ES2882294T3 - Electrical connector assembly for a lighting unit - Google Patents

Abstract

An electrical connector assembly (1) arranged to electrically connect together at least one supply-side power supply cable (302) and a device power supply cable (202), wherein the electrical connector assembly (1) includes: a first connector (3) arranged for electrical connection to one of the supply side and device power supply cables (302,202), said first connector (3) including a set of first electrical connectors (7); and a second connector (5) arranged for electrical connection to the other of the supply side power supply and device power supply cables (302,202), said second connector (5) including a set of second electrical connectors (55); The sets of first and second electrical connectors (7,55) are arranged for mating to form an electrical connection between the supply side power and device power cables (302,202) and for unmating to break the electrical connection. ; wherein the set of first electrical connectors (7) is molded into a plastic support member (13), thereby incorporating at least part of each first electrical connector (7) within the plastic support member (13), wherein each first electrical connector (7) comprises first and second parts (9,11), and each second part (11) protrudes outwardly from the support member (13) into a terminal block (31); The terminal block (31) includes a set of first openings (37) and a set of resilient electrical connectors (39), and the second portion (11) of each first electrical connector extends toward a respective first opening (37) and forms an electrical connection with a first part (41) of a respective resilient electrical connector (39); and wherein the terminal block (31) snaps onto the first electrical connectors (7).

Description

DESCRIPTION

Electrical Connector Assembly for a Light Unit

The invention relates to an electrical connector assembly. The electrical connector assembly is arranged to connect electrical power cables together. The invention also relates to a lighting unit and lighting system each including the electrical connector assembly, and a method of manufacturing a first connector, which is part of the electrical connector assembly.

Electrical connector assemblies for electrically connecting a lighting unit power cable to a network lighting ring are known. This type of electrical connector assembly includes a first electrical connector that is connected to the supply side and a second connector that engages the lighting unit power cable. However a significant disadvantage of such known electrical connector assemblies is that they are difficult to manufacture and assemble, for example it is necessary to manually insert each electrical connector into a housing during an assembly process. Thus the assembly is error prone and is relatively slow and expensive.

A further problem is that the structure of at least one connector part is not particularly optimized. For example, a known example includes a conventional screw-operated terminal block for receiving wires that are connected to electrical connectors through a PCB. This requires additional components to fabricate and is relatively difficult for an electrician to install.

Known connectors are disclosed in US2018/269602 and CN108468989 which disclose a similar electrical connector assembly for use in a lighting unit.

Therefore the invention seeks to provide an apparatus and a method for manufacturing a connector that mitigates at least one of the aforementioned problems or at least provides an alternative solution to known solutions.

According to one aspect, there is provided an electrical connector assembly arranged to electrically connect together at least one supply-side power cable and a device power cable according to claim 1.

The invention provides assembly advantages for the electrical connector since molding the set of first electrical connectors into the plastic support means that each electrical connector does not need to be individually assembled to a support member, for example by hand. Manual assembly is a time-consuming, expensive and highly dexterous process that is prone to errors, for example dropping electrical connectors. The arrangement also allows a press terminal block to slide over the electrical connectors, as described in more detail below. In preferred arrangements the first connector is attached to the supply side power cable and the second connector is attached to the device power cable.

The second connector is typically attached to the device power cable during a device assembly process and is sold in a configuration with the second connector attached to it. The first connector is typically attached to at least one supply-side power cable by an electrician, for example during a device installation process. Once the first connector is installed, subsequent removal and replacement of the device can be performed by an inexperienced person, such as a homeowner, by simply detaching the current device's second connector from the first installed connector and then connecting the second. connector of a new device to the first installed connector. The processing is similar to removing and inserting a plug into a receptacle.

It will be appreciated that the electrical connector assembly may be sold separately from a lighting unit, for example to allow it to be upgraded to an existing fixture.

The electrical connector assembly allows the device, such as a lighting unit and preferably a solid state lighting unit, to be electrically connected to electrical power circuitry. For example, electrical power circuitry having an electrical supply and at least one supply-side power cable connected directly or indirectly to the electrical supply.

The first connector includes a plurality of first electrical connectors, for example two or three first electrical connectors. The assembly may include at least one of hot, switched hot, and neutral connectors. The assembly may include a ground connector. The second connector may include a plurality of second electrical connectors, for example two or three second electrical connectors. The assembly may include at least one of hot, switched hot, and neutral connectors. The assembly may include a ground connector.

The support member may include a mounting wall. The mounting wall may comprise a cuboid block.

The support member may include a plurality of tubular shells. The plurality of tubular covers may protrude outwardly from a first side of the mounting wall. Each tubular shell may project perpendicularly outwards from the first side of the mounting wall.

Each first electrical connector includes a first part. Each first part may protrude outwardly from the support member, and preferably from a first side of the support member. Each first part of each first electrical connector is receivable within a respective one of the tubular shells. Typically the number of tubular covers matches the number of first electrical connectors. Each tubular sheath is preferably disposed coaxially with the first part of its respective first electrical connector.

The first part of each first electrical connector can be lengthened. Each tubular shell may be circumferentially molded around the first part of its respective first electrical connector.

Each tubular shell may be integrally formed with the mounting wall during the molding process.

The tubular covers can be arranged parallel to each other. Each tubular cover may have a longitudinal axis. The longitudinal axes may be arranged parallel to each other. Typically the covers are offset from each other in a first direction, such as a lateral direction.

Each tubular sheath may extend beyond a distal end of the first part of its respective first connector. This protects the electrical connector and provides clearance and creepage compliance.

The first part of each first electrical connector may comprise a female connector. For example, the first part may comprise a plurality of tips distributed circumferentially. The female connector can be arranged to receive a male connector. The female part of the connector can be used to electrically test the connection to the supply cables.

Each first electrical connector comprises a second part. Each second part protrudes outwardly from the support member towards a terminal block. This arrangement allows for easy assembly of the electrical connector assembly. Every second part can protrude outwards from the mounting wall. Each second part may project out from a second side of the mounting wall directly on the terminal block, and preferably on a first side of the terminal block. The second side of the mounting wall may be opposite the first side of the mounting wall. The second part of each first electrical connector may extend in a direction that is opposite to the direction of its respective first part.

The second part of each first electrical connector may comprise a male connector, such as a pin. The first and second parts of each first electrical connector may be arranged coaxially. Preferably each first electrical connector is elongated. Preferably each first electrical connector is rectilinear. The first part of each first electrical connector may comprise a front side and the second part of each first electrical connector may comprise a rear side with respect to the insertion direction of the first connector.

The terminal block includes a set of first openings. Each first opening is arranged to receive a respective one of the second portions of the first electrical connectors. The terminal block includes a set of resilient electrical connectors. The second part of each first electrical connector forms an electrical connection with a first part of a respective resilient electrical connector through a respective first opening. The engagement of the terminal block with the second portions of each first electrical connector may provide sufficient retaining force to fix the position of the terminal block within the first connector. That is, no additional fixing means, such as screws and/or adhesive, are required to fix the location of the terminal block within the first connector.

During assembly, the terminal block is pushed over the first few electrical connectors. This is a very quick and easy assembly method and leads to a low manufacturing cost.

The terminal block may include a set of second openings each arranged to receive a respective wire from the feeder cable, and typically the supply-side feeder cable. Each resilient electrical connector may include a second part that is arranged to electrically connect with a respective wire from the power cable. The first and second parts of each resilient electrical connector are electrically connected together thereby allowing electricity to flow between the power cable and the set of first electrical connectors.

The terminal block may be arranged to receive a plurality of supply-side feed wires, for example in a "loop-in""loop-out" arrangement. In this arrangement, one of the supply-side feed cables carries electricity to the first connector and another of the supply-side feed cables "loops out" electricity to the next light fixture and connector in the circuit. of lighting. In this arrangement, the terminal block may include at least one of: a plurality of live terminals, a plurality of ground terminals, and a plurality of neutral terminals.

The terminal block may be a quick release terminal block. This terminal block is convenient for installers as it does not require a tool to operate, such as a screwdriver, and speeds up installation.

The terminal block may include a set of manually operable actuators. Each actuator may be arranged to actuate the second part of a respective resilient electrical connector, thereby allowing the respective resilient electrical connector to move into and/or out of electrical connection with the respective wire. When the respective actuator is in a non-actuated condition, the second part of the respective resilient electrical connector is arranged to bias against its respective wire, thereby fixing it in place. In this way the second part of the respective resilient electrical connector is arranged to mechanically load its respective wire in the non-actuated condition.

Each manually operable actuator may include a lever. Each lever can be pivotally attached to a terminal block housing. For example, one end of each lever can be pivotally attached to the terminal block housing. The lever may include an actuating member. The actuating member may be located on one side of the lever, such as the lower side of the lever. The actuator member may be arranged to act on the second part of its respective resilient electrical connector, or an intermediate component attached thereto, to move the second part of the respective resilient electrical connector between wire-engaging and non-wire-engaging positions. .

The support member may include a base. The base can be arranged perpendicular to the mounting wall. The base can be integrally formed with the mounting wall and tubular shells during the molding process.

The terminal block can be mounted on the base.

The first connector may include a cover. The cover may form a housing with the support member. The housing may house the terminal block and an end portion of at least one power cable. Preferably the housing is arranged to receive end portions of a plurality of supply side feed cables. The cover may be arranged to snap fit to the support member, for example to snap fit to at least one of the base and mounting wall. The support member base may provide a base for the housing. The support member mounting wall may provide a front wall of the housing.

One of the first and second connectors may include a latch and the other of the first and second connectors may include a latch receiving formation. The latch and latch receiving formation may be arranged to releasably connect the first and second connectors together. The latch arrangement helps prevent physical separation of the first and second connectors when they are electrically connected together.

The first connector may include a cord grip adapter that is arranged to adapt the size of a cord receiving opening from a first size to a second size. The first size can be larger than the second size. The cord grip adapter may be an integral part of the support member, which is formed during the molding process. The cord grip adapter may include a plurality of flexible straps. The cord grip adapter includes a socket located at the distal ends of the flexible straps, which is adapted to accommodate the size of the opening.

The second connector may include a plurality of tubular sheaths. A first part of each second electrical connector can be housed within a respective one of the tubular covers. The first part of each second electrical connector is preferably a male connector, eg a pin. The first part of each second electrical connector is preferably rectilinear. Typically the number of tubular covers matches the number of second electrical connectors. Preferably each tubular sheath extends beyond a distal end of the first part of its respective second connector. This protects the electrical connector.

The tubular shells of one of the first and second connectors may each be sized and shaped to receive at least part of a respective one of the tubular shells of the other of the first and second connectors therein. In this way each tubular cover of one of the first and second connectors acts as a receptacle for receiving a respective one of the tubular covers of the other of the first and second connectors. The tubular covers that are arranged to receive at least a portion of a respective one of the other tubular covers each have an internal diameter that is greater than or equal to the external diameter of the respective tubular covers that are received. The inner surface of each receiving tubular shell is spaced from its electrical connector housed therein to create a space to receive the respective tubular shell of the other connector.

In preferred embodiments, each tubular shell of the second connector is sized and shaped to receive at least part of a respective one of the tubular shells of the first connector. For example, the inside diameter of each second connector tubular sheath may be greater than or equal to the outside diameter of its respective first connector tubular sheath. The inner surface of each second connector tubular shell is spaced apart from the first part of its respective second electrical connector housed therein to create a space for receiving the respective first connector tubular shell.

One of the first and second connectors includes at least one key, and preferably a plurality of keys. The other of the first and second connectors includes at least one slot for receiving the key, and preferably a plurality of slots each arranged to receive a respective one of the keys. The keys and slots are arranged for mating engagement. The key slot arrangement helps prevent relative rotation between the first and second connectors. At least one of the tubular covers can include the key. At least one of the tubular covers can include the slot to receive the key. Preferably each tubular cover of the first connector includes a respective one of the keys. Preferably each tubular shell of the second connector includes a respective one of the slots that is arranged to receive a respective one of the keys.

According to another aspect there is provided a lighting unit including an electrical power cable and an electrical connector assembly in accordance with any configuration described herein.

The lighting unit may include at least one solid state lighting device. The lighting unit may include at least one LED light source. The lighting unit may include at least one PCB.

The lighting unit may be a recessed luminaire which is arranged to be fitted into an opening formed in a partition such as a ceiling. The lighting unit is preferably an LED recessed luminaire.

The lighting unit may include a fire resistant housing. The fire resistant housing may include material that melts at a temperature greater than or equal to 900C, preferably greater than or equal to 950C, and more preferably greater than or equal to 1000C. For example, the housing may include at least one of steel, brass, copper, and ceramic. The housing may be made of sheet material. In a particularly preferred arrangement the fire resistant housing is made of steel. The housing can be made by pressing sheet material, for example by pressing sheet steel. The housing can include a plurality of materials. For example, the housing may comprise a plurality of parts joined together. The fire resistant housing may have a flange on an open side of the housing. The flange prevents fire from passing through gaps between the light unit and a ceiling.

The recessed light fixture may include a heat sink. The heat sink can be mounted on the rear of the fire rated enclosure. The heat sink is completely optional since many modern LEDs no longer require a heat sink to function properly. A heat sink may be required for some high power applications.

The LED light source and PCB can be mounted inside the fire resistant housing. For example, the LED light source and PCB can be mounted on a front face of the end wall of the housing. Alternatively, the PCB and LED light source can be mounted on the rear side of the fire resistant housing. The fire resistant housing may include at least one hole formed through the housing to allow light emitted from the LED light source to pass through the housing.

According to another aspect, a lighting system is provided, including: electrical circuitry including an electrical supply and at least one supply-side power cable connected directly or indirectly to the electrical supply; a lighting unit having a power cord; and an electrical connector assembly according to any configuration described herein. The electrical connector assembly electrically connects the at least one supply side power cable and the lighting unit power cable together. The lighting unit can be arranged according to any configuration described in this document.

The electrical supply is typically a mains supply. Additionally, or alternatively, the electrical supply may include at least one electrical cell or power generation means such as a solar panel.

In use, the first connector is electrically bonded to the at least one supply-side feeder cable. Typically this is done by an electrician. The second connector is electrically attached to the device power cable. This can be done when the light unit is manufactured and assembled, or it can be done at another time, such as during the installation process. The first and second connectors are electrically connected together by moving the set of first electrical connectors into mating engagement with the set of second electrical connectors. The lighting unit can be disconnected from the electrical supply circuit by uncoupling the first and second electrical connectors.

According to another aspect there is provided a method of manufacturing a first connector according to claim 17. The first connector is part of the electrical connector assembly according to any configuration described herein. The method includes: providing a set of first electrical connectors; placing the set of first electrical connectors in a mold to make a support member; inserting a fluid plastic material into the mold; and allowing the plastic material to solidify to form the support member, said support member having a mounting wall and a plurality of tubular shells projecting outwardly from a first side of the mounting wall, wherein the set of first electrical connectors is at least partially incorporated within the mounting wall, a first part of each first electrical connector is housed within a respective one of the tubular shells, and a second part of each The first electrical connector protrudes outwardly from a second side of the mounting wall. The method includes providing a terminal block having a set of first openings and a set of resilient electrical connectors, pushing the terminal block onto the set of first electrical connectors such that the second portion of each first electrical connector extends toward a respective first opening and forms an electrical connection with a first part of a respective resilient electrical connector.

The second side of the mounting wall may be opposite the first side of the mounting wall. The molding step may make use of any suitable molding method, for example an injection molding method.

The fluid plastic material can be a thermoplastic, such as at least one of Polycarbonate (PC), Polypropylene (PP), and Polyamide (PA).

The terminal block may be a quick release terminal block.

The method may include sizing the outer diameter of each tubular shell to fit a respective tubular shell in a second connector.

Embodiments of the invention will now be described by way of example only with reference to the drawings, in which:

Figure 1 is an exploded isometric view of an electrical connector assembly according to one embodiment, including a supply-side connector and a device connector;

Figure 2 is an isometric view of an electrical terminal block mounted on the supply-side connector shown in Figure 1;

Figure 3 is a rear end view of the electrical terminal block of Figure 2;

Figure 4 is a longitudinal cross-sectional view of the electrical terminal block of Figure 2;

Figure 5 is an isometric view of the electrical connector assembly of Figure 1 in an assembled state, wherein the supply and device side connectors are connected together;

Figure 6 is a longitudinal cross-sectional view of the electrical connector assembly of Figure 1, with the supply and device side connectors connected together (NB the electrical terminal block is shown in a simplified form for clarity of layout global);

Figure 7 is an enlarged view of part of Figure 6;

Figure 8 is a schematic view of an embodiment of the lighting system; Y

Figure 9 is a schematic view of a lighting unit, which is part of the lighting system of Figure 8.

Figures 1 to 6 show an electrical connector assembly 1 according to one embodiment. The electrical connector assembly 1 is arranged to electrically connect the supply and device side power cables 302,202 together. For example, a device 200, such as a solid state lighting unit, having a power cable 202 may be connected to electrical power circuitry. The electrical circuitry may include a power supply 300 and at least one supply-side power cable 302, which is electrically connected to the power supply 300 either directly or indirectly.

Each power cable 202,302 includes a hot wire 203,303 and a neutral wire 205,305. Each cable 202,302 may also include a ground wire 207,307.

The electrical connector assembly 1 includes a first supply side connector 3 and a second device connector 5 . Supply side connector 3 is connectable to at least one supply side power cable 302 and device connector 5 is connectable to device power cable 202 . The supply and device side connectors 3,5 may be mated together, in a releasable manner, in order to electrically connect the device 200 to the power supply 300 . The supply and device side connectors 3,5 can be unmated to electrically disconnect the device 200 from the power supply 300 .

In some arrangements the supply side connector 3 may be connected to a plurality, eg two or three, first electrical wires 302 in order to loop electrical current to other devices, such as other lighting units 200.

Supply side connector 3 includes a plurality of first electrical connectors 7, which are arranged to mate with a plurality of complementary electrical connectors on device connector 5. Each electrical connector 7 includes a first part 9. The first part 9 comprises a front part of the electrical connector. The first part 9 preferably comprises a female electrical connector. Each connector 7 electrical it includes a second part 11. The second part 11 is a rear part of the electrical connector. Preferably the second part 11 comprises a male connector, such as a pin. The second part 11 is typically rectilinear or includes a rectilinear coupling part. The terms front and back are with respect to the connection direction of the supply side connector 3 with the device connector 5. The supply side connector 3 typically includes two or three electrical connectors 7 . Typically, the supply side connector 3 includes hot, neutral and ground electrical connectors 7 . In some arrangements the supply side connector 3 may include live and neutral electrical connectors 7 only.

Electrical connectors 7 are molded into a plastic support member 13 during manufacture. That is, the support member 13 comprises a molded plastic component, and when the component is formed by a molding process, such as injection molding, the electrical connectors 7 are located in the mold and the mold is then filled with material. fluid plastic. The fluid plastic material is molded onto the electrical connectors 7 in accordance with the shape of the mould, and any spacers present, to produce the support member 13, when the plastic material solidifies, with the electrical connectors 7 incorporated therein. Typically, the plastic material comprises a thermoplastic material such as at least one of Polycarbonate (PC), Polypropylene (PP), and Polyamide (PA). This manufacturing method provides an arrangement that is easier to assemble than a conventional arrangement, eg individual electrical connectors do not need to fit into cavities formed in a support member during the assembly process. This leads to a decrease in assembly time and assembly cost, and without additional components allows the use of a push-fit terminal block 31.

Support member 13 includes a mounting wall 14. The mounting wall 14 has a front side 16 and a back side 18. The terms front and back are with respect to the connection direction of the supply side connector 3 with the device connector 5. Each electrical connector 7 is mounted on the mounting wall 14. The electrical connectors 7 are arranged in parallel with each other. Each electrical connector 7 extends through mounting wall 14. The first part 9 of each electrical connector protrudes perpendicularly outwards from the front side 16 of the wall. The second part 11 of each electrical connector projects perpendicularly outwards from the rear side 18 of the wall. Support member 13 includes a plurality of covers 15, one for each electrical connector 7 . Each cover 15 comprises a cylindrical tube protruding outwards from the front side 16 of the wall. Each cover 15 houses the first part 9 of its respective electrical connector. Each cover 15 protrudes axially beyond a distal end of the first part 9 of its respective electrical connector, thereby protecting the connector. Each cover 15 includes a key 17 which runs axially along the length of the cover 15. The keys 17 help to properly align the supply and device side connectors 3,5 and to prevent relative rotation of the connectors 3, 5 supply side and device in use.

The supply side connector includes a cover 21 that is arranged to snap fit onto the support member 13 to form a housing 19. The support member 13 includes snap-fit latches 22 that are arranged to engage formations 24 of Formed snap fit coverage. 21. The skilled person will appreciate that the cover 21 may include at least one snap-fit latch 22 and that the support member may include at least one snap-fit formation 24. Mounting wall 14 provides at least part of a forward end wall of housing 19. Support member 13 may include a base 23. Base 23 extends perpendicularly from a lower end of rear side 18 of mounting wall 14 . Thus the support member 13 has an L-shaped configuration when viewed from the side (see Figure 1).

Housing 19 has an opening 25 located towards a rear end 27 for receiving supply side cables 302 . Support member 13 includes a cord grip adapter 29 for attaching cables 302 to housing 19. Cord grip adapter 29 may be an integral part of the support member, which is formed during the molding process. The cord grip adapter includes a plurality of flexible straps 30 . The cord grip adapter 29 includes a socket 32 located at distal ends of the flexible straps 29 . The cord grip adapter 29 is an optional part that the installer may choose to use depending on the thickness of the cable they are connecting to. The Cord Grip Adapter 29 is designed to accept two thicknesses of cord. For the thinner of the two cables the installer can use plug 32 to make opening 25 slightly smaller and thereby grip the thinner cable.

A terminal block 31 is located in housing 19. Terminal block 31 is electrically connected to electrical connectors 7 on a first side 33 and is electrically connectable to supply side wires 302 on a second side 35. Block 31 The terminal strip includes a first set of three openings 37 on the first side. Each opening 37 receives the second part 11 of a respective electrical connector therein. Each opening 37 is axially aligned with the second part 11 of its respective electrical connector, which allows the terminal block 31 to be pushed over the electrical connectors 7 during the assembly process. This provides a quick assembly process. For example, terminal block 31 can slide into position along base 23, and sits on base 23 in its rest position. Terminal block 31 includes resilient internal electrical connectors 39 . Each resilient connector 39 includes a first portion 41 that is arranged to resiliently engage the second portion 11 of its respective first electrical connector. In some arrangements, no additional fixing means, such as screws or adhesive, are required to fix the terminal block 31 within the housing 19. Frictional and/or resilient engagement between the resilient connector 39 and the electrical connectors 7 is sufficient to firmly locate terminal block 31. However in some provisions additional fixings can be used. For example, there may be retaining clips on the base 23 which help to lock the terminal block 31 in position.

Terminal block 31 includes a second set of three openings 44 formed in second side 35. Each opening 44 is arranged to receive a respective wire, hot 303/neutral 305/ground 307, from supply side cable 302. Each resilient connector 39 includes a second portion 43 that is arranged to resiliently engage its respective wire 303,305,307 to firmly hold the wire in engagement with terminal block 31. Each resilient connector 39 includes a third part 47 that electrically connects the first and second parts 41,43 of the resilient connector together and allows an electrical current to flow between the wire and the respective electrical connector 7, and thus the device 200 and the 300 electrical supply.

The terminal block 31 has a mechanism to provide quick wire binding and quick wire release. That is, it is not necessary to secure the wires 303,305,307 to their resilient connectors 39 using screws. The terminal block 31 includes 3 levers 49 which are pivotally attached to an upper side 51, preferably towards the first side 33. Each lever 49 is associated with a respective resilient connector 39. Each lever 49 includes a drive member 53 which is arranged to move the second part 43 of its respective resilient connector. Typically the actuation member 53 is located on an underside of the lever 49. In its non-actuated state, the second part 43 of the resilient connector is biased into engagement with its respective wire 303,305,307. When lever 49 is depressed by the user, actuation member 53 biases second part 43 of the resilient connector away from wire 303,305,307, which allows wire 303,305,307 to be easily inserted into opening 44 to a position where the second part 43 of the resilient connector will engage the wire when the user releases the lever 49. When the lever is released, the resilience of the second part 43 causes the second part 43 to return to its unactuated wire-engaging position, and the lever 49 returns. to its unpressed state. The mechanism can also be used to remove wire 303,305,307 from terminal block 31. Depressing the lever 49 releases the biasing force applied to the wire 303,305,307 by the second part 43 of the resilient connector, thereby allowing the wire to be withdrawn from the terminal block 31.

Terminal block 31 may include additional openings 46 to receive additional cable wires. For example, one or more additional supply-side power cables 302 may be connected to the supply-side connector 3, thereby looping into additional devices 200, such as additional lighting units.

The device connector 5 includes a plurality of second electrical connectors 55, which are arranged to mate with the first electrical connectors 7 on the supply side connector 3. Each second electrical connector 55 comprises a male connector portion 57 that is arranged to electrically connect with a respective one of the first female portions 9 of the electrical connectors 7, and a terminal 59 for receiving a respective wire 203,205,207 from the device cable 202. Each terminal 59 has an associated screw 61 which is used to attach the respective wire 203,205,207 to terminal 59. Terminals 59 are mounted on a second terminal block 63. The male connector portions 57 protrude out of the second terminal block 63 into tubular covers 65 . The male connector portions 57 are elongated and are disposed coaxially with the tubular covers 65 . Each electrical connector 55 is inserted into the second terminal block 63 individually during assembly, in a manner conventional in some arrangements.

Each cover 65 projects axially beyond a distal end of its respective male connector portion 57 . Each tubular shell 65 has an internal diameter that is large enough to receive a respective one of the shells 15 of the supply side connector 3 . The inner surface 66 of each shell 65 is spaced from the outer surface of its respective male connector portion 57 to allow the shell 15 to be received within the shell 65. Each tubular shell 65 has a longitudinal slot 67 which is arranged to receive a respective one of the keys 17. When the supply and device side connectors 3 and 5 are connected together the covers 15 on the supply side connector 3 slide axially in their respective covers 65 on the device connector 5, the keys 17 slide into their respective slots 67, and the plug portions 57 of the device connector 5 slide into, and electrically connect with, the socket portions 9 of the supply side connector 3.

The device connector 5 includes a base 69 and a cover 71. The cover 71 overlaps the base and the second terminal block 63. Cover 71 is attached to base 69 by screws 73.

The cover 71 includes a latch 75 which is arranged to engage a latch receiving formation 77 on the cover 21. The latch 75 is arranged to engage the latch receiving formation 77 when the supply side connectors 3,5 and device are connected together. The latch 75 and receiving formation 77 hold the connectors 3,5 together. The latch 75 includes an actuating button 79. A user can separate the supply and device side connectors 3.5 by pressing button 79 to release the latch and separating the connectors 3.5. It will be appreciated that instead latch 75 may be mounted to cover 21 and latch receiving formation 77 may be mounted to cover 71.

Typically, device connector 5 is attached to device cable 202 during the device 200 assembly process. Thus, it is anticipated that device 200 will be sold with device connector 5 pre-attached. Of course, the electrical connector assembly can be sold separately from the device, for example for upgrade purposes.

The supply side connector 3 is attached to the supply side cables 302 by an electrician during an installation process. Device 200 is connected to the circuitry by connecting device connector 5 to supply side connector 3. Where the device comprises a lighting unit, such as a recessed luminaire, the recessed luminaire is then mounted in an opening formed in a ceiling and secured in place. In the future, if the light unit needs to be replaced e.g. due to a light unit failure, or simply a change in light unit style, the user can disconnect the existing light unit from the power supply. power and connect a new lighting unit to the power supply without the need for an electrician. The user simply disconnects the supply side connector 3 from the existing device connector 5 and then connects the new device connector 5 to the already installed supply side connector 3. Thus setting up a new lighting unit 200 no longer requires an experienced electrician.

Figures 7 and 8 show a lighting system 100 according to one embodiment. The lighting system includes: at least one lighting unit 200 having an electrical cable 202; an electrical connector assembly 1 similar to that described above; and additional electrical circuitry including an electrical supply 300, such as a mains supply, and at least one supply-side cable 302 is connected directly or indirectly to the electrical supply 300.

Lighting unit 200 may be a recessed light fixture, and is preferably a solid-state recessed light fixture. For example, the recessed light fixture 200 may include at least one LED light source 204, such as an LED chip, and a p Cb 206. The recessed light fixture includes a power supply cable 202 that is connected to the PCB 206. joins a device connector 5 attached to the cable 202.

The recessed light fixture 200 may include a fire resistant housing 208 . The fire resistant housing includes material that melts at a temperature greater than or equal to 900C, preferably greater than or equal to 950C, and even more preferably greater than or equal to 1000C. For example, housing 208 can include at least one of steel, brass, copper, and ceramic. Housing 208 may be made of sheet material. In a particularly preferred arrangement the fire resistant housing is made of steel. Preferably the housing 208 is made by pressing sheet material, for example by pressing sheet steel. Fire resistant housing 208 may have a flange 210 on one open side. Flange 210 prevents fire from passing through gaps between lighting unit 200 and a ceiling. The recessed light fixture 200 may include a heat sink 212. Preferably the heat sink 212 is mounted on a rear side of the fire resistant housing. Heat sink 212 is completely optional since many modern LEDs no longer require a heat sink to function properly. However a 212 heat sink may be required for some high power applications. The LED light source 204 and PCB 206 may be mounted within the fire resistant housing 208, for example on a front face of the end wall 214 thereof (see FIG. 8). Alternatively, the LED light source 204 and PCB 206 may be mounted on a rear side of the fire resistant housing 208, and the fire resistant housing may include at least one hole formed through the housing 208 to allow light emitted by the LED light source 204 passes through the housing.

Illumination unit 200 may include at least one of: an optical device 216, such as at least one lens; a front cover 218; and a clipping element 220.

Lighting system 100 may be used in a domestic dwelling, such as a house or apartment, or may be used in other facilities such as offices, stores, community buildings, and the like. The lighting system 100 typically includes several lighting units 200, which are each individually connected to additional electrical circuitry via electrical connector assemblies 1 described above. The electrical circuitry typically includes at least one network lighting circuit defined by electrical wires 302 that is connected to a network distribution board. The or each network lighting circuit may include other devices that are typically included in such circuits such as electrical switches, dimmers, and other controllers.

The person will appreciate that modifications may be made to the above embodiments which fall within the scope of the invention, for example the first part of each electrical connector on the supply side may comprise a male connector and the first part of each electrical connector on the lighting unit side may comprise a female connector.

The molded support member may sit within a housing rather than being part of the housing.

In some arrangements the connector described as supply-side connector 3 above may be attached to device cable 202 instead of supply-side cable 302, and the connector described as device connector 5 above may be attached to cable 302 . supply side instead of device cable 202.

In some arrangements the electrical connectors 55 on the device connector 5 may be molded into a plastic support member, in a similar manner to the electrical connectors 7 on the supply side connector 3.

In some arrangements the second terminal block 63 on the device connector 5 may be replaced by a terminal block 31 similar to that used on the supply side connector 3, the electrical connectors 55 being adapted for this purpose. For example, instead of electrical connectors 55 including terminals 59, the length of connectors 55 may be increased to allow a portion of the connectors to protrude into openings 37.

Not all covers need to include a key or keyway.

The electrical power supply circuitry may include batteries or a power generation device such as at least one photovoltaic unit.

Claims (17)

An electrical connector assembly (1) arranged to electrically connect together at least one supply-side power cable (302) and a device power cable (202), wherein the electrical connector assembly (1) electrical connector includes: a first connector (3) arranged for electrical connection to one of the cables (302, 202) for supply-side power supply and device power supply, said first connector (3) including a set of first connectors (7) electrical; and a second connector (5) arranged for electrical connection to the other of the power supply and device power cables (302,202), said second connector (5) including a set of second electrical connectors (55); the sets of first and second electrical connectors (7,55) are arranged for mating coupling to form an electrical connection between the supply side power and device power cables (302,202) and for decoupling to break the electrical connection ; wherein the set of first electrical connectors (7) is molded into a plastic support member (13), thereby incorporating at least part of each first electrical connector (7) within the plastic support member (13), wherein each first electrical connector (7) comprises first and second parts (9,11), and each second part (11) protrudes outwardly from the support member (13) at a terminal block (31); the terminal block (31) includes a set of first openings (37) and a set of resilient electrical connectors (39), and the second portion (11) of each first electrical connector extends into a respective first opening (37) and forms an electrical connection with a first part (41) of a respective resilient electrical connector (39); and wherein the terminal block (31) snaps onto the first electrical connectors (7). The assembly of claim 1, wherein the support member (13) includes a mounting wall (14) and a plurality of tubular shells (15) protrude outwardly from a first side (16) of the mounting wall. , and the first part (9) of each first electrical connector is housed within a respective tubular cover (15). The assembly of claim 2, wherein each tubular shell (15) projects perpendicularly outwardly from the first side (16) of the mounting wall, and preferably the tubular shells (15) are parallel to one another. The assembly of any one of the preceding claims, wherein the terminal block (31) includes a set of second openings (44) each arranged to receive a respective wire (303, 305, 307) from the cable (302). ) power supply, each resilient electrical connector (39) includes a second portion (43) that is arranged to electrically connect with a respective wire (303, 305, 307) from the power cable (302). 5. The assembly of claim 4, wherein the terminal block (31) includes a set of manually operable actuators (49,53), each actuator (49,53) being arranged to actuate the second part (43) of a respective resilient electrical connector (39), thereby allowing the respective wire (303, 305, 307) to move into and/or out of electrical connection with the respective resilient electrical connector (39). The assembly of claim 5, wherein each actuator (49,53) includes a lever (49) that is pivotally attached at one end to a terminal block housing. The assembly of any one of the preceding claims, wherein the support member includes a base (23) and a cover (21), and the terminal block (31) is mounted to the base (23). The assembly of any one of the preceding claims, wherein the engagement of the terminal block (31) with the second portions (11) of each first electrical connector provides sufficient retaining force to fix the position of the terminal block (31). terminals inside the first connector. The assembly of any one of the preceding claims, wherein one of the first and second connectors (3,5) includes a latch (75) and the other of the first and second connectors includes a latch receiving formation (77), wherein the latch (75) and latch receiving formation (77) are arranged to releasably connect the first and second connectors (3,5) together. The assembly of any one of the preceding claims, wherein the first connector includes a cord grip adapter (29). The assembly of any one of the preceding claims, wherein the second connector (5) includes a plurality of tubular shells (65) and a first part (57) of each second electrical connector is housed within a respective one of the shells. (65) tubular, and wherein the tubular covers (15,65) of one of the first and second connectors (3,5) are each dimensioned and shaped to receive at least part of a respective one of the covers (15,65) tubular of the other of the first and second connectors (3,5) therein. 12. The assembly of claim 11, wherein each tubular cover (15,65) of one of the first and second connectors (3,5) includes a key (17) and each tubular cover (15,65) of the other of the first and second connector (3,5) includes a slot (67) to receive a respective one of the keys (17), and preferably each tubular cover (15) of the first connector (3) includes a key (17) and each cover (65 Tubular ) of the second connector (5) includes a slot (67) to receive a respective one of the keys (17). A lighting unit (200) including an electrical power cable (202) and electrical connector assembly according to any one of the preceding claims. 14. The lighting unit of claim 13, wherein the lighting unit (200) includes at least one solid-state lighting device (204). 15. The lighting unit of claim 13 or 14, wherein the lighting unit (200) is a recessed luminaire that is arranged to be fitted into an opening formed in a partition such as a ceiling, and preferably the lighting unit (200 ) of lighting includes a fire resistant housing (208). 16. A lighting system, including: electrical circuitry including a power supply and at least one supply-side power cable (302) connected directly or indirectly to the power supply (300); a lighting unit (200) having a power cord (202); and an electrical connector assembly according to any one of claims 1 to 12; wherein the electrical connector assembly is arranged to electrically connect the at least one supply side power cable (302) and the lighting unit power cable (202) together. 17. A method of manufacturing a first connector (3) that is part of an electrical connector assembly arranged to electrically connect together at least one supply side power cable (302) and one power cable (202) device, wherein the electrical connector assembly (1) includes: said first connector (3) arranged for electrical attachment to one of the supply side power and device power cables (302,202), said first connector including (3) a set of first electrical connectors (7); and a second connector (5) arranged for electrical connection to the other of the supply side and device power cables (302,202), said second connector (5) including a set of second electrical connectors (55); the first and second electrical connector assemblies (7,55) are arranged for mating coupling to form an electrical connection between the first and device power leads (302,202) and for decoupling to break the electrical connection; wherein the set of first electrical connectors (7) is molded into a plastic support member (13), thereby incorporating at least part of each first electrical connector (7) within the plastic support member (13), wherein each first electrical connector comprises first and second parts (9,11), and each second part (11) protrudes outwardly from the support member (13) at a terminal block; wherein the support member (13) includes a mounting wall (14) and a plurality of tubular covers (15) protruding outwardly from a first side (16) of the mounting wall, and the first part (9) of each first electrical connector is housed within a respective tubular shell (15), said method including: providing a set of first electrical connectors (7); placing the set of first electrical connectors (7) in a mold to manufacture a support member (13); insert fluid plastic material into the mold; allowing the fluid plastic material to solidify to form the support member (13), said support member (13) having a mounting wall and a plurality of tubular shells (15) protruding outwardly from a first side (16) of the mounting wall, wherein the set of first electrical connectors (7) is incorporated at least partially within the mounting wall, a first part (9) of each first electrical connector is housed within a respective one of the covers ( 15) tubular, and a second part (11) of each first electrical connector protrudes outwardly from a second side of the mounting wall; providing a terminal block (31) having a set of first openings (37) and a set of resilient electrical connectors (39); press fit the terminal block (31) into the set of first electrical connectors (7) such that the second part (11) of each first electrical connector (7) extends into a respective first opening (37) and forms an electrical connection with a first part (41) of a respective resilient electrical connector (39).