;

[0048] Figure 12- shows another embodiment of a face plate;

[0049] Figure 13 - shows another embodiment of a face plate;

[0050] Figure 14 - shows another embodiment of a face plate;

[0051] Figure 15 - shows another embodiment of a face plate;

[0052] Figure 16 - shows another embodiment of a face plate;

[0053] Figure 17 - shows another embodiment of a face plate;

[0054] Figure 18 - shows another embodiment of a face plate;

[0055] Figure 19 - shows another embodiment of a face plate;

[0056] Figure 20 - shows an embodiment of a base plate or grid plate;

[0057] Figure 21A - shows a front perspective view of the face plate of Figure 17 connected to the base plate or grid plate of Figure 20 to form an electrical unit; and [0058] Figure 21B - shows a rear perspective view of the electrical unit of Figure 21A.

DESCRIPTION OF EMBODIMENTS [0059] According to one aspect described herein, there is provided a face plate in which at least a portion of the face plate is extruded. Figure 1A shows an extruded element 110’ of indefinite length, but constant cross-section. The extrudate is a hollow length of material providing a substantially rectangular cross-section with rounded edges. It will be appreciated

2019204172 14 Jun 2019 however, that any suitable cross-section may be provided as required. Figure IB shows an end view of the extrudate of Figure 1A and Figure IC shows a side view of the extrudate of Figure 1A.

[0060] It will be appreciated that the material used may be any suitable material, including plastic materials such as polyethylene (PE), polypropylene, polyvinyl chloride (PVC) acrylonitrile butadiene styrene (ABS) and polycarbonate, and metallic materials such as lead, tin, copper, steel, aluminium, as well as some ceramics.

[0061] In some aspects, the extrudate is then cut to a desired size, and then, depending on the desired configuration of the face plate being constructed, one or more apertures are stamped, cut or otherwise formed in one or more surfaces of the extrudate 110’. Figure 2A shows the extrudate 110’ of Figure 1A with an aperture 101 formed therein, forming a frame 110. Figure 2B shows a rear view of the extrudate 110’ of Figure 2A, with a second aperture 101’ formed therein. In some embodiments, indentations forming a face plate frame body locator 102, 102’ are provided, as will be described in more detail below.

[0062] In some aspects, the extrudate may then be further processed by sandblasting (for example) to remove rough edges, anodizing to add colour and to provide surface protection, and/or chamfering edges via CNC (for example) all as will be understood by the person skilled in the art.

[0063] According to an aspect, this forms a face plate frame 110.

[0064] Accordingly, it can be seen that providing at least a portion of a face plate as an extruded piece provides great flexibility in producing face plates of different configurations because this part does not need to be made differently for each configuration and can be tailored to a particular configuration simply by modifying the number and type of cut-outs to form the apertures 101.

[0065] Figure 3A shows a top perspective view of another component of the face plate according to another aspect. Figure 3A shows a face plate body 120 which will be connected to face plate frame 110 as described further below. Face plate body 120 can be made by any suitable material, including any of the materials listed above, and by any suitable means, including molding or casting.

2019204172 14 Jun 2019 [0066] In some embodiments, as shown in Figure 3A, face plate body 120 has at least one face plate aperture 121. This aperture can be used to receive a switch element, or provide access to a socket on a base plate (see further below).

[0067] Figure 3B shows a rear perspective view of the face plate body of Figure 3 A. Shown in this view are a number of elements extending from the face plate body 120. Face plate body frame locators 122, 122’ engage with a portion of the face plate frame when the face plate body 120 is connected to or engaged with face plate frame 110, and serve to provide stability to the face plate body 120 and prevent movement within face plate frame 110 (e.g. sliding movement). In use, in some embodiments, face plate body frame locators 122, 122’ locate within or engage with face plate frame body locators 102, 102’ shown in Figure 2B.

[0068] Also shown in Figure 3B are face plate body frame engagers 123, 123’, 123”, 123’”. These engage with the face plate frame 110 to retain the face plate body 120 within face plate frame 110 and prevent it from being separated from face plate frame 110 even when pressure is applied to face plate body 120, for example, when a user applies a force to actuate a switch that may be supported by face plate body 120.

[0069] Also shown in Figure 3B are face plate body base plate connectors 124, 124’, 124”, 124”’. These serve to connect to the base plate (not shown in this view) as will be described in more detail below.

[0070] Also shown in Figure 3B is face plate body end cap engagement region 125 (and another, 125’, at the other end). As will be described in more detail below, this region engages with an end cap 130 (see Figures 5A, 5B and 6) to further retain face plate body 120 within face plate frame 110 and further prevent slipping or dislocation.

[0071] Figure 4A shows face plate 100 formed from the combination of face plate frame 110 and face plate body 120. In some embodiments, as shown in Figure 4A, face plate body 120 is simply pushed down into the aperture 101’of face plate frame 110 and face plate body frame engagers 123, 123’, 123”, 123”’ snap into place to retain face plate body 120 therein. As can be seen in Figure 4B, in the embodiment shown, the face plate body frame engager 123 is disposed underneath and within, a lip formed by the curve of the face plate frame 110 so that any upward force (in relation to the arrangement of Figure 4B) applied to the face plate body 120 by a user, is transferred to the face plate body frame engager to push up against the lip

2019204172 14 Jun 2019 and is thereby countered by the lip of the face plate frame 110 to prevent movement of the face plate body 120.

[0072] Also shown in Figure 4A is face plate body switch support 127. In some embodiments, this element may be part of the original body mould. In some embodiments, this element may be added as a separate piece by gluing, bonding or otherwise adhering or connecting.

[0073] It will also be appreciated that in some embodiments, the provision of face plate body frame engager 123 (and its equivalents 123’, 123”, 123”’) can also provide support to the face plate frame 110 against external crushing forces applied to those regions.

[0074] Figure 4C shows a front perspective view of the face plate 100 of Figure 4A. Shown in this view are face plate ends 103, 103’. According to some embodiments, face plate ends 103, 103’ can be capped by use of end caps 130 as shown in Figures 5A and 5B. Figure 5A shows an underside perspective view of end cap 130 and Figure 5B shows a top perspective view of end cap 130.

[0075] End cap face plate body engager 133 engages with the corresponding face plate body end cap engagement region 125 when the end cap is inserted into the face plate end 103 to sandwich the face plate body end cap engagement region 125 between it and the inner surface of face plate frame 110 to further prevent separation of the face plate body 120 from face plate frame 110. In some embodiments, and edge 133a of end cap face plate body engager 133 abuts against a step 125a of face plate body end cap engagement region to provide further stability to the face plate body 120 to prevent sliding.

[0076] End cap face plate body locator 134 also receives face plate body end cap locator 126 (see Figure 4A) to provide further stability to the connection.

[0077] End cap frame connectors 132, 132a and 132’, 132a’ are also provided, which allow, in some embodiments, a snap fit connection of end cap 130 as it is inserted into face plate end 103. Of course, any other means of connection can be used, including friction fit. In the embodiment shown in Figures 5A and 5B, as the end cap 130 is inserted into the face plate end 103, end cap frame connectors 132, 132’ are deflected downwardly and connectors 132a, 132a’ are deflected inwardly. As the end cap is fully inserted, connectors 132, 132’ pass face plate frame end bar 104 (see Figure 4A), and resume their undeflected positions, locking into

2019204172 14 Jun 2019 place behind the bar 104. End cap frame connectors 132a, 132a’ also deflect inwardly as end cap 130 is inserted, but remain in a deflected position and are biased outwardly due to the inherent resiliency of the end cap material, to push against the inside of frame 110 to provide further frictional force to keep end cap 130 in place. To remove end cap 130, a user simply pushes back on end cap 130 from within the frame, accessible through frame aperture 101’ to overcome the forces provided by end cap frame connectors 132, 132a, 132’, 132a’.

[0078] End cap 130 also has end face 131 which, when inserted into frame 110, provides a closed end to the face plate 100.

[0079] Figure 6 also shows face plate body 120 secured within face plate frame 110 by the end cap face plate body engagers 133, 133’ engaging with and placed over corresponding face plate body end cap engagement regions 125, 125’ respectively (not visible in this view since they are beneath the end cap face plate body engagers 133, 133’).

Figure 7A shows a front perspective view of face plate 100. In this example, switch actuator 400 is provided, and connected to face plate body switch support 127 (see Figure 6) and as shown in Figure 7B, being a rear perspective view of the face plate 100 of Figure 7A. Further detail on the connection of switch elements with a face plate is set out in Australian Patent Application No. 2015275225 entitled “Electrical System, Apparatus and Method” and Australian Patent Application No. 2016235020 entitled “Connectors for Electrical System” previously incorporated by reference.

[0080] Figure 8A shows a face plate frame 110 according to another embodiment, in which there are provided two face plate frame apertures 101, 101’ on the front and one face plate frame aperture 101” on the rear.

[0081] Figure 8B shows face plate body 120 according to this embodiment, having two repeated body patterns 120a, 120b, each having a face plate aperture 121 and 121’ for receiving switch elements, and each having further face plate body apertures 121” and 121’” for providing access to electrical sockets disposed in a corresponding base plate or grid plate 200 (not shown, but see Figures 20 to 2IB for more detail).

[0082] It will be appreciated that while face plate body 120 is shown in Figure 8B as a single piece having sections 120a, 120b, on some embodiments, the two pieces can be provided as separate and distinct pieces.

2019204172 14 Jun 2019 [0083] Face plate body 120 also has face plate body frame locators 122, 122’ (not visible in this view), face plate body frame engagers 123,123', 123, 123'(the latter two not visible in this view) and face plate body base plate connectors 124,124', 124, 124' (the latter two not visible in this view) as previously described.

[0084] Figure 8C shows the assembled face plate 100 of the frame and body of Figures 8A and 8B, with switch actuators 400, 400'.

[0085] Numerous other face plate configurations are also possible, including those shown in Figures 9 to 19.

[0086] Figure 9 shows a face plate 100 for a power outlet with a switch aperture 121 and a socket aperture 12Γ. Figure 10 shows a face plate 100 with socket and switch apertures 12Γ, 121 and a second switch aperture 121”. Figure 11 shows a 2-gang face plate 100. Figure 12 shows a face plate 100 with a 2-gang socket and switch combination with an additional switch aperture. In some embodiments, the additional switch aperture may receive a USB port from a USB charging device. More details on this aspect are described in Australian Patent No 2011334615 entitled “USB Outlet Charger” previously incorporated by reference.

[0087] Figure 13 shows a 3-gang switch face plate 100. Figure 14 shows a 4-gang switch face plate 100. Figure 15 shows a 4-gang switch/socket combination face plate 100. Figure 16 shows a 2-gang switch socket combination face plate 100 of the type shown in Figure 12. Figure 17 shows a 5-gang switch face plate 100. Figure 18 shows a 3-gang USB charging device with a device support 600 as described in more detail in Australian Provisional Patent Application entitled “Electrical Outlet and Support for Electrical Device” previously incorporated by reference.

[0088] Figure 19 shows a face plate 100 with no front apertures (but with an aperture at the back for receiving a base plate) or other features, providing a blank cover plate, which may be used to cover an unused grid pate or outlet, until such time as it is to be used. At that time, the face plate 100 can be exchanged for a different face plate 100 such as any of those shown in Figures 9C to 19 for example, according to a desired use.

[0089] It will be appreciated from embodiments such as shown in Figures 15 and 16, that significant manufacturing savings in complexity and cost can be had from the various aspects described herein, in that a single piece in the form of an extruded face plate frame 110 can be

2019204172 14 Jun 2019 used to form a face plate of any desired combination, simply by cutting an extruded piece 110’ to the desired length and stamping, cutting or otherwise forming the desired aperture(s) according to the intended use.

[0090] Figure 20 shows an embodiment of a base plate, such as a grid plate 200. Grid plate 200 has grid plate face plate connectors 210, 210’, 210”, 210’”. These connectors engage with corresponding face plate body base plate connectors 124, 124’, 124”, 124” as previously described. Base plate screws 250, 250’ can be used to mount base plate 200 to a surface such as a wall.

[0091] When face plate 100 is connected to base plate 200, electrical unit 500 is formed as shown in Figure 21 A. In this case, the face plate used would be that shown in Figure 17. Figure 21B shows the electrical unit 500 from a rear perspective view showing face plate 100 connected to base plate 200.

[0092] While the various aspects described herein refer to the face plate frame 110 being extruded, similar benefits can be obtained by starting with a sheet of material (e.g. aluminium), stamping or cutting it as required to form one or more apertures, and folding it to provide the same shape/cross-section as that of the embodiments disclosed herein. The edges that are brought together may then be welded or otherwise connected as required. Accordingly in a broad aspect there is provided a face plate comprising a face plate frame (that in some embodiments is not moulded), and a face plate body that may or may not be moulded.

[0093] According to another aspect, there is provided a method of producing a face plate, the method comprising extruding a length of material to provide an extrudate; forming one or more apertures in the extrudate to provide a face plate frame; inserting a face plate body into the face plate frame such that at least a portion of the face plate body is located within the one or more apertures. In some embodiments, the method further comprises inserting at least one end cap into an end of the face plate frame.

[0094] Throughout the specification and the claims that follow, unless the context requires otherwise, the words “comprise” and “include” and variations such as “comprising” and “including” will be understood to imply the inclusion of a stated integer or group of integers, but not the exclusion of any other integer or group of integers.

2019204172 14 Jun 2019 [0095] The reference to any prior art in this specification is not, and should not be taken as, an acknowledgement of any form of suggestion that such prior art forms part of the common general knowledge.

[0096] It will be appreciated by those skilled in the art that the invention is not restricted in its use to the particular application described. Neither is the present invention restricted in its preferred embodiment with regard to the particular elements and/or features described or depicted herein. It will be appreciated that the invention is not limited to the embodiment or embodiments disclosed, but is capable of numerous rearrangements, modifications and substitutions without departing from the scope of the invention as set forth and defined by the following claims.

Claims (21)

1. A face plate for connection to a base plate of an electrical unit, wherein at least a portion of the face plate is extruded.

2. A face plate as claimed in claim 1 wherein the at least a portion of the face plate that is extruded is a face plate frame.

3. A face plate as claimed in any one of claims 1 or 2 further comprising a face plate body connected to the face plate frame.

4. A face plate as claimed in any one of claims 1 to 3 wherein an end of the face plate is closed by an end cap.

5. A face plate as claimed in claim 4 wherein the end cap provides some retention of the face plate body to the face plate frame.

6. A face plate as claimed in any one of claims 3 to 5 wherein the face plate body provides some retention of the face plate body to the frame.

7. A face plate as claimed in any one of claims 3 to 6 wherein the face plate body provides reinforcement to the face plate frame.

8. A face plate as claimed in any one of claims 3 to 7 wherein the face plate body supports one or more switch actuators.

9. A face plate as claimed in any one of claims 3 to 8 wherein the face plate body comprises connectors for connecting the face plate to the base plate.

10. A face plate body for use in the face plate of any one of claims 1 to 9, the face plate body comprising:

at least one aperture for receiving a switch element or providing access to a socket; and at least one face plate frame engager for engaging with the face plate frame.

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11. A face plate body as claimed in claim 10 further comprising at least one face plate frame locator for locating within a part of the face plate frame to reduce movement of the face plate body within the face plate frame.

12. A face plate body as claimed in any one of claims 10 or 11 further comprising at least one end cap engagement region for engaging with an end cap inserted into an end of the face plate.

13. A face plate body as claimed in any one of claims 10 to 12 further comprising an end cap locator for locating with an end cap inserted into the face plate.

14. An end cap for insertion into an end of a face plate frame, the end cap comprising:

an end face for providing a closed face to the end of the face plate frame when inserted into the end of the face plate frame; and an end cap face plate frame connector for connecting the end cap to the face plate frame when the end cap is inserted into the end of the face plate frame.

15. An end cap as claimed in claim 14 further comprising a face plate body engager for engaging with a face plate body.

16. An end cap as claimed in claim 15 wherein in use, the face plate body engager serves to retain the face plate body to the face plate frame when the end cap is inserted into the end of the face plate frame.

17. An end cap as claimed in any one of claims 14 to 16 further comprising an end cap face plate body locator for locating with the face plate body.

18. An electrical unit comprising a base plate mounted to a surface and a face plate as claimed in any one of claims 1 to 9.

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19. A method of producing a face plate, the method comprising:

extruding a length of material to provide an extrudate;

forming one or more apertures to provide a face plate frame; and inserting a face plate body into the face plate frame such that at least a portion of the face plate body is located within the one or more apertures.

20. A method as claimed in claim 19 further comprising inserting at least one end cap into an end of the face plate frame.

21. A face plate comprising:

a face plate frame comprising at least one face plate frame aperture; and a face plate body connected to the face plate frame and at least partially located within the at least one face plate frame aperture, the face plate body comprising:

at least one face plate body aperture for receiving a switch actuator or for providing access to a socket.