CA1201499A - Electrical plug of dead front design - Google Patents

Electrical plug of dead front design

Info

Publication number
CA1201499A
CA1201499A CA000419486A CA419486A CA1201499A CA 1201499 A CA1201499 A CA 1201499A CA 000419486 A CA000419486 A CA 000419486A CA 419486 A CA419486 A CA 419486A CA 1201499 A CA1201499 A CA 1201499A
Authority
CA
Canada
Prior art keywords
housing
terminal block
cover shell
cord
housing portion
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired
Application number
CA000419486A
Other languages
French (fr)
Inventor
Ronald Thibeault
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Cooper Industries LLC
Original Assignee
Cooper Industries LLC
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Cooper Industries LLC filed Critical Cooper Industries LLC
Application granted granted Critical
Publication of CA1201499A publication Critical patent/CA1201499A/en
Expired legal-status Critical Current

Links

Abstract

ELECTRICAL PLUG OF DEAD FRONT DESIGN

Abstract The present invention is a quickly assembled electrical plug of dead front design. An integrally molded hinge connects the dead front terminal block to a first housing portion and a similar hinge connects the second housing portion to the first. Also connected by molded hinges to this composite assembly are two cord gripping strain relief fingers which are held in firm contact with the cord after assembly by a cover or shell. The line terminals are designed in connection with the terminal block so that their wiring screws all face in the same direction and may be connected to the cord conductors during assembly without rotation of the plug. After the cover shell is screwed onto the device, a ratchet assembly molded into one of the housing portions and cooperating with elements contained in the shell prevents inadvertant loosening of the shell.

Description

4~
Backqround of the_Invention The present invention comprises a quickly assembled electrical plug of dead front design.
While many electrical wiring devices still are of the so-called live front variety, in which the conductive terminals are connected to the cord conductors through the face of the device, the trend in industry is toward the safer, dead front design. In ~ead front plugs, the terminals are wired from the back of the device, and the non-conductive face contains slots or the like through which the terminal prongs protrude. Several dead front plug designs have been proposed, bu~ these generally have been complex and expensive--to produce, or must be molded with the line cord in place.

Summary of the Invention The present invention concerns a dead front electrical plug comprising a cover, a composite, integrally molded assembly and contact terminals. The molded composite member includes the terminal block, a irst semi-cylindrical housing portion connected to the terminal block by a molded hinge, a second ~emi-cylindrical housing portion connected to the first housing portion by a second molded hinge, and two cord gripping fingers integrally connected to the hou~ing portions by further molded hinges. ~he terminal block of this composite member is designed so that all terminal wiring screws are accessible from the same direction. Therefore~

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they May be connected during assembly wi~hout the need to rotate the devi~e. Peatures ~ontained in the housing portion~, the terminal blo~k and ~he cover shell cooperRte once the plug has been ~ ~embled and the ~hell added to provi~e resistan~e to longitudin~l 3nd ~ransverse ~tresses that occur during use of the plug. In a preferred embodiment, there is, also molded into the housing portions, a ratchet pa~l which cooperates with ratchetramp surfaces on the interior of the cover shell. The ratchet action allows the shell to be screwed on, but prevents inadvertant loosening of the shell.
These and other features of the inven~ion will be ~ore fully described in connection with the following detailed description of a preferred embodiment.

Description of the Drawings Figure 1 is a side view of an assemble~ 3-wire plug ~ccording to the present invention.
Figure 2 is an exploded view in per~pe~tive of the 3-wire plug shown in Figure 1.
Figure 3 i5 a plan view of the composite member of the pre~ent invention, shown in its unassembled configur~tion with the ter~inal prongs installed.
Figure 4 is a side view o the composite member of the present invention, ~hown in its unassembled ~onfiguration with the terminals prongs installed.
Figure 5 is a front view o the line terminal prong~ u~ed in the plug of the present invention.

~, Figure 6 is a side view of the line terminal prongs used in the plug of the precent inventions.
Figure 7 is a front view of the ground terminal prong used in the plug of the present invention.
Figure 8 is a side view of the ground terminal prong used in ~he plug of the present invention.
Figure 9 is a front view of the composite member in its partially assembled state, with the terminal prongs installed.
Figure lO is an end view of the assembled plug of the present invention.

Detailed Description The Figures show the preferred embodiment of the present invention. Referring first to Figure l, the invention as there pictured comprises a terminal block lO
with line terminal prongs 2 and 3 and ground terminal prong 4 extending from the front thereof, housing portions 20 and 40 interconnected by hinge 7, and a cover or shell 60 which has been ccrewed onto the assembly over the housing. Cover 60 has a rear end 61 with an opening therethrough for the line cord~ a tapered portion 62 with a frusto-conical interior surface and a generally cylindrical portion 63 haviny grooved areas 64 to provide a be~ter grip. Finally, Figure l sho~s ratchet pawl 42 molded into housing portion 40. Its interaction with cover 60 will be clarified in the discussion of subsequent figures.

.. . . . . .. . .. .. . . . .

Figure 2 shows how cover 60 mates with the assembled composite member 5. Cover 60, at it~ front end, has molded onto its interior surface eight convoluted ratchet ramp ~urfaces 65 which interact with ratchet pawl 42 on housing portion 40 in a manner described below to prevent backing off of cover 60 after wiring and assembly. The middle interior segment of cover 60 is threaded, as shown at 66, and the rear end of cover 60 has a frusto-conical shaped interior which terminates in opening 61 through which the line cord freely passes.
~ During assembly, cover 60 first encloses cord grip fingers 21 and 41 which are integrally molded respectively onto the rear of housing portions 20 and 40, as described in more detail below~ Then the threaded interior segment 66 of cover 60 engages the threaded exterior segment 50 of member 5. As the cover 60 is screwed home, the angle of the cord grip fingers 21 and 41 is forced to assume that of the frusto-conical interior of the coverO The fingers are thus caused to move inwardly towards each other and thereby to grip the cord which lies between them. During the last stages of tightening of cover 60 on member 5, ratchet pawl 42 will engage the convoluted ramp surfaces 65. When the tightening is complete, ratchet paw~ 42 will be engaged as shown in Figure 1, with a portion exposed where it can be reached for radially inward depression to release the ratchet action to facilitate intentional disassembly of the plug.

Figure 10 shows the mating of ratchet pawl 42 wi~h one of ramp sur f aces 6 5 .
To facilitate the manual gripping cf member 5 as ~over 60 is tightened down onto that member~ grooved areas ~uch as 222 are provided around the lower end of the ex~erior surface of housing portions 20 and 40.
~ he detailed structure of the member 5 is best seen in Figures 3 and 4. The fiYe main elements of member 5 are terminal block 10, housing portions 20 and 40, and cord grip fingers 21 and 41. Terminal block 10 is connected to housing portion 4D ~y integrally molded hinge 6. ~ousing portions 20 and 40 are joined by a similar hinge 7. Cord grip fingers 21 and 41 are joined respectively to housing portions 20 and 40 by hinges 8 and 9.
Terminal block 10 comprises a flat front face 11 containing openings for line terminal prongs 2 and 3 and ground terminal prong 4. Immediately behind front face 11 is a disk 12 of slightly greater diameter than face 11. The periTneter of this disk seats in grooves 23 and 43 in housing portions 20 and 40 when the plug is assembled. This interlock provides resistance to longitudinal stress on the plug such as occurs when the plug is disconnected from a socket. It will be noted that disk 12 ha~ flattened sections 13 and 14 at opposite positions around its perimeter 90~ away from hinge 6. These flattened sections facilitate insertion of terminal block 10 into housing portion 40 in view o the relative stiffness of the preferrecl thermoplastics ~aterials:
polypropylene or, for high temperature environments, nylon.
Formed on the rear face of disk 12 are three upstanding insulated chambers which contain the rear portions of line terminal prongs 2 and 3 and ground terminal prong 4. As is best seen in Figures 3, 4 and 9, the rear portion OI each of terminal prongs 2 and 3 i5 seated in a chamber ormed by front wall 15, outside wall 16, rear wall 17 and middle wall 18. Wall 15 has two arcuate cut-out portions thrvugh which protrude the wiring screws of terminal prongs 2 and 3. The chamber for the reae portion of ground terminal prong 4 is bounded by front wall 19, side walls 191 and 192 and as i~s rear wall, the walls 15 that form the front walls of the chambers for the line terminals. Wall 19 has an arcuate cut-out portion through which protrudes the wiring ~crew of terminal prong 4. As appears most clearly in Figures 4 and 9, the chamber for ground terminal prong 4 is shallower than the chambers for line terminal prongs 2 and 3, so that all three wiring screws are accessible for wiring in the same direction, a featuEe of the present invention which facilitates its assembly as compared to prior art devices.
Housing portion 20 contains two generally semi-circular internally mounted shelves 24 and 25 and r along its side wall remote from hinge 70 a rectangular latch 26.
Shelves 24 and 25 respectively have slots 27 and 28 therethrough. Housing portion 40 contains ratchet pa~l 42 and also semi-circular internally mounted shel~ 44, contoured , ~ C~

to fit around wall 18 of terminal block 10 and having sl~ts 45 and 441 therethrough. Housing portion 40 further includes, along i~s side wall remote from hinge 7, a rectangular seat 46 adapted to receive la~ch 26 of housing 20. Latch 26 snaps into engagement with seat 46 at the end of the assembly operation. When, near the end of the plug assembly operation, housing portions 20 and 40 are brought together around terminal block 10, the lower edge of shelf 2S
rests on a shoulder formed in wall 15 and shelves 24 and 44 meet The end of the line cord abuts wall 18 which, as best shown in Figure 9, extends upward through slot 45 above shelves 24 and 44O The ground and line conductors reach the ground and line terminal screws through slots 27, 28 and 441.
In addition, as seen in ~igures 3 and 4, housing portion 40 includes two tabs 47 and 48 along its side wall remote from hinge 7, which tabs interlock during assembly respectively with slots 29 and 291 alony the side wall of housing portion 20 remote from hinge 7. These interlocks provide additional resistance to longitudinal stress on the assembled plug. Further, housing portion 40 has molded on its inner surface blocks 49 and 491. These blocks abut the rear wall 17 of terminal block 10 when the terminal block has been rotated about hinge 6 into position within housing portion 40 during assembly, and the abutment of the blocks against wall 17 provides resistance to tr2nsverse stress arising during use of the plug.

Cord grip fingers 21 and 41 contain serrated gripping surfaces 210 and 410 and rounded shoulders on their outer surfaces, such as shoulder 411 seen on finger 41 in ~igure 4. These shoulders are contacted by the frusto-conical inner surface of cover 60 as cover 60 is screwed down onto the housing during assembly thereby causing the cord gripping action described above.
Figures 5 and 6 show the unique line terminal prong design utilized in the present invention to place all wiring screws in a common orientation for wiring. The terminal includes a blade 71 and a head 72 containing the wiring screw 73. Though formed from an initially flat metal blank, the plane of the head of ~he terminal is rotated 90 from the plane of the blade. By contrast, as seen in Figures 7 and 8, the ground terminal 4 has a contact element 81 formed in the standard configuration and a head B2 containing screw 83 and lying in a plane parallel to the plane of the original blank.
It will be apparent to persons skilled in the art that various other terminal and blade configurations, required for other amperage and voltage applications, may be substituted for those shown in Figures 5-8 without departing from the spirit and scope of the present invention.

_g_

Claims (6)

I claim:
1. An electrical connector of the dead front type comprising:
(A) a composite member of insulating material including (a) a terminal block having a central axis and including protruding electrical terminal prongs, (b) two substantially semi-cylindrical housing portions, each housing portion having a section that aligns with a section of the other housing portion to form a threaded exterior segment when the housing portions are brought together during assembly, (c) a plurality of cord grip fingers, at least one of the fingers being adjacent to but spaced from the top edge of each housing portion, (d) a first flexible hinge means connecting the housing portions along their heights so that they may be brought together during assembly to form a housing, (e) a second flexible hinge means connecting the bottom edge of one housing portion with an edge of the terminal block so that the central axis of the terminal block may be brought into coincidence with the axis of the housing during assembly, (f) additional flexible hinge means connecting each cord grip finger to the top edge of the adjacent housing portion, and (B) a cover shell of insulating material having a threaded interior portion adapted to mate with the threads of the housing, the cover shell having a first end remote from the terminal block with an opening therethrough for passage of an electrical cord, the first end having a frusto-conical interior surface adapted to drive the cord grip fingers against the cord when the cover shell is screwed onto the housing, and having an opposite open end adapted to receive the assembled housing.
2. The connector of claim 1 further including ratchet means for preventing the inadvertant unscrewing of the cover shell from the housing.
3. The connector of claim 2 wherein the ratchet means comprises a pawl formed on one of the interior surface of the cover shell and one of the housing portions, and a plurality of ramps formed on the other of the interior surface of the cover shell and the housing portions.
4. The connector of claim 3 wherein the pawl is formed in one of the housing portions and the plurality of ramps are formed around the interior surface of the housing portions adjacent the end thereof adapted to receive the terminal block.
5. The connector of claim 4 wherein a portion of the pawl protrudes from within the cover shell when the cover shell is fully screwed onto the housing.
6. An electrical connector comprising (A) a composite member including (a) a terminal block of insulating material having protruding electrical terminal prongs, (b) two substantially semi-cylindrical housing portions of insulating material, (c) a plurality of cord grip fingers of insulating material, at least one of the fingers being adjacent to the top edge of each housing portion, (d) a first flexible hinge means connecting the housing portions along their heights so that they may be brought together during assembly to form a housing, (e) a second flexible hinge means connecting the bottom edge of one housing portion with a edge of the terminal block so that the terminal block may be rotated into a position across the bottom of the one housing portion during assembly, (f) additional flexible hinge means connecting each cord grip finger to the top edge of the adjacent housing portion, and (B) a cover shell of insulating material having a first end remote from the terminal block with an opening therethrough for passage of an electrical cord and a opposite open end adapted to receive the assembled housing, the first end having a frusto-conical interior surface adapted to drive the cord grip fingers against the cord when the cover shell receives the assembled housing containing the terminal block, (C) the housing portions and the cover shell further including cooperating means for preventing unintentional removal of the cover shell from the assembled housing.
CA000419486A 1982-01-15 1983-01-14 Electrical plug of dead front design Expired CA1201499A (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US33982982A 1982-01-15 1982-01-15
US339,829 1982-01-15

Publications (1)

Publication Number Publication Date
CA1201499A true CA1201499A (en) 1986-03-04

Family

ID=23330791

Family Applications (1)

Application Number Title Priority Date Filing Date
CA000419486A Expired CA1201499A (en) 1982-01-15 1983-01-14 Electrical plug of dead front design

Country Status (1)

Country Link
CA (1) CA1201499A (en)

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