GB2468372A - Plug lid and base - Google Patents

Abstract

An electrical plug has a space beyond its terminals to allow wires to be pushed through more than normal. The wires can then be trimmed so that only the required length is used in the plug. This may be achieved by having free space 14, 15 on the plug base behind the terminals, and having corresponding projections (10, Fig 3) on the lid of the plug to provide the missing insulation. Alternatively, the plug may have ramps (222, Fig 10a) to direct the wires upward where they can be trimmed, or the terminals of the plug may be mounted on a plate so that they can be uplifted together.

Description

Page 1 e Plug Lid and Base Back2round A rewireable UK electric plug normally comprise two parts -a base in which the pole connectors and other parts are mounted and a lid which completes the enclosure and insulation of internal parts. Because of the fuse and live terminal wire location and the earth pole connector location, there is normally only a small separation of these parts and their respective terminal wires. The insulation on the base of the plug, which surrounds a pole connector head is usually such that a terminal wire can enter the pole connector when it is in its working position but the same terminal wire cannot pass beyond the pole connector head. Passing a terminal wire right through a pole connector head can usually only be done at the moment by uplifting a pole connector from its moulded seat, inserting a terminal wire then trimming and then forcing the stub between the fully enclosing insulating wall The present design is slightly awkward in that it involves guessing terminal wire length needed or moving pole connectors, or both. The present design allows that it can be seen that wiring has been completed with good insulation of conducting parts as far as is possible, before the final insulation provided by the lid, is completed.

A plug can be designed whereby the terminal wires can be inserted fully without firstly uplifting the pole connectors from their moulded seat. A plug may also be developed that comprises more parts than just the base or the lid on which insulating mouldings can be provided. For example pole connectors may be mounted on a sub assembly that can be detached from both the plug lid and the plug base.

Statement of Invention

A plug can be made such that the core wires are inserted to and through their fasteners, then trimmed without uplifting the pole connectors first. This requires that an exit gap is provided in the insulating material around the pole connector seated position. The consequent loss in the insulation provided by the pole connector seat has to be provided elsewhere. The component part of the plug that mounts the pole connectors ( be it the base or another part) then requires that insulation is provided on the other co-operating parts of the plug that will complete the missing insulation when the plug is fully assembled.

Page 2 Advantages The design of the plug can be reconsidered, to allow terminal wires to be fully inserted to pole connectors without moving the pole connector positions from their originally provided position on whatever part of the plug it is that provides the insulating mouldings for the pole connectors. The advantage of not uplifting pole connectors to insert and trim is that often they get detached completely and everything separates out. To that end, the pole connectors, fasteners and fuse yokes, could now be fixed in place, as uplifting is not needed. Wires can be inserted un-stripped, trimmed then withdrawn for stripping if desired.

Page 3

Introduction to drawing_s

Fig I. A plug base interior.

Fig 2. A plug lid (exterior view).

Fig 3. A lid with extended insulation.

Fig 4. Diagram showing excess wire to be trimmed Fig 5. Diagram showing wires trimmed and insulated from each other.

Fig 6. Various embodiments of the insulation Fig 6a. An embodiment with different fastener positions Fig 7. The lid with earth and live insulation ( exterior view) Fig 8. Another embodiment with moved fasteners.

Fig 9. Sloped walls but normal fasteners Fig 10. A raised or extended part ID Fig 10 a. Traditional plug insulation with deflection moulding (222) Fig I I. A separate or additional pole mounting from a lid and base Fig 12. A separate or additional pole mounting from a lid and base Fig 13. Assembling parts illustrated completes the insulation Page 4

Detailed Description of Drawings

Fig I. A typical and already existing plug base I, showing pole connectors 2,3 and 4, fuse 5, and fuse yokes 6 and 7. Surrounding these parts are insulation 8. To insert and trim on this plug the pole connectors must be uplifted. Trimming must be close enough to allow the stub to squeeze in to the small space available when the pole connector is replaced down to its recess.

Fig 2. A typical plug lid 9, viewed from above. The hatched lines indicate mouldings on the interior of the lid.

Fig 3. A plug lid 9, rotated to show the interior side. An extended part 10, is indicated. As shown this part would mate to the base 1, to provide insulation between the earth pole connector (including the earth wire) and the fuse yoke and live fastener. An end elevation of the lid 9, and the extended part 10, is also shown. This extended part 10, could also be provided on the base instead if a design required it. Or, part 10, could be provided on both the lid and the base such that neither the lid or the base had an extended part 10, but when assembled together the same effect was achieved. In other words, the insulating part 10, specifically to insulate the earth pole connector and its core wire from the live fuse yoke and its fastener and its core wire need not be an extension as in Fig 3 but could be shared between the lid and the base. An advantage of providing part I 0, on the base alone would be that the user could visually check that the earth and live core wires were suitably separated before attaching the lid. For example part 10, as a block, is provided on the base. When core wires are located next to the block, they need to be separated OK. This can be checked visually and corrected if not separated. A further element to part I 0, may be provided on the lid that slots over the part of 10, that is on the base, In this way, should there be an excess of wire around the part 10 on the base, then corresponding part 10 on the lid, will not fit over the part of JO, that is on the base, until this excess of wire is trimmed off or rearranged, to allow the lid to be installed.

Page 5 Fig 4. A style of plug where mouldings are such that core wires can be inserted then trimmed which makes getting the lengths of wire needed correct much easier. This means leaving clear space (gaps) in the moulding 8, as indicated at points 12 and 13. Free space marked as 14 and IS are provided, for core wires to enter. The free space or aperture allowed for the core wire to pass right through the fastener could be either a hole or a U-shape (open at the top) cut in the insulation round the fasteners. The latter, allows the core wire stub to be uplifted more and therefore trimmed closer to the fastener.

It can be seen that if this method of inserting then trimming is provided for, then it is critical that all of the earth and live assemblies including the core wires are insulated from each other. This is achieved with part 10. Around the neutral this is less critical as it is always well distanced from the other conducting parts of the plug.

Figs. A part 10, marked where it would locate on the base. The lid, that the part 10 could be integrated to, is not shown. The part 10, may also be thinner to allow the wires to pass further and then be trimmed. The earth and live assemblies can be also be formed further apart which allows more room to apply this method of insulating them from each other.

Fig 6. Several possible embodiments of a part 10, to insulate between the earth and live assemblies. These embodiments could be integral to the base if a design required it.

Fig 6a. The part 10, in a different position, on the lid 9, insulating the live and the earth ( because the live fastener has been moved) Another part I I, is used to insulate the earth from the neutral, because the neutral fastener has also been moved. Notches, 1 7, 1 8 and 19 are provided to accommodate the core wire stub ends.

Fig 7. A diagram of the exterior of a plug lid 9, showing the typical orientation of the insulating part 10 (shaded) Page 6 Fig 8. A plug base I, with part of the base walls formed to slope down as indicated at the points 16. The plug lid 9, has corresponding sloped walls to form the insulating seal when the two parts are assembled. Part 10, insulates the earth and the live. Part 11, insulates the earth from the neutral. While parts 10 and II are integral to the plug lid, the spaces they would occupy when assembled to the base are shown on the plan view of the base.

Wiring is easy. A downside of this arrangement is the extra cost of providing a conductive strip ( copper) between the relocated neutral fastener and its pole connector.

But the method of insulating the neutral in the same way could still be applied if the neutral fastener is left in its usual position, directly on top of the pole connector. As a double check that core wires are located correctly, a portion of the lid (or all) may be transparent to enable a visual check. This might look attractive to some. Other methods to ensure correct assembly can also be used. For example, keeping the insulating parts 10 and II, as thin as possible and ensuring the wires are trimmed as short as possible, should ensure no trapping of wires between the lid and base when assembled. That is, maximise the space allowed for the wire stub ends.

Fig 9. Diagram showing sloped base walls 16, around fasteners in their normal positions.

The enclosure and insulation of the interior, is completed using the base I, with sloped walls 16, and a corresponding lid 9, with sloped walls 16. The sloped walls allow fingers to get in easily and take hold of the core wire ends, which if desired can be bent upwards to allow trimming as short as possible. If the length of the space for the wire stub end, exceeds the depth of that space, then it should be possible to trim short enough that, when replaced down again, the wire stub will not extend past the end of such a space. The top and end of such internal insulating spaces can be further enclosed, using the lid. The shape of part 10 allows both earth and live wires to pass without uplifting the pole connectors and the wires can be easily manipulated by hand. The height of the part 10 shown, indicates that this height can be more or less than the height of the base, if desired. Its height, could be such as to contact the underside of the lid when assembled.

Also shown is the possibility of a part 20, which could be a hollow counterpart, to the part 10. When the lid is assembled to the base, part 20, could slot over part 10. This would push and keep the core wire stubs down, in to the space(s) 15, should a user have left longer core wire stubs than needed. Part 20, could also be formed so as to grip any excess of the wire stub. This may provide additional anchoring over and above that anchoring given by the screw fastener. It might be possible to get rid of the screw fasteners and anchor and make electrical contact using this (lid) method, which would save money on fastener screws. A part 21, is indicated to show that the same method(s) can be employed for the neutral core wire, if needed. The space 14, allowing easy access to the neutral core wire end, is shown. As with the part 10, the parts 20 and 21 can have greater or less depth, as required.

Note: Often, the live fastener and upper fuse yoke are not aligned along the upper edge, with the fuse yoke extending into the space 15, indicated, more than does the fastener.

The fuse yoke(s) can be moved to avoid this.

Page 7 Fig tO. This drawing shows a plug lid and base. It can be seen that the insulation between the live and earth core wire ends is provided by a part (10) integral to the base (1) of the plug. This part (10) in this case, is of a height such that when the plug lid (9) is attached to the plug base (1), then the part (10) extends in to the plug lid (1). The part (10) can be so formed that its upper face (lOut) and the outer edge (lOoe) fit to the lid (9) in such a way as to create a complete and total insulation between the earth core wire end and the live core wire end. For example the part (10) may simply make contact with the under sides of the lid (9) when the lid is in it working position. Another way, is to have a part (20) on the underside of the lid which will fit over the part (10) when the lid is assembled. This second method will guarantee that no gaps exist in the insulation between the live and the neutral, through which a single copper strand might accidentally or inadvertently pass. The depth that the part (20) extends in to the plug base (1) is such that a gap (15) remains between the lower face (2Olf) of part (20) and the interior body of the plug base (1) such that the core wire ends of the earth and live can occupy this space on either side of the part (10). The same end result can be achieved without the increased height of part (10) by using a suitable depth of part (20).

There is a "fail-safe" element to the presently existing design of the pole connectors insulating seat. Because an exit for the core wire does not normally exist in the pole connector seat, the user is obliged to ensure that there is very little excess protruding from the fastener exit hole ( by trimming or pulling back a little before fastening). Only like this is, it possible to re-seat the pole connectors. This ensures that excess wire is not left which could short with other electrically conducting parts or in extreme cases protrude from the plug walls when the lid is attached to the base.

With the proposed change as in Fig. 10 this can be perhaps achieved by having the part (20) on the lid extending such that it contacts the plug base and the lid will not attach properly if a wire lies under the part (20).

The arrangement of Fig 16. achieves this more neatly by forcing the user to cut wires short enough to pass the faces of the part (10). ( See Fig 16.) Page 8 Fig 10 a. Alternative methods are possible, rather than leaving substantial "empty space "gaps in the insulation at the wire exit side of a fastener hole to allow trimming -such as those created by the sloped walls (16) in figs 9 and 10. One way would be to provide a means to deflect a wire being inserted right through the fastener, such that the wire then takes an upward course from the fastener exit. This deflection means could be a small ramp situated directly between the exit side of a fastener and the substantially normal and commonly used insulation ( 8 in Fig 1) at the exit side of a fastener, Simply curving or sloping or scalloping the traditional (already commonly used) insulating wall behind a fastener (222) may well be enough to deflect a core wire upwards. In this way the core wire end would be easily trimmed without for example leaving gaps in the plug base outer wall as outlined elsewhere in this proposal. Such a deflecting moulding may be formed in such a way that after a wire has been trimmed and then removed to strip the ends, the excess stripped wire protruding from the fastener (if any) can be tucked around the edges or sides of the deflecting moulding. Or, the wire excess could simply sit on the deflecting structure itself with final insulation from other core wires being ensured by the shape of the nearby insulation. That is the deflecting part may be shaped on the required side to provide insulation from other electrical parts in a similar way to (10) in Fig 10 without hindering deflection of the wire upward. In this way the traditional and commonly used insulation behind and around fasteners as shown by example at (8) in fig I, can remain substantially the same. With any method that allows insertion and trimming of core wires in a plug with lid and base, parts that are normally loose such as the live and neutral pole connectors and the live fastener and associated fuse yokes, can now be fixed in place to prevent awkardness and the possible loss of these parts. The earth may remain a loose friction fit to prevent plugging in without the lid.

Page 9 Fig ii. This drawing shows how the completion of insulation of the earth and live terminal endings may be achieved in the same way as previously described but for a plug that comprises more parts than just the two parts of a lid (component that covers the plug fittings such as pole connectors) and a base (component that supports the fittings when the plug is opened) as many present designs use. The drawing shows an additional plug mounting (22) which allows the internal plug parts and pole connectors to be detached from the base, while still being held together. Such a mounting (22) may be shaped as shown, to allow the earth and live terminal wires to be inserted in such a way as to extend out the other side of the respective pole connectors. In many existing plug designs this is only possible by pushing on the pole connectors so that the pole connectors become raised out of their insulating mountings. This is because many present designs of insulating mounts for pole connectors only have a gap to position the terminal wire on the entry side to the pole connector when in its operational position, and not on the exit side.

This can be seen in the drawing of Fig I. The parts (8) of Fig I indicate insulating material between the earth and the live through which terminal cannot pass.

The part (22) is formed to allow the terminal wires to pass right through the pole connector without firstly uplifting the pole connector from the component (22). So doing, allows that any excess wire length protruding from pole connector can be trimmed off, even after the terminal wire has been anchored to the pole connector by tightening, for example, a pole connector fastener screw. This means the normal insulation between the earth and live as found on most existing plug designs, as in Fig I, is no longer present.

Further, the empty space (23) provided on the part (22) allows that a cutting tool can have access to the terminal wires to trim them as close as possible to the respective pole connectors. As discussed in the descriptions I to 10, this lack of insulation between the earth an live can instead be completed by assembling such a part (22) to a base (I) and to a lid (9) on which lid or base or both the required insulation is provided to complete the insulation of the earth and live terminal wires, by assembling the plug together.

Fig 12. A plan view of an example of the part described in Fig 11. The neutral is shown in an orientation such that it will be wired through a face of the pole connector that is 90 degrees from the normal. Wiring as normal is also possible if the fastener hole is manufactured in the usual place and not as illustrated.

Page 10 Fig 13. Shown are a plug base with insulation part 10, on the base. Also shown is the plate or additional part (22) mounting the pole connectors and, in this case, also the fuse yokes and fuse. The part (22) has the spaces (23) allowing locating or mating to the part (10). As shown, the part (10) is shaped to allow conductor wire stubs to rest in recesses.

The part (10) could be manufactured without recesses, instead presenting a flat face to the wire stubs. Further. instead of recesses the part (10) could present indents ( rather than be flat or recessed) that locate to gaps in the additional mounting (22), This would mean a user would have to pull the wires back a little before final tightening of fastener screws and also that a degree of squeezing or forcing any protruding wire stub alongside part 10 as the parts were assembled. This squeezing or forcing of wire stubs when locating pole connectors is often required when re-wiring plugs presently in common use.

Fig 14. The highlighted detail shows how the part (10) could be made with indents that would fit to the gaps in the insulation around a pole connector. This would replicate as well as is possible the way pole connectors are insulated in most plugs already in circulation. The wire stubs would have to be cut as short as possible, then pulled backe before fastening, to allow assembly. Or the upper part may be indented and the lower part, not indented to create a small recess, under the indented part.

Fig 15. The highlighted detail shows how part (10) could have flat faces Fig 16. The highlighted detail shows how part (10) could be raised in height. This would minimise risk of stray copper strands extending vertically to unwanted areas. Part (10) could also be formed so that its walls extend into a slot on the part (22), which would minimise risk of unwanted copper strands extending horizontally to unwanted areas.

The user is obliged to keep wires ends short enough to allow the part (22) to be assembled in to the base. This is very similar to the long established fail-safe" system of re-seating a pole connector into a seat which is blanked off at the fastener core wire exit side. Both methods oblige a user to minimise excess core wire stub ends, which may short with other parts or in extreme cases protrude from the plugs main walls after the lid and base are assembled together. That is, the lateral insulation of electrically conducting parts before assembling the lids, is completed to the same standard using parts (10) and (22) as that of already existing plugs of conventional design, that do not use parts (10) and (22) Alternative Embodiment Other plug types

Claims (16)

1. What is claimed is: 1. A rewireable UK style, electrical plug housing comprising of at least the two co-operable parts of a lid and base, which has modification(s) to the normal commonly used insulation, these modifications allowing and complimenting the method of rewiring where core wires are inserted fully into, through and substantially ( more than is presently possible in the working position) beyond the core wire exit hole or point on a respective fastener or pole connector head (which then allows trimming), no matter if the respective fasteners are rewired by this aforementioned method, in their working positions on the base, or if the fasteners are uplifted simultaneously from the base as a sub assembly to then be rewired by this same aforementioned insert and trim method, and further that should the insulation normally required by the regulating authority to be on . the base be incomplete (when the fasteners have been tightened on the trimmed core wires and the fasteners are in the operational position) because of this modification to the normal insulation, ** then this missing insulation is provided instead on a part of the plug other than the base, such as for example, the plug lid.
2. 2. An electrical plug base as in claim 1, where respective core wires can be inserted through their respective fasteners in their working position, because, the insulation directly behind the fastener exit hole, has a gap in it and because the usual exterior insulating wall of the plug also has a corresponding gap in it, such that as the core wire is inserted it passes first through the former gap and then through the latter gap.

   :
3. 3. A plug as in claim 1, which has respective and appropriately shaped mouldings, or the like, on the lid underside, or other(non base) plug part which when it is assembled to the base will locate to the area of corresponding and respective missing insulation behind a fastener as in claim 2, and which lid also may be correspondingly shaped on its exterior walls to fill the gaps in the walls of the base in claim 2, the lid or other part performing the function of replacing the missing insulation of the base in claim 2.
4. 4. An electrical plug base as in claim 1, with no gaps in the exterior insulating wall and where respective core wires can be inserted through their respective fasteners in their working position, . : because the insulation directly adjacent to the fastener exit hole at the back of the fastener, has been formed as a cutaway or ramp, leading away from the fastener core wire exit hole, which will *lj* deflect an exiting core wire upwards, relative to the insertion direction, thereby guiding the core wire end in a direction leading over the exterior insulating wall or above the average height of the base. S... 5,
5. 5

   * 5. A plug as in claim 1, which has respective dimples or pins or the like on the lid underside or on another (non base) plug part, which when assembled to the base will locate in to the *::: : corresponding and respective cut aways or ramps in the base of claim 4.
6. 6. An electrical plug base as in claim 1, where respective core wires can be inserted through their : *** respective fasteners in their working position, because the insulation directly adjacent to the * fastener exit hole at the back of the fastener, has been formed as a tunnel, leading away from the ** , fastener core wire exit hole. * S* * -5
7. 7. A plug as in claim 1, which has respective dimples or pins or the like on the lid underside or on another (non base) plug part, which when assembled to the base will locate in to the corresponding and respective tunnels in the base of claim 6.
8. 8. An electrical plug base as in claim 1, where respective core wires can be inserted through their respective fasteners in their working position, because the insulation directly adjacent to the fastener exit hole at the back of the fastener, has been formed as a channel, leading away from the fastener core wire exit hole.
9. 9. A plug as in claim 1, which has respective dimples or pins or the like on the lid underside or on another (non base) plug part, which when assembled to the base will locate in to the corresponding and respective channels in the base of claim 8, while leaving room for any core wire end that may be present.
10. 10. An electrical plug base and lid, as in claim 1, where respective core wires can be inserted through their respective fasteners in their working position, and where an insulating moulding exists on the base to separate the (for example) ex9osed and fastened earth and live core wire ends and for which moulding a reciprocal moulding exists on the lid, such that on assembly they butt up to or locate by overlapping the one aforementioned moulding to the other such that excess core wire ends cannot contact each other.
11. 11. An electrical plug base and lid, as in claim land 10, where respective core wires can be inserted through their respective fasteners in their working position, and the separation and insulating means for ( eg. ) the earth wire and live core wire ends, comprises a moulding on the base which extends to a height above that of the base exterior walls such that it will butt up closely to the _": . underside of the plug lid when it is assembled, thereby closing any gap between (eg. ) the earth and live wire ends, a user being able to see clearly that separation of the earth and live is good *:: *. before assembling the lid.
12. 12. An electrical plug base as in claim 1, where respective core wires can be inserted through their * . -respective fasteners in their working position, and such that should an extra inner wall style of insution be normally required on the base for ( eg. ) the neutral wire end or to go around all the fasteners, in addition to the plugs exterior wall, but which inner wall would hinder the insertion of co'f wires as described, then this extra inner wall can be provide on the lid instead and be of such a depth as to butt up closely to the plug base, bearing in mind that a user should be sure no wire * will be trapped under the said extra inner wall on the underside of the lid, while locating the lid.
13. 13. An electrical plug base and lid as in claim 1, where respective core wires can be inserted through their respective fasteners in their working position, by using any combination of the different methods in claims 1,2,3,4,5,6, 7,8,9,10 11 and 12 for any respective fastener.
14. 14. An electrical plug base, as in claim 1, with insulation which should the plug be utilising a plate or the like, to allow some or all fasteners to be uplifted at one time, for rewiring out with their working position, but on which said p'ate no exit hole insulation exists between (for example) the now exposed and fastened earth and the neutral wire ends while outwith the plug, then the said insulation on the base will complete the missing insulation around fasteners exit holes when the plate is located back to its working position on the base.
15. 15. An electrical plug base and lid, as in claim 12,3,4,5,67,8,9, 10,11,12,13 and 14, where respective core wires can be inserted through their respective fasteners in their working position or out with their working position, where the replacement insulation for the needed missing insulation of the core wire ends may also include indents to fill any gap in a pole connector seat or fastener seat or, recesses to accommodate any excess core wire end protruding from a tightened and operational fastener.
16. 16. An electrical plug substantially as hereinbefore described with reference to and as shown in the accompanying drawings.Amendments to the claims have been filed as follows: What is claimed is: 1 A re-wireable UK plug housing consisting of the two co-operable parts of a SINGLE and EXCLUSIVE pole connector mounting (the base) and the final insulation (the lid), which has the insulation of the base of the plug formed in such a way that when wiring or re-wiring the plug, the respective core wires of the main power cord can be inserted through each respective pole connector head while the pole connector is in it's operational position, this core wire insertion being such that the end of each respective core wire extends far enough out from the back of it's respective pole connector head to allow the excess wire of each respective core wire to be trimmed to the required length while both the respective pole connector is in it's operational position ( down) and the respective core wire is also in it's operational position (inserted).2. A re-wireable plug as in claim 1 where the required final operational electrical insulation of the plug is completed by joining the two co-operable parts together to form the final operational plug assembly.3. A re-wireable plug housing as in claims 1 and 2 where pole connectors may be loose fitted (only locked in their working position once the lid is assembled) or fixed (cannot easily or normally be moved even with the lid off) as required, so that, for example the earth could slide out of the housing should it be attempted to connect the plug to live power without the lid, thereby preventing the live and neutral from getting power with the lid off.4. A re-wireable electric plug substantially as hereinbefore described with reference to and as shown in the accompanying drawings. * SS* S. S** * S * S. * * S * S.S a..S S. *S * * . * S