AU720384B3 - Electrical connector system - Google Patents

Description

AUSTRALIA

PATENTS ACT 1990

ORIGINAL

COMPLETE SPECIFICATION PETTY PATENT Invention Title: ELECTRICAL CONNECTOR SYSTEM Name of Applicant: UTILUX PTY LIMITED The following statement is a full description of this invention, including the best method of performing it known to me/us: -2- SOCKET OUTLET ARRANGEMENT The present invention relates to a socket outlet arrangement, and particularly, but not exclusively, to a socket outlet arrangement for a domestic power supply.

Plug-pin socket connectors are well known. Plug pins consist of a forwardly extending portion, in use extending from the face of a plug housing and comprising a substantially flat blade element or a cylindrical plug-pin element. The complementary socket connector consists of a suitably conductive receptacle for mechanical and electrical interengagement with the plug-pin connector. A plurality of such socket connectors (usually three) are employed in most domestic socket outlets. The socket connector also has a conductive portion connected (usually crimped) to a conductor connected or connectable to a power supply (usually mains power supply) so that electrical power can be provided to a device when the device is "plugged in". A socket connector is usually housed in an insulating housing having passageways therethrough for receiving plug pins to mate with the socket connectors.

It is known to provide socket outlets in arrays of two or more, in "power boards", for example, thereby making available extra socket outlets. Power boards usually comprise an insulating housing, mounting a conductive, usually metal assembly, with which the socket connectors are integral. For example, one known power board comprises an assembly which includes three separate brass webbings, one for each of earth, live and neutral provided with socket connectors formed at appropriate positions along the length of each of the brass webbings. The brass webbings are then mounted with respect to each other so that the socket connectors are positioned appropriately to receive -the plug pins of three-pin plugs, for example, via 399300 -349\34S48doc -~cJ -3passageways through an insulating wall of the power board connector. Each webbing has to be separately manufactured or assembled and the positioning of each of the socket connectors on the webbing predetermined to ensure the correct pattern of socket outlets post assembly.

Such an arrangement has a number of problems.

Firstly, because solid conductive webbings are used, a great deal of relatively expensive material is incorporated in the power board. Further, the manufacture and assembly of the webbings is complex and time consuming and therefore increases the expense of the power board.

Further, if it is desired to manufacture different power boards having different patterns and different numbers of socket outlets, then a new webbing arrangement must be designed and manufactured. This lack of versatility in the design and manufacturing process leads to increased cost.

Further, where it is required to use a different type of socket receptacle (for example in a different country where the plug-pins may be of a different shape e.g., round, square), again it is necessary to redesign the entire connector webbing arrangement.

The present invention provides a socket outlet arrangement for a domestic power supply, comprising a plurality of buses, each bus being arranged to connect to a conductor of a particular polarity of a domestic power supply or earth, each of the buses having been arranged in a predetermined layout, and a plurality of socket connector members, each being of the same form, each socket connector member including a single socket for receiving a corresponding plug pin in mechanical and electrical interengagement, each socket connector being individually mounted to one of the buses during assembly of the socket J.\Spe3OO- 399300- 349\34548.doc .i 1J t r r! -4outlet arrangement, and each individual socket connector member being arranged, during mounting, with respect to socket connector member(s) on other bus(es) to provide an array of socket connector members in a pattern suitable for receiving the pins of a domestic plug to connect the plug to the appropriate polarity of power supply or earth, a plurality of socket connector members being mounted in this way to each bus, whereby to provide a plurality of socket connector arrays for receiving a plurality of domestic plugs.

Preferably, the socket outlet arrangement also includes a guide means for guiding the buses in the predetermined layout. Preferably, the guide means is also arranged to locate the socket connector member. The guide means is preferably mounted to a housing.

Preferably, the guide means can locate the buses and socket connector members in a predetermined desired pattern within a housing. This enables, for example, power boards to be manufactured easily. All that is required are buses and a plurality of socket connector members which can be mounted to the buses in the desired configuration. The guide means may be moulded as a plastics track, for example, within the housing to receive the socket connector members and buses in the desired configuration.

Preferably, use of the guide means restricts the path of the bus, and preferably enables the use of uninsulated conductive buses, such as uninsulated wire, for example.

This is a distinct advantage, as uninsulated wire is less costly.

Preferably, the plug socket connector member includes a portion mounting a displacement device which is arranged to fit to the bus in an interfering manner. The displacement device preferably comprises a slot within a DJSpcc300- 39900 349\34548.doc

''S

portion of the connector member which fits over the bus and the walls of which press into the sides of the bus.

Alternatively, the connector member may be secured to the bus by means of an ultrasonic weld, crimp or other means.

Preferably, the bus is a single strand conductive wire, copper wire. It may, however, be multiple strand.

The arrangement of the present invention preferably has the advantage of allowing material savings, as it is not necessary as in the prior art to provide a complex webbing comprising a substantial amount of material. All that is required is single strand wire buses and the socket connector members. Further, any pattern that is required can be built. The guide means may need to be rearranged in each case, but the bus and socket connector member will fit to any appropriate guide means. Further, only one stamping tool is necessary to stamp the connector members which may be the same throughout.

For applications in other countries, it is a simple matter to merely stamp different types of connector members.

The primary application of the present invention, is in relation to the manufacture of power boards.

Nevertheless, the invention may have general application in, for example, wall mounted plug-pin socket assemblies (domestic wall mounts, for example) or any other types of electrical socket assemblies.

Features and advantages of the present invention will become apparent from the following description of an embodiment thereof, by way of example only, with reference to the accompanying drawings, in which: 399\O- 349\34548.doc Z- c -6- Figure 1 is a perspective view from above and one side of a socket connector member and bus utilised in accordance with an embodiment of the present invention; Figure 2 is a perspective view from above of a socket outlet arrangement in accordance with an embodiment of the present invention, and Figure 3 is a perspective view from above of the socket outlet arrangement of Fig. 2, in the absence of a housing for the purposes of clarity.

Referring to the drawings, a socket outlet arrangement in accordance with an embodiment of the invention is illustrated, and comprises a socket connector member 1 which is arranged to be mounted to a conductive bus 2. The socket connector member 1 can be mounted at any desired position along the bus 2 so that predetermined patterns of connector members 1 can be achieved, during installation, to produce a desired plug socket connector pattern.

The illustrated embodiment shows how a plug-pin socket array for a power board may be arranged. Referring to figure 2, three busses 2a, 2b, 2c are provided and laid down within guide means 3a, 3b, 3c within a housing 4 according to a predetermined pattern for the power board socket outlet array. The guide means includes insulating tracks 5a within which the conductive buses are laid down, and insulating receptacles 5 for receiving socket connector members 1 in a predetermined pattern. The guide means also includes pins 5b which assist in guiding the buses 2. Note that in some cases pins 5b could be used instead of the insulating guides 5a in a similar manner to a "peg board".

As can be seen from the figures, particular figure 2, a predetermined pattern provides for three socket outlets for the type of plugs used in Australia. The buses 2a, 2b, 2c are in this embodiment a single strands of wire and they J\SpccMOO 399\3 349\34548.doc 'C 'k

V

I

-7may be uninsulated because the guide means will retain them in position. Standard "tulip" socket connectors 6 are provided on the socket connector member 1 for receiving the blade connectors which are used in Australia. Any other type of connector may be used, depending upon the plug pin which is wished to be connected (this may, of course, vary from country to country) The power board cover is not shown, but it will be appreciated that it will be a standard type of cover which includes passageways within the insulating cover to marry with the tulip connectors 6. The wire buses 2a, 2b, 2c will be connected to live, neutral, and earth conductors in operation and, as is usual with a power board, a cable will lead to a plug which can be plugged into a wall-mounted socket to provide power to the power board. Other circuitry may be included in the housing 4.

The plug socket connector members 1 also include a portion 8 mounting a displacement device 9. The displacement device comprises walls of the portion 9 defining a slot 10. The slot 10 fits over the bus 2 and the walls press into the side of the bus 2 to provide a secure interference mechanical and conductive connection.

Other types of connection to the bus may be made, crimp, welding, etc.

On assembly, the preferred way is to first of all fold the buses into the guide means, and then fit the socket connectors.

The bus 2, in this embodiment, is a single strand copper wire. The bus may alternatively be multiple stranded wire, such as 7 stranded wire, for example.

It will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the invention as shown in the specific embodiments J;:Spcc300- 399\300- 349\34548.doc 'i c -8without departing from the spirit or scope of the invention as broadly described. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive.

J:ASpecAOO 399300 34934548.doc 'i -4-

C-)

NT9-'

Claims (3)

1. A socket outlet arrangement for a domestic power supply, comprising a plurality of buses, each bus being arranged to connect to a conductor of a particular polarity of a domestic power supply or earth, each of the buses having been arranged in a predetermined layout, and a plurality of socket connector members, each being of the same form, each socket connector member including a single socket for receiving a corresponding plug pin in mechanical and electrical interengagement, each socket connector being individually mounted to one of the buses during assembly of the socket outlet arrangement, and each individual socket connector member being arranged, during mounting, with respect to socket connector member(s) on other bus(es) to provide an array of socket connector members in a pattern suitable for receiving the pins of a domestic plug to connect the plug to the appropriate polarity of power supply or earth, a plurality of socket connector members being mounted in this way to each bus, whereby to provide a plurality of socket connector arrays for receiving a plurality of domestic plugs.

2. A socket outlet arrangement in accordance with claim i, further comprising guide means which is arranged to guide the buses in the predetermined layout and to secure the socket connectors in position.

3. A socket outlet arrangement in accordance with claim 1 or claim 2, wherein each socket connector member includes a portion mounting a displacement device which is arranged to fit to the bus in an interfering manner. JASpeciA3OO- 399\30- 349\34548-oc J N" C C.-T Dated this 27th day of March, 2000 UTILUX PTY LIMITED By their Patent Attorneys GRIFFITH HACK J:\SpcA300 399\300 349\34548.doc