WO2010103272A1 - Modular mains power distribution system - Google Patents

Modular mains power distribution system Download PDF

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Publication number
WO2010103272A1
WO2010103272A1 PCT/GB2010/000428 GB2010000428W WO2010103272A1 WO 2010103272 A1 WO2010103272 A1 WO 2010103272A1 GB 2010000428 W GB2010000428 W GB 2010000428W WO 2010103272 A1 WO2010103272 A1 WO 2010103272A1
Authority
WO
WIPO (PCT)
Prior art keywords
module
module according
mains power
modules
modular
Prior art date
Application number
PCT/GB2010/000428
Other languages
French (fr)
Inventor
Roger Leslie Brown
Alan Maurice Ferdman
Original Assignee
Roger Leslie Brown
Alan Maurice Ferdman
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 Roger Leslie Brown, Alan Maurice Ferdman filed Critical Roger Leslie Brown
Publication of WO2010103272A1 publication Critical patent/WO2010103272A1/en

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Classifications

    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R24/00Two-part coupling devices, or either of their cooperating parts, characterised by their overall structure
    • H01R24/84Hermaphroditic coupling devices
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/46Bases; Cases
    • H01R13/514Bases; Cases composed as a modular blocks or assembly, i.e. composed of co-operating parts provided with contact members or holding contact members between them
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R25/00Coupling parts adapted for simultaneous co-operation with two or more identical counterparts, e.g. for distributing energy to two or more circuits
    • H01R25/003Coupling parts adapted for simultaneous co-operation with two or more identical counterparts, e.g. for distributing energy to two or more circuits the coupling part being secured only to wires or cables
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R27/00Coupling parts adapted for co-operation with two or more dissimilar counterparts
    • H01R27/02Coupling parts adapted for co-operation with two or more dissimilar counterparts for simultaneous co-operation with two or more dissimilar counterparts
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/44Means for preventing access to live contacts
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/46Bases; Cases
    • H01R13/465Identification means, e.g. labels, tags, markings
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/46Bases; Cases
    • H01R13/502Bases; Cases composed of different pieces
    • H01R13/506Bases; Cases composed of different pieces assembled by snap action of the parts
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/46Bases; Cases
    • H01R13/516Means for holding or embracing insulating body, e.g. casing, hoods
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/66Structural association with built-in electrical component
    • H01R13/665Structural association with built-in electrical component with built-in electronic circuit
    • H01R13/6675Structural association with built-in electrical component with built-in electronic circuit with built-in power supply
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/66Structural association with built-in electrical component
    • H01R13/665Structural association with built-in electrical component with built-in electronic circuit
    • H01R13/6691Structural association with built-in electrical component with built-in electronic circuit with built-in signalling means
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/66Structural association with built-in electrical component
    • H01R13/70Structural association with built-in electrical component with built-in switch
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/66Structural association with built-in electrical component
    • H01R13/70Structural association with built-in electrical component with built-in switch
    • H01R13/713Structural association with built-in electrical component with built-in switch the switch being a safety switch
    • H01R13/7135Structural association with built-in electrical component with built-in switch the switch being a safety switch with ground fault protector
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/66Structural association with built-in electrical component
    • H01R13/719Structural association with built-in electrical component specially adapted for high frequency, e.g. with filters
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/73Means for mounting coupling parts to apparatus or structures, e.g. to a wall

Definitions

  • the present invention relates to a modular mains power distribution system. 5 More particularly, the present invention relates to a user-configurable modular mains power distribution system.
  • the present invention relates to a modular design for a free trailing mains power distribution system, comprising a range of modules and associated accessories, including for instance multi-outlet mains power distribution modules and the like, and which provides a dedicated interlocking mains power connectivity method independent of the other mains outlets as used by conventional peripheral equipment.
  • Dedicated accessory modules such as power meters, timers, filters and other devices may be connected together serially in a daisy chain, as required by the user's specific circumstances. Components may be added to or removed from the serial chain at any time, without disconnecting appliance plugs from their sockets in relevant modular components.
  • No conventional mains sockets within the modules disclosed are used by the interconnection and power distribution means. Components of the system mate together both mechanically and electrically, employing separate mechanical features to provide each function and this provides an interlocking connection.
  • Mains power interconnection is provided by an array of sockets and pins located at an end or both ends of a system module arranged to be intrinsically safe, such that live pins are never presented to the user. This is achieved by having all unused available power positions as female sockets, whilst the mating parts that provide power continuity into a module are male pins.
  • a power supply module for supplying mains power to a modular mains power distribution system.
  • the power supply module comprises a body, means for connecting to a mains power source, and connecting means at an extremity of the body, for connecting the module to a second module to which to supply mains power.
  • the connecting means comprises electrically conducting means and mechanically engaging means respectively for defining an electrical path between connected modules and mechanically engaging modules with one another, and are defined by a female socket-like element.
  • the means for connecting to a mains power source is preferably a cable having a length comprised between 1 meter and 5 meters.
  • a termination module for a modular mains power distribution system.
  • the termination module comprises a body and connecting means at an extremity of the body, for connecting the module to a second module from which to receive mains power.
  • the connecting means comprises electrically conducting means and mechanically engaging means respectively for defining an electrical path between connected modules and mechanically engaging modules with one another, and are defined by a male plug-like element.
  • an in-line module for a modular mains power distribution system.
  • the in-line module comprises a body, first connecting means at a first extremity of the body, for connecting the module to a second module from which to receive mains power, and second connecting means at a second extremity of the body, for connecting the module to a further module to which to supply mains power.
  • the connecting means comprising electrically conducting means and mechanically engaging means respectively for defining an electrical path between connected modules and mechanically engaging modules with one another.
  • the first connecting means are defined by a male plug-like element
  • the second connecting means are defined by a female plug-like element.
  • each connecting extremity is preferably shaped for registration with a connecting extremity of another module.
  • a feature providing mechanical strength is an overlapping stepped mating feature, asymmetrically placed at each extremity of an in-line module, or placed at the only extremity requiring mating features in a single-ended, non extendable module.
  • the pins and sockets normally used for electrical connection are respectively located substantially at facing stepped mating features, although in some components these may be insulated or electrically unconnected pins for reasons of safety.
  • the connecting extremity preferably includes a stepped surface, for registering with a complementary stepped surface at an extremity of another module.
  • the stepped surfaces are preferably asymmetrical relative to one another.
  • the male plug-like element and the female plug-like element may be envisaged.
  • vertically arranged pins and sockets are disposed in the same plane as the mains outlets provided, whilst the system modules are arrayed at right angles relative to the pin and socket plane, and disposed at one end of a feed or termination module, or at both ends of an in-line module.
  • the pin and socket forms may follow conventional UK mains plug and socket dimensions and shape conventions, to satisfy UK technical and approvals requirements.
  • these dimensions and shape conventions are significantly larger than necessary, particularly by non- UK approvals boards and mains interconnect design requirements, smaller pins and sockets may easily be accommodated, without compromising functionality.
  • the male plug-like element is defined by a plurality of shrouded pins or turrets, whereby the female socket-like element is advantageously defined by a plurality of recesses adapted to receive the shrouded pins or turrets.
  • the shrouded pins or turrets may extend at a vertical angle relative to the top surface of the module, and both the shrouded pins or turrets and the recesses may be tapered.
  • the interlocking conical turrets and recesses advantageously separate mechanical stresses from the electrical connection pins and sockets during use.
  • the connecting means are preferably configured such that an earth terminal of a first module connects to an earth terminal of a second module, a live terminal of the first module connects to a live terminal of the second module and a neutral terminal of the first module connects to a neutral terminal of the second module.
  • a further mechanical strengthening feature is a latch connecting mated system components.
  • the latch is spring-loaded, such that it engages automatically upon mating of any pair of system components and ensures that the electrical connections cannot become inadvertently separated.
  • a preferred location for the latch is in the vertical face of abutting system components, which facilitates a latch having a large width, for added strength of the parts and an improved latching function.
  • the latch may be a manually releasable latch, and in this case is preferably a resiliently deformable latch.
  • An advantageous embodiment of the latching means is a resiliently deformable member shaped substantially as an arrow and maintained between guiding pins, wherein simultaneous compression of both tips of the arrow - shaped member causes the tip to withdraw between the guiding pins into a recess defined in the body, for unlatching latched parts.
  • This embodiment employs a one-piece deformable latch, so formed for limiting the number of components employed, reducing cost and the size of parts required, as well as maintain a compact product profile with minimal wasted space.
  • Other forms of latch may be envisaged and applied, so long as they provide easy engagement and disengagement of the system components.
  • a supply or in-line module may comprise any of a residual current circuit device or ELCB for protection against earth leakage or shock to system components and devices connected to them; a user - activated switch for switching current from a first module to a second module, after connecting the first and second modules; a programmable module for controlling the ON/OFF timings of all subsequent system modules and connected loads; a power monitor; a single noise filter or individual electrical noise filters
  • a useful embodiment of an in-line or termination module includes a dedicated AC or DC outlet module providing multiple low voltage power outlets for such devices as wired or wireless personal computer peripherals and wireless communication devices, or any other low-voltage AC or DC powered device or rechargeable device normally employing an AC or DC supply.
  • Another useful embodiment of an in-line or termination module includes a recharger module for "walkie talkie" radios and other communications devices, data loggers and other similar devices that may provide multiple dedicated recharging sites within the module.
  • a particularly useful embodiment of an in-line module is a distribution module comprising at least two main power sockets, optionally having an individual switch for each socket, or a single switch for any amount of sockets.
  • the sockets are preferably arranged at an angle relative to the main axis of the module, in order to reduce the surface requirement, or size, of the module. The angle may be 45 degrees.
  • an in-line module is an automatic or manually controlled standby-saving module reacting to a reduction in power consumption of one designated socket to turn off others in the serial chain.
  • this module may be adapted to react to a reduction in power consumption via any of a plurality of socket outlets to turn off others in the serial chain.
  • this module may be adapted to be controllable by remote control through RFID, wireless, infra-red or other controlling signal, to allow remote control over the master device driving one or more subsequent system components or power outlets to respond.
  • any of the above module may be fitted with a display device selected from the group comprising LED, neon, CFL, EL, LCD or other, for indicating ON/OFF status, process information and/or other data useful to the user.
  • Screw mounting bosses may be provided on any system module that extends beyond pin and socket-mounting steps provided at the end of a typical extendable system component, such that the overhanging component may be securely fixed or be provided with support feet.
  • screw mounting bosses are implemented laterally on the module, for fastening or otherwise securing the module or a modular arrangement of same in place, since the modules are intended for serial and/or parallel arrangement.
  • modules When configuring a system, either initially or by adding modules at any given time, modules may be connected in a linear configuration, in order to make the system long and narrow for location along a wall, skirting board or bench. Alternatively, modules may be connected in a parallel configuration, side-by-side or back-to-back, to reduce the length and increase the width of the arrangement, where such a configuration is more appropriate for a user's requirements.
  • an in-line module is a dog-leg module, having first and second extremities substantially adjacent to one another.
  • This module allows rotation through 180 degrees of the mains power supply path, wherein mains power received from a previous module in a chain of same can be supplied to a next module located substantially parallel to this previous module.
  • This dog-leg module may double as a supply module, if fitted with means for connecting to a mains power source.
  • the first connecting means defined by a male plug-like element remains unpowered, for safety reasons.
  • a modular mains power distribution system which results from the combination of any number of modules previously introduced, and would at the very least consist of a power supply module according to the first aspect, and a second module according to either the second or third aspect.
  • the power supply module may be a dog-leg supply module fitted with means for connecting to a mains power source.
  • a typical minimal system will consist of a power supply module connected to a multi-socket distribution module, wherein any number of sockets may be incorporated in the distribution module.
  • a removable link component is preferably be used to link adjacent system modules.
  • the link component preferably comprises peg-like members connected by a joining member, each peg-like member being adapted to engage a respective lateral screw mounting boss of an adjacent module.
  • Each peg-like member preferably comprises deformable ribs, to achieve interference fit in the screw mounting boss.
  • the surface of the joining member opposite the two peg-like members preferably sits flush with the top face of the adjacent modules.
  • a cover is preferably be used on a, or each, system module, to prevent dust accumulation on the module surface and to facilitate cleaning.
  • the cover may be opaque, substantially translucent or partially translucent.
  • the cover preferably includes a window.
  • the cover may advantageously include a latching mechanism.
  • the cover may also advantageously include at least one user - editable or user - writable portion. This portion may be a pre - prepared surface, or a pre - printed or write - on label secured to the portion area, the securing being selected from the group comprising adhesive, magnetic, static and mechanical securing.
  • the cover preferably includes at least one lateral slot, for permitting the passage of the appliance cable trailing the appliance plug.
  • the cover includes a plurality of lateral slots, respectively for permitting the passage of the appliance cable trailing each appliance plug.
  • the system may be kept in position by using removable foot components, which may be embodied as conical rubber feet, to be inserted in through screw mounting bosses, with sub populations in excess of four feet, one disposed at each corner of the system.
  • the foot component is preferably manufactured from a resilient material, having a shore A hardness in the range of Shore A 40 to Shore A 80, preferably still a shore A hardness of 60.
  • a particularly useful embodiment of the foot component includes a shank portion having annular ribs for providing an interference fit within the screw mounting boss, and a conical shape extending 5 away from the module base for concentrating the module weight at the cone tip.
  • Figure 1 shows the topside aspect of a modular unit, including a first male socket extremity
  • Figure 2 shows the underside aspect of the modular unit of Figure 1 , including a second female socket extremity
  • Figure 3 shows two modular units positioned for mating
  • FIG. 4 shows two modular units mated with each other
  • Figure 5 shows a topside aspect of a modular power supply unit
  • Figure 6 shows an underside aspect of the modular power supply unit of5 Figure 5;
  • Figure 7 shows a topside aspect of a modular power supply unit positioned for mating with the modular unit of Figures 1 to 4;
  • Figure 8 shows an underside aspect of a modular power supply unit positioned for mating with the modular unit of Figures 1 to 4;
  • Figure 9 shows a topside aspect of the modular power supply unit mated with the modular unit of Figures 1 to 4;
  • Figure 10 shows a resilient latch mechanism
  • Figure 11 shows the resilient latch mechanism of Figure 10 fitted within a housing of a modular unit
  • Figure 12 shows a removable cover for a modular unit, positioned beforeo fitting
  • Figure 13 shows the removable cover of Figure 12 fitted to a modular unit
  • Figure 14 shows a mounting screw-boss of a modular unit
  • Figure 15 shows a link component for use with the mounting screw-boss of
  • Figure 16 shows a link component fitted between two modular units
  • FIG. 17 is an exploded view of a first example of a modular arrangement of six system components, including two multi-socket distribution modules, two link components, a dog-leg power supply module and a dog-leg power link module;
  • Figure 18 shows the example modular arrangement of Figure 17 fully5 assembled
  • Figure 19 shows a foot component
  • Figure 20 is an underside view of a multi-socket distribution block fitted with o three conical feet of Figure 19, and a fourth foot about to be inserted; and Figure 21 shows a second example of a modular arrangement of three system components, including two multi-socket distribution modules and a power supply module.
  • a first embodiment which comprises a mains distribution module, which contains four mains power sockets 2 arrayed in the top face of the block.
  • the sockets are disposed at 45° to the axes in order to reduce the overall size of the module and to provide a smoother exit for the respective cables of connected appliances, more in line with the main axis of the module.
  • Conventional 90° or other orientations or other array configurations may be accommodated by this general design, and any other number of sockets within the total power handling capability of the system may be envisaged.
  • a step 3 is shown in the module, which forms a mounting for the mains inlet point power pins 4.
  • a conventional UK three-pin system is shown shrouded, with a taller central earth or ground pin to ensure this electrical connection is made first upon insertion, with live and neutral power connections disposed either side of the central earth or ground pin, with a separation distance and shrouded path length between conductors being a minimum of 4mm as dictated by mandatory UK creepage and clearance regulations.
  • Other arrangements of pins, with and without shrouds may be envisaged and applied, providing they meet local, applicable electrical safety legislation.
  • a shutter mechanism may be employed to cover the in-line power distribution socket apertures, in preference to a tubular form shroud, to prevent ingress of users' digits when the electrical connections are formed, but before the components are fully mated.
  • a preferred embodiment may use a shuttered shielding arrangement, although this is not a mandatory requirement under current UK regulations.
  • the power pins 4 distribute electricity to the sockets 2 by conventional bus bars or other common electrical connectivity methods as are standard in the industry and known to those skilled in the art.
  • a pair 5 of guide and registration turrets is provided to ensure that a mating power supply module or other adapter or module within the system is prevented from being mated at an excessive angle to the power pins.
  • the guide and registration turrets are disposed in a symmetrical fashion and provide a mechanical register to prevent any lateral forces being transferred to the power pins or shrouds, during insertion or in normal everyday use if the module is hit or otherwise impacted.
  • the pin and socket arrangement comprising the power interconnects, follow conventional UK dimensions and configurations as these already meet the necessary mandatory regulations regarding current carrying capacity and heating effects due to I2R losses of the contact forms and the requirement for the earth pin making first contact, before the live and neutral pins make electrical contact.
  • This arrangement is capable of distributing 13A, 250V alternative current (AC) to a connected load.
  • buttons 6 are disposed either side of the body of each system component to release a latch 7 for easy separation of connected modules.
  • mating sockets 11 cooperate with turrets 5 of the next module, and are tapered for easy initial registration and subsequent tightening of the joint, as well as improved registration as the parts become fully mated.
  • Sprung-loaded latch 7 co-operates with a mating release 13 in the next module, whereby the latch prevents unintended separation after the registration turrets 5 and sockets 11 become fully engaged.
  • An overlapping end projection 10 co-operates with the power pin step 3 of a connected module.
  • Figure 4 With reference to Figure 4, the two modular components of Figure 3 are shown in full mechanical and electrical mating, with the parts fitting together to present a uniform contour and feature alignment.
  • the multi-socket modular power outlet shown in Figures 1 to 4 provides mains power distribution, but is essentially passive, because there is no connection to the mains.
  • a power supply module is required, which connects to and relays mains power to the first module of any system of interconnected modules and components described herein.
  • a power supply module 14 is shown connected via a free - trailing mains cable 16 which, in the UK, would consist of a triple core, double insulated 13A 230/25Ov AC - capable cable manufactured to approved standards for connection to the mains supply through a conventional mains plug (not shown) with a moulded or otherwise effected strain relief 15.
  • the power supply module includes finger grips 18, which assist the plugging operation onto the multi-socket module shown in Figures 1 to 5, or any other module described herein employed as the first device in any modular configuration of the system components, for example a daisy chain of modular multi-socket mains power outlets.
  • the power module includes tapered sockets 17 and latch release 13 to engage with the turrets of the connecting module, as previously described.
  • the power supply module may be optionally fitted with a power ON display that may be neon, LED or other conventionally employed illuminating indicator 19.
  • a switch button may be included to provide control over the series of daisy-chained devices. Any ON display indicator may be incorporated into the switch or as a separate component.
  • FIG. 5 is shown with a socket arrangement 12, which in this case comprises insulated shrouded electrical contacts, for connection with the first modular device in the daisy chain through the electrical connector pins 4 as shown in Figure 1.
  • a socket arrangement 12 which in this case comprises insulated shrouded electrical contacts, for connection with the first modular device in the daisy chain through the electrical connector pins 4 as shown in Figure 1.
  • the power supply module of the system is shown in close proximity to a multi-socket distribution module with shrouded electrical connections in a near - mated condition, respectively in top and underside views.
  • the power supply module of the system is shown in full mechanical and electrical mating with the multi-socket distribution module, with the parts fitting together to present a uniform contour and feature alignment, thereby displaying the alignment of profile features common to the design concept carried through each component of the modular system.
  • a one - piece latching mechanism having side buttons and made from a substantially resilient material.
  • the mechanism is substantially arrow-shaped.
  • the central latch tongue which is the tip of the arrow shape, is displaced following the direction shown as 20.
  • the latching mechanism of Figure 10 is shown located within a housing of a module of the system, wherein the latch tongue is located between guide pins 21. Registration and location of the mechanism within the housing are provided by the button - engaging latch holes in the housing, and
  • a module cover 22 may be applied to a system module, in the example a multi-socket distribution module 23 populated with appliance plugs, following the direction shown as 24.
  • the cover 22 compriseso lateral slots 25, through which appliance cables 26 may pass.
  • a mounting screw boss 27 is shown along a side of the illustrated multi-socket distribution module 23.
  • Several mounting screw bosses 27 may be provided along one or each side of the illustrated multi-socket5 distribution module, or other system components.
  • the mounting screw boss 27 is disposed so as to align with other system components, when these are placed in "back to back" or parallel “side by side” orientation.
  • the boss is recessed from the top face to provide good electrical separation of any metal mounting screws or other fasteners, from the power or ground pins and sockets located on the top o face.
  • the boss is also recessed into the side of the unit, to allow close side-by-side positioning of adjacent system components.
  • Figure 15 shows a resilient, preferably elastomeric, link component 31 that may be manually pushed into any unpopulated mounting screw boss of adjacent5 system components, to provide mechanical registration and interlocking between parallel modules.
  • Deformable gripping ribs 28 are provided to ensure good retention, while upstanding grippable bosses 29 are flush with the top face of the system components when fully pressed into their intended mounting position.
  • a pair of distribution modules are shown connected o together back to back by a link component 31 , the top face of boss 29 being flush with the top face of the distribution modules.
  • an exploded view of a modular arrangement of system components is shown, which comprises two back to back-oriented multi- socket distribution modules 30, two link components 31 , a dual width, dog-leg power feed module 32 that links the ends of the two multi-socket distribution modules and a second dog-leg power link module 33 which provides electrical connectivity through to the second module.
  • the female socket electrical connectors in the power feed module 32 provide mains power to the first multi-socket distribution module 30.
  • the pins of the first multi-socket distribution module 30 conduct power to its opposite end, which presents intrinsically safe power sockets that may be shrouded or preferably shuttered, for connection to the second dog-leg power link module 33.
  • This second module has electrical connection pins that mate into the first powered multi-socket distribution block 30, and at the other end presents a set of intrinsically safe sockets that feed the second multi-socket distribution block 30 in the same manner as the first module. Finally, the socketed end of the second multi-socket distribution block 30 is plugged into the power feed module 32.
  • the presented pins of this component are not otherwise connected to any electrical power and thus may be manufactured from plastic or other insulating material.
  • this set of components would be difficult to assemble if absolutely constrained in all three dimensions during mating, the clearance achieved by use of tapered pins and recesses of the interlocking turrets provide enough angular clearance during the assembly process to facilitate this action.
  • the interlocking links 31 may then be pushed into the central, adjoining holes for added security.
  • a foot component is shown, which is manufactured from an elastomeric material.
  • the foot component comprises a shank provided with deformable ribs 34, and a shaped extremity 35, in example a cone having an apex pointing away from the shank.
  • This component may be typically manufactured from Viton or other synthetic rubber.
  • the material of manufacture preferably has a Shore A hardness in the range of 40 to 80, preferably still a Shore A hardness of 60.
  • Figure 20 shows an underside of a multi-socket distribution module 30 having through screw-mounting bosses in which, respectively, three foot components such as shown in Figure 19 have been inserted and one foot component is about to be inserted, in the direction shown as 36.
  • the ribs provide a gripping function against the internal diameter of an empty screw-mounting boss, whereby a user may push-fit a foot component within same.
  • the conical extremity of the foot component 35 includes a broader flanged end, having a diameter larger than the screw-mounting boss diameter to limit insertion, and a point which, when the assembly is oriented normally, allows the weight of the multi-socket distribution block or other module so fitted, to be locally concentrated and thus provide an anti-slip function for the assembly.
  • the pointed tip prevents slippage on floors or other smooth surfaces as well as engaging in tufted pile or woven materials, such as carpets, to retain the distribution module or other system components fitted in place.
  • FIG. 21 an alternative modular arrangement of system components is shown, which comprises a power supply module 31 connected to a multi-socket distribution module 30 at a first extremity of same, a second multi- socket distribution module 30a being connected at a second extremity of the first module 30, in order to provide mains sockets in a linear arrangement.
  • each module includes both switched and non-switched power bars.
  • a further pair of switched live and switched neutral bus-bars are included.
  • the two bus-bars are hardwired to the permanent 3 bus-bars.
  • the switched rails are switched off.
  • a user - operated mechanical switch on each such module allows that module to be configured for obtaining live power from either the permanent live bus-bar or the switched live bus-bar.
  • This further bus-bar configuration is useful when combining modules in a modular arrangement of system components, wherein one or more modules in the arrangement are capable of interrupting power supply to dependent modules. Otherwise, only the first power switching module (first relative to the power supply module in the chain) may be usefully employed, regardless of any other power switching modules depending on this first module for power supply.
  • first power switching module first relative to the power supply module in the chain
  • the first power switching module may be usefully employed, regardless of any other power switching modules depending on this first module for power supply.
  • the further pair of switched live and switched neutral bus-bars overcome this limitation, by permitting module-selective switching regardless of the module position in the chain.
  • the timer module is off, then the next multi-socket module is likewise off, since its two bus-bars are hardwired to the permanent 3 bus-bars.
  • the energy - saving module can still function by picking up its power from the non-switched rails, as can the final multi- socket module dependent on it for power supply.
  • Further system components conferring additional and/or dedicated functionality to any modular arrangement of system components are provided below by way of non-limitative example, and include:
  • a power supply module 31 including a mains power plug tethered to a free trailing cable having a length of 1 ,5 meter, 3 meters or 5 meters;
  • a multi-socket distribution module including 2 or more mains power sockets
  • a multi-socket distribution module including 2 or more mains power sockets, having individual socket switches;
  • a multi-socket distribution module including 2 or more mains power sockets, having a single switch for all sockets;
  • a multi-socket distribution module incorporating a single or individual electrical noise filters as typically employed to provide "clean" power to personal computers and other sensitive electronic equipment;
  • a programmable module which may optionally double as a power supply or in-line module, and which controls the ON/OFF timings of all subsequent system modules and/or connected loads;
  • an automatic or manually controlled standby-saver module for reducing power consumption of appliances plugged in the module or in the serial chain, and which is controllable by remote control through wired, wireless, radio, infra-red, universal serial bus or other, to allow remote control over the module driving one or more subsequent system components or power outlets to respond;
  • a dedicated AC or DC outlet module that provides multiple low voltage power outlets for such devices as wired or wireless personal computer peripherals and wireless communication devices, or any other low-voltage AC or DC powered device or rechargeable device normally employing a raw AC or DC source, often but not exclusively in the range of 3v to 12v;
  • USB charger module with a series of USB sockets and an internal 5V supply, such that devices that have a USB interface can be plugged in and charged from it; • a charger module for "walkie talkie" radios and other communications devices, data loggers and other similar devices that may provide multiple dedicated recharging sites within the module, often employing some control over the charging function;
  • a power meter module consisting of a female end and male end with a power meter in between;
  • a dog-leg power link module often, but not exclusively used in association with the dog-leg power feed module, to provide electrical continuity from a5 powered module to an adjacent or parallel module;
  • a networking module including circuitry to allow the communication of data signals to and from a computing device connected to the module, across the mains power circuit;
  • any of the above modules fitted with a display device employing an LED, neon, CFL, EL, LCD or other display technology to indicate ON/OFF status, process information or other data useful to the user;
  • a cover unit that fits over a single module or any arrangement of multiple o modules, having cable passages and preventing dust accumulating on the system components so-covered, and made from an opaque material, for instance injection-moulded and optionally provided with a latching mechanism; • a cover as described above but transparent or partially transparent to allow visual access to any displays within the system;
  • a cover having one or more user - editable or user - writable portions, for instance in proximity to sockets or cable passages, and either by writing directly on the portion or portions, the portion or portions having a pre - prepared surface, or by securing pre - printed or write - on labels to the portion or portions, the securing being adhesive, magnetic, static, mechanical or any suitable alternative.

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Abstract

A modular mains power distribution system is disclosed, having interlocking means (3,8) between at least two modules, the interlocking means comprising electrical conducting means (4), mechanical guidance means (5) and releasable latching means (7). The system may include any number of functional modules, which are arranged in a serial or parallel layout, or in a layout combining serial and parallel arrangements. The functional modules provide the system with user configurable modularity, according to a user's local and/or temporal requirements, for instance for permitting control and/or monitoring of mains power distribution modules and loads connected thereto.

Description

MODULAR MAINS POWER DISTRIBUTION SYSTEM
Field of the Invention
The present invention relates to a modular mains power distribution system. 5 More particularly, the present invention relates to a user-configurable modular mains power distribution system.
Background to the Invention
There are rarely enough wall-mounted mains power sockets available for o powering the ever-increasing amount of electrical devices or appliances used in households. Users therefore regularly purchase multi-socket or extension mains power distribution outlets or blocks, which have a single mains power plug for connection to a wall-mounted mains power socket, and which feature several mains power sockets, either in proximity to the wall-mounted mains power socket5 or remotely via an extension cable.
Many electrical devices are not conveniently close to a wall-mounted power socket, so extension cables and the devices' own cables are run across the floor. Several multi-socket mains power distribution outlets are often connected in o parallel from two or more wall-mounted power sockets or, alternatively, connected in series with one plugging into the other in a daisy-chained manner, so that power points can be brought sufficiently close to devices or appliances remote from wall- mounted power sockets. Either of these configurations features several disadvantages. 5
When connected in series, one extension socket of each extension outlet is lost to use when the input socket of the next extension outlet is connected thereto. When connected in parallel or in series, depending on the type and supply requirements of appliances connected to the extension sockets, there is also a o possibility of overloading the wall-mounted mains sockets to which the multi-socket mains distribution outlets are connected. Loose cabling lying on the floor represents a trip hazard. Conventional multi-socket mains power distribution outlets tend to slide on carpets or other smoother surfaces, and so rarely stay in place after their initial installation. Moreover, in households with younger children, there is always a concern about infants accessing mains sockets, whether used or not, for reasons of electrical safety. Multi-socket mains power distribution outlets are often located on the floor and in places easily accessible to young children. Furthermore, multi-socket outlets located on the floor, as is often the case, gather dust and are difficult to clean, particularly when populated with appliance plugs.
Many households now use a variety of devices for configuring mains power distribution, such as timers, power monitors, controllers or protection systems for their mains powered electrical appliances, and other plug-in devices which use power sockets that may otherwise be employed to power the main equipment in use, necessitating pro-rata provision of additional sockets, compounding the quantity of daisy-chained distribution outlets and cables.
Summary of the Invention
The present invention relates to a modular design for a free trailing mains power distribution system, comprising a range of modules and associated accessories, including for instance multi-outlet mains power distribution modules and the like, and which provides a dedicated interlocking mains power connectivity method independent of the other mains outlets as used by conventional peripheral equipment.
Dedicated accessory modules such as power meters, timers, filters and other devices may be connected together serially in a daisy chain, as required by the user's specific circumstances. Components may be added to or removed from the serial chain at any time, without disconnecting appliance plugs from their sockets in relevant modular components. No conventional mains sockets within the modules disclosed are used by the interconnection and power distribution means. Components of the system mate together both mechanically and electrically, employing separate mechanical features to provide each function and this provides an interlocking connection. Mains power interconnection is provided by an array of sockets and pins located at an end or both ends of a system module arranged to be intrinsically safe, such that live pins are never presented to the user. This is achieved by having all unused available power positions as female sockets, whilst the mating parts that provide power continuity into a module are male pins.
According to a first aspect of the modular mains power distribution system according to the invention, there is provided a power supply module for supplying mains power to a modular mains power distribution system. The power supply module comprises a body, means for connecting to a mains power source, and connecting means at an extremity of the body, for connecting the module to a second module to which to supply mains power. The connecting means comprises electrically conducting means and mechanically engaging means respectively for defining an electrical path between connected modules and mechanically engaging modules with one another, and are defined by a female socket-like element. The means for connecting to a mains power source is preferably a cable having a length comprised between 1 meter and 5 meters.
According to a second aspect of the modular mains power distribution system according to the invention, there is provided a termination module for a modular mains power distribution system. Comprising. The termination module comprises a body and connecting means at an extremity of the body, for connecting the module to a second module from which to receive mains power. The connecting means comprises electrically conducting means and mechanically engaging means respectively for defining an electrical path between connected modules and mechanically engaging modules with one another, and are defined by a male plug-like element. According to a third aspect of the modular mains power distribution system according to the invention, there is provided an in-line module for a modular mains power distribution system. The in-line module comprises a body, first connecting means at a first extremity of the body, for connecting the module to a second module from which to receive mains power, and second connecting means at a second extremity of the body, for connecting the module to a further module to which to supply mains power. The connecting means comprising electrically conducting means and mechanically engaging means respectively for defining an electrical path between connected modules and mechanically engaging modules with one another. The first connecting means are defined by a male plug-like element, and the second connecting means are defined by a female plug-like element.
Throughout these aspects of the modular mains power distribution system according to the invention, each connecting extremity is preferably shaped for registration with a connecting extremity of another module. A feature providing mechanical strength is an overlapping stepped mating feature, asymmetrically placed at each extremity of an in-line module, or placed at the only extremity requiring mating features in a single-ended, non extendable module. The pins and sockets normally used for electrical connection are respectively located substantially at facing stepped mating features, although in some components these may be insulated or electrically unconnected pins for reasons of safety. The connecting extremity preferably includes a stepped surface, for registering with a complementary stepped surface at an extremity of another module. For in-line modules according to this embodiment, the stepped surfaces are preferably asymmetrical relative to one another.
Several embodiments may be envisaged for the male plug-like element and the female plug-like element. In a preferred embodiment, vertically arranged pins and sockets are disposed in the same plane as the mains outlets provided, whilst the system modules are arrayed at right angles relative to the pin and socket plane, and disposed at one end of a feed or termination module, or at both ends of an in-line module.
In a preferred embodiment, the pin and socket forms may follow conventional UK mains plug and socket dimensions and shape conventions, to satisfy UK technical and approvals requirements. However, as these dimensions and shape conventions are significantly larger than necessary, particularly by non- UK approvals boards and mains interconnect design requirements, smaller pins and sockets may easily be accommodated, without compromising functionality.
In a preferred embodiment, the male plug-like element is defined by a plurality of shrouded pins or turrets, whereby the female socket-like element is advantageously defined by a plurality of recesses adapted to receive the shrouded pins or turrets. The shrouded pins or turrets may extend at a vertical angle relative to the top surface of the module, and both the shrouded pins or turrets and the recesses may be tapered. The interlocking conical turrets and recesses advantageously separate mechanical stresses from the electrical connection pins and sockets during use. With a conical form, at the onset of mating during configuration of a system with at least two system components, there is initially a large clearance between the male and female features, allowing early angular and positional misalignment, with the parts being progressively drawn together until tightly constrained when fully mated. In the mid-mating condition, the electrical connection pins and sockets are thus essentially aligned, to allow easy onset of insertion of these parts. The mating turrets engage before the electrical connections, therefore provide a secondary aligning function for ease of assembly by a user.
The connecting means are preferably configured such that an earth terminal of a first module connects to an earth terminal of a second module, a live terminal of the first module connects to a live terminal of the second module and a neutral terminal of the first module connects to a neutral terminal of the second module. A further mechanical strengthening feature is a latch connecting mated system components. In a preferred embodiment the latch is spring-loaded, such that it engages automatically upon mating of any pair of system components and ensures that the electrical connections cannot become inadvertently separated. A preferred location for the latch is in the vertical face of abutting system components, which facilitates a latch having a large width, for added strength of the parts and an improved latching function. The latch may be a manually releasable latch, and in this case is preferably a resiliently deformable latch. An advantageous embodiment of the latching means is a resiliently deformable member shaped substantially as an arrow and maintained between guiding pins, wherein simultaneous compression of both tips of the arrow - shaped member causes the tip to withdraw between the guiding pins into a recess defined in the body, for unlatching latched parts. This embodiment employs a one-piece deformable latch, so formed for limiting the number of components employed, reducing cost and the size of parts required, as well as maintain a compact product profile with minimal wasted space. Other forms of latch may be envisaged and applied, so long as they provide easy engagement and disengagement of the system components.
Many alternative embodiments of power supply, termination and in-line modules are envisaged for use with the modular mains power distribution system according to the invention.
A supply or in-line module may comprise any of a residual current circuit device or ELCB for protection against earth leakage or shock to system components and devices connected to them; a user - activated switch for switching current from a first module to a second module, after connecting the first and second modules; a programmable module for controlling the ON/OFF timings of all subsequent system modules and connected loads; a power monitor; a single noise filter or individual electrical noise filters A useful embodiment of an in-line or termination module includes a dedicated AC or DC outlet module providing multiple low voltage power outlets for such devices as wired or wireless personal computer peripherals and wireless communication devices, or any other low-voltage AC or DC powered device or rechargeable device normally employing an AC or DC supply. Another useful embodiment of an in-line or termination module includes a recharger module for "walkie talkie" radios and other communications devices, data loggers and other similar devices that may provide multiple dedicated recharging sites within the module.
A particularly useful embodiment of an in-line module is a distribution module comprising at least two main power sockets, optionally having an individual switch for each socket, or a single switch for any amount of sockets. The sockets are preferably arranged at an angle relative to the main axis of the module, in order to reduce the surface requirement, or size, of the module. The angle may be 45 degrees.
Another particularly useful embodiment of an in-line module is an automatic or manually controlled standby-saving module reacting to a reduction in power consumption of one designated socket to turn off others in the serial chain.
Alternatively, this module may be adapted to react to a reduction in power consumption via any of a plurality of socket outlets to turn off others in the serial chain. Advantageously, this module may be adapted to be controllable by remote control through RFID, wireless, infra-red or other controlling signal, to allow remote control over the master device driving one or more subsequent system components or power outlets to respond.
Any of the above module may be fitted with a display device selected from the group comprising LED, neon, CFL, EL, LCD or other, for indicating ON/OFF status, process information and/or other data useful to the user. Screw mounting bosses may be provided on any system module that extends beyond pin and socket-mounting steps provided at the end of a typical extendable system component, such that the overhanging component may be securely fixed or be provided with support feet. Preferably, screw mounting bosses are implemented laterally on the module, for fastening or otherwise securing the module or a modular arrangement of same in place, since the modules are intended for serial and/or parallel arrangement.
When configuring a system, either initially or by adding modules at any given time, modules may be connected in a linear configuration, in order to make the system long and narrow for location along a wall, skirting board or bench. Alternatively, modules may be connected in a parallel configuration, side-by-side or back-to-back, to reduce the length and increase the width of the arrangement, where such a configuration is more appropriate for a user's requirements.
With reference to parallel arrangement of modules, another useful embodiment of an in-line module is a dog-leg module, having first and second extremities substantially adjacent to one another. This module allows rotation through 180 degrees of the mains power supply path, wherein mains power received from a previous module in a chain of same can be supplied to a next module located substantially parallel to this previous module. This dog-leg module may double as a supply module, if fitted with means for connecting to a mains power source. In this particular embodiment, the first connecting means defined by a male plug-like element remains unpowered, for safety reasons.
According to still a further aspect of the present invention, a modular mains power distribution system is provided, which results from the combination of any number of modules previously introduced, and would at the very least consist of a power supply module according to the first aspect, and a second module according to either the second or third aspect. Alternatively the power supply module may be a dog-leg supply module fitted with means for connecting to a mains power source. A typical minimal system will consist of a power supply module connected to a multi-socket distribution module, wherein any number of sockets may be incorporated in the distribution module.
A removable link component is preferably be used to link adjacent system modules. The link component preferably comprises peg-like members connected by a joining member, each peg-like member being adapted to engage a respective lateral screw mounting boss of an adjacent module. Each peg-like member preferably comprises deformable ribs, to achieve interference fit in the screw mounting boss. The surface of the joining member opposite the two peg-like members preferably sits flush with the top face of the adjacent modules.
A cover is preferably be used on a, or each, system module, to prevent dust accumulation on the module surface and to facilitate cleaning. The cover may be opaque, substantially translucent or partially translucent. The cover preferably includes a window. The cover may advantageously include a latching mechanism. The cover may also advantageously include at least one user - editable or user - writable portion. This portion may be a pre - prepared surface, or a pre - printed or write - on label secured to the portion area, the securing being selected from the group comprising adhesive, magnetic, static and mechanical securing.
Where the module is for receiving at least one appliance plug, the cover preferably includes at least one lateral slot, for permitting the passage of the appliance cable trailing the appliance plug. Alternatively, where the module is for receiving multiple appliance plugs, then the cover includes a plurality of lateral slots, respectively for permitting the passage of the appliance cable trailing each appliance plug.
If not permanently secured in position by fasteners, but left trailing, the system may be kept in position by using removable foot components, which may be embodied as conical rubber feet, to be inserted in through screw mounting bosses, with sub populations in excess of four feet, one disposed at each corner of the system. The foot component is preferably manufactured from a resilient material, having a shore A hardness in the range of Shore A 40 to Shore A 80, preferably still a shore A hardness of 60. A particularly useful embodiment of the foot component includes a shank portion having annular ribs for providing an interference fit within the screw mounting boss, and a conical shape extending 5 away from the module base for concentrating the module weight at the cone tip.
Brief Description of the Drawings
For a better understanding of the invention and to show how the same may be carried into effect, there will now be described, by way of example only, o specific embodiments, methods and processes according to the present invention with reference to the accompanying drawings in which:
Figure 1 shows the topside aspect of a modular unit, including a first male socket extremity; 5 Figure 2 shows the underside aspect of the modular unit of Figure 1 , including a second female socket extremity;
Figure 3 shows two modular units positioned for mating;
o Figure 4 shows two modular units mated with each other;
Figure 5 shows a topside aspect of a modular power supply unit;
Figure 6 shows an underside aspect of the modular power supply unit of5 Figure 5;
Figure 7 shows a topside aspect of a modular power supply unit positioned for mating with the modular unit of Figures 1 to 4;
Figure 8 shows an underside aspect of a modular power supply unit positioned for mating with the modular unit of Figures 1 to 4; Figure 9 shows a topside aspect of the modular power supply unit mated with the modular unit of Figures 1 to 4;
Figure 10 shows a resilient latch mechanism;
5
Figure 11 shows the resilient latch mechanism of Figure 10 fitted within a housing of a modular unit;
Figure 12 shows a removable cover for a modular unit, positioned beforeo fitting;
Figure 13 shows the removable cover of Figure 12 fitted to a modular unit; Figure 14 shows a mounting screw-boss of a modular unit; 5 Figure 15 shows a link component for use with the mounting screw-boss of
Figure 14;
Figure 16 shows a link component fitted between two modular units;
o Figure 17 is an exploded view of a first example of a modular arrangement of six system components, including two multi-socket distribution modules, two link components, a dog-leg power supply module and a dog-leg power link module;
Figure 18 shows the example modular arrangement of Figure 17 fully5 assembled;
Figure 19 shows a foot component;
Figure 20 is an underside view of a multi-socket distribution block fitted with o three conical feet of Figure 19, and a fourth foot about to be inserted; and Figure 21 shows a second example of a modular arrangement of three system components, including two multi-socket distribution modules and a power supply module.
Detailed Description
There will now be described by way of example a specific mode contemplated by the inventors. In the following description numerous specific details are set forth in order to provide a thorough understanding. It will be apparent however, to one skilled in the art, that the present invention may be practiced without limitation to these specific details. In other instances, well known methods and structures have not been described in detail so as not to unnecessarily obscure the description.
With reference to Figure 1 , a first embodiment is shown which comprises a mains distribution module, which contains four mains power sockets 2 arrayed in the top face of the block. In this illustration, the sockets are disposed at 45° to the axes in order to reduce the overall size of the module and to provide a smoother exit for the respective cables of connected appliances, more in line with the main axis of the module. Conventional 90° or other orientations or other array configurations may be accommodated by this general design, and any other number of sockets within the total power handling capability of the system may be envisaged.
A step 3 is shown in the module, which forms a mounting for the mains inlet point power pins 4. A conventional UK three-pin system is shown shrouded, with a taller central earth or ground pin to ensure this electrical connection is made first upon insertion, with live and neutral power connections disposed either side of the central earth or ground pin, with a separation distance and shrouded path length between conductors being a minimum of 4mm as dictated by mandatory UK creepage and clearance regulations. Other arrangements of pins, with and without shrouds may be envisaged and applied, providing they meet local, applicable electrical safety legislation. A shutter mechanism may be employed to cover the in-line power distribution socket apertures, in preference to a tubular form shroud, to prevent ingress of users' digits when the electrical connections are formed, but before the components are fully mated. A preferred embodiment may use a shuttered shielding arrangement, although this is not a mandatory requirement under current UK regulations.
The power pins 4 distribute electricity to the sockets 2 by conventional bus bars or other common electrical connectivity methods as are standard in the industry and known to those skilled in the art. In the embodiment shown, a pair 5 of guide and registration turrets is provided to ensure that a mating power supply module or other adapter or module within the system is prevented from being mated at an excessive angle to the power pins. The guide and registration turrets are disposed in a symmetrical fashion and provide a mechanical register to prevent any lateral forces being transferred to the power pins or shrouds, during insertion or in normal everyday use if the module is hit or otherwise impacted.
The pin and socket arrangement, comprising the power interconnects, follow conventional UK dimensions and configurations as these already meet the necessary mandatory regulations regarding current carrying capacity and heating effects due to I2R losses of the contact forms and the requirement for the earth pin making first contact, before the live and neutral pins make electrical contact. This arrangement is capable of distributing 13A, 250V alternative current (AC) to a connected load.
However, as regulatory bodies consider the pin forms of the example to be oversized and to represent a potential safety factor, reduced pin and socket dimensions may also be employed, without however compromising system function, therefore many flat, circular or other pin shapes may be easily substituted. A pair of buttons 6 are disposed either side of the body of each system component to release a latch 7 for easy separation of connected modules. With reference to Figure 2, mating sockets 11 cooperate with turrets 5 of the next module, and are tapered for easy initial registration and subsequent tightening of the joint, as well as improved registration as the parts become fully mated. Sprung-loaded latch 7 co-operates with a mating release 13 in the next module, whereby the latch prevents unintended separation after the registration turrets 5 and sockets 11 become fully engaged. An overlapping end projection 10 co-operates with the power pin step 3 of a connected module.
With reference to Figure 3, two modular components of the system are shown in close proximity to one another in a near - mated condition, with an arrow showing the mating direction.
With reference to Figure 4, the two modular components of Figure 3 are shown in full mechanical and electrical mating, with the parts fitting together to present a uniform contour and feature alignment.
The multi-socket modular power outlet shown in Figures 1 to 4 provides mains power distribution, but is essentially passive, because there is no connection to the mains. To provide electrical power connectivity, a power supply module is required, which connects to and relays mains power to the first module of any system of interconnected modules and components described herein.
With reference to Figure 5, a power supply module 14 is shown connected via a free - trailing mains cable 16 which, in the UK, would consist of a triple core, double insulated 13A 230/25Ov AC - capable cable manufactured to approved standards for connection to the mains supply through a conventional mains plug (not shown) with a moulded or otherwise effected strain relief 15. The power supply module includes finger grips 18, which assist the plugging operation onto the multi-socket module shown in Figures 1 to 5, or any other module described herein employed as the first device in any modular configuration of the system components, for example a daisy chain of modular multi-socket mains power outlets. In a similar way to the previously described interlocking features, the power module includes tapered sockets 17 and latch release 13 to engage with the turrets of the connecting module, as previously described.
The power supply module may be optionally fitted with a power ON display that may be neon, LED or other conventionally employed illuminating indicator 19.
A switch button may be included to provide control over the series of daisy-chained devices. Any ON display indicator may be incorporated into the switch or as a separate component.
With reference to Figure 6, an underside of the power supply module of
Figure 5 is shown with a socket arrangement 12, which in this case comprises insulated shrouded electrical contacts, for connection with the first modular device in the daisy chain through the electrical connector pins 4 as shown in Figure 1.
With reference to Figures 7 and 8, the power supply module of the system is shown in close proximity to a multi-socket distribution module with shrouded electrical connections in a near - mated condition, respectively in top and underside views.
With reference to Figure 9, the power supply module of the system is shown in full mechanical and electrical mating with the multi-socket distribution module, with the parts fitting together to present a uniform contour and feature alignment, thereby displaying the alignment of profile features common to the design concept carried through each component of the modular system.
With reference to Figure 10, a one - piece latching mechanism is shown, having side buttons and made from a substantially resilient material. The mechanism is substantially arrow-shaped. When the buttons are pressed towards one another following the direction shown as 19, the central latch tongue, which is the tip of the arrow shape, is displaced following the direction shown as 20.
Releasing the buttons allows the resilient material to recover its original shape, and the latch tongue to return to its latched projecting position. With reference to Figure 11 , the latching mechanism of Figure 10 is shown located within a housing of a module of the system, wherein the latch tongue is located between guide pins 21. Registration and location of the mechanism within the housing are provided by the button - engaging latch holes in the housing, and
5 the pins 21 guiding the latch tongue.
With reference to Figures 12 and 13, a module cover 22 may be applied to a system module, in the example a multi-socket distribution module 23 populated with appliance plugs, following the direction shown as 24. The cover 22 compriseso lateral slots 25, through which appliance cables 26 may pass.
With reference to Figure 14, a mounting screw boss 27 is shown along a side of the illustrated multi-socket distribution module 23. Several mounting screw bosses 27 may be provided along one or each side of the illustrated multi-socket5 distribution module, or other system components. The mounting screw boss 27 is disposed so as to align with other system components, when these are placed in "back to back" or parallel "side by side" orientation. The boss is recessed from the top face to provide good electrical separation of any metal mounting screws or other fasteners, from the power or ground pins and sockets located on the top o face. The boss is also recessed into the side of the unit, to allow close side-by-side positioning of adjacent system components.
Figure 15 shows a resilient, preferably elastomeric, link component 31 that may be manually pushed into any unpopulated mounting screw boss of adjacent5 system components, to provide mechanical registration and interlocking between parallel modules. Deformable gripping ribs 28 are provided to ensure good retention, while upstanding grippable bosses 29 are flush with the top face of the system components when fully pressed into their intended mounting position. With reference to Figure 16, a pair of distribution modules are shown connected o together back to back by a link component 31 , the top face of boss 29 being flush with the top face of the distribution modules. With reference to Figure 17, an exploded view of a modular arrangement of system components is shown, which comprises two back to back-oriented multi- socket distribution modules 30, two link components 31 , a dual width, dog-leg power feed module 32 that links the ends of the two multi-socket distribution modules and a second dog-leg power link module 33 which provides electrical connectivity through to the second module.
The female socket electrical connectors in the power feed module 32 provide mains power to the first multi-socket distribution module 30. The pins of the first multi-socket distribution module 30 conduct power to its opposite end, which presents intrinsically safe power sockets that may be shrouded or preferably shuttered, for connection to the second dog-leg power link module 33.
This second module has electrical connection pins that mate into the first powered multi-socket distribution block 30, and at the other end presents a set of intrinsically safe sockets that feed the second multi-socket distribution block 30 in the same manner as the first module. Finally, the socketed end of the second multi-socket distribution block 30 is plugged into the power feed module 32.
To prevent any electrical safety hazard, the presented pins of this component are not otherwise connected to any electrical power and thus may be manufactured from plastic or other insulating material. As this set of components would be difficult to assemble if absolutely constrained in all three dimensions during mating, the clearance achieved by use of tapered pins and recesses of the interlocking turrets provide enough angular clearance during the assembly process to facilitate this action. The interlocking links 31 may then be pushed into the central, adjoining holes for added security.
The fully assembled modular arrangement of system components is shown in Figure 18, and may be secured to a surface, with fasteners or otherwise, or used in a free trailing manner. With reference to Figure 19, a foot component is shown, which is manufactured from an elastomeric material. The foot component comprises a shank provided with deformable ribs 34, and a shaped extremity 35, in example a cone having an apex pointing away from the shank. This component may be typically manufactured from Viton or other synthetic rubber. The material of manufacture preferably has a Shore A hardness in the range of 40 to 80, preferably still a Shore A hardness of 60.
Figure 20 shows an underside of a multi-socket distribution module 30 having through screw-mounting bosses in which, respectively, three foot components such as shown in Figure 19 have been inserted and one foot component is about to be inserted, in the direction shown as 36. The ribs provide a gripping function against the internal diameter of an empty screw-mounting boss, whereby a user may push-fit a foot component within same.
The conical extremity of the foot component 35 includes a broader flanged end, having a diameter larger than the screw-mounting boss diameter to limit insertion, and a point which, when the assembly is oriented normally, allows the weight of the multi-socket distribution block or other module so fitted, to be locally concentrated and thus provide an anti-slip function for the assembly. The pointed tip prevents slippage on floors or other smooth surfaces as well as engaging in tufted pile or woven materials, such as carpets, to retain the distribution module or other system components fitted in place.
With reference to Figure 21 , an alternative modular arrangement of system components is shown, which comprises a power supply module 31 connected to a multi-socket distribution module 30 at a first extremity of same, a second multi- socket distribution module 30a being connected at a second extremity of the first module 30, in order to provide mains sockets in a linear arrangement.
In an alternative embodiment, each module includes both switched and non-switched power bars. In this embodiment, rather than just 3 bus-bars from end to end and which carry earth, live and neutral respectively, a further pair of switched live and switched neutral bus-bars are included. For modules requiring or offering no further specific functionality than carrying mains power, for instance a multi-socket distribution module 30 or a dog-leg power feed 32 or link module 33, the two bus-bars are hardwired to the permanent 3 bus-bars. However, for modules requiring or offering further specific functionality in connection with the effective power supply, for instance a timer module or an energy - saving module, only the switched rails are switched off. A user - operated mechanical switch on each such module allows that module to be configured for obtaining live power from either the permanent live bus-bar or the switched live bus-bar.
This further bus-bar configuration is useful when combining modules in a modular arrangement of system components, wherein one or more modules in the arrangement are capable of interrupting power supply to dependent modules. Otherwise, only the first power switching module (first relative to the power supply module in the chain) may be usefully employed, regardless of any other power switching modules depending on this first module for power supply. By way of example, in a modular arrangement including a serial chain composed of a timer switch module, then a multi-socket module, then an energy - saving switch module and a final multi-socket module, if the timer module is off, then the remaining modules, including the energy - saving module, cannot function. Likewise, if the chain was in reverse order and the energy - saving module is off, then the remaining modules, including the timer module, cannot function.
The further pair of switched live and switched neutral bus-bars overcome this limitation, by permitting module-selective switching regardless of the module position in the chain. Reprising the above example, if the timer module is off, then the next multi-socket module is likewise off, since its two bus-bars are hardwired to the permanent 3 bus-bars. However, the energy - saving module can still function by picking up its power from the non-switched rails, as can the final multi- socket module dependent on it for power supply. Further system components conferring additional and/or dedicated functionality to any modular arrangement of system components are provided below by way of non-limitative example, and include:
• a power supply module 31 including a mains power plug tethered to a free trailing cable having a length of 1 ,5 meter, 3 meters or 5 meters;
• a multi-socket distribution module, including 2 or more mains power sockets;
• a multi-socket distribution module, including 2 or more mains power sockets, having individual socket switches;
• a multi-socket distribution module, including 2 or more mains power sockets, having a single switch for all sockets;
• a multi-socket distribution module incorporating a single or individual electrical noise filters as typically employed to provide "clean" power to personal computers and other sensitive electronic equipment;
• a power supply module with power ON/OFF switch to any serially connected outlet;
• a surge module with a transient surge arrest and filtering module between the module's respective connecting means;
• a power supply or in-line module with a residual current circuit device between the module's respective connecting means, for protecting against earth leakage/shock protection to all system components and devices connected to them; • a power supply module hardwired to a free cable acting as the primary unit within a system with or without an a residual current circuit device or other control device, and provided with one or more socket outlets;
• a programmable module, which may optionally double as a power supply or in-line module, and which controls the ON/OFF timings of all subsequent system modules and/or connected loads;
• a power supply or in-line module containing a power monitor between the module's respective connecting means;
• an automatic or manually controlled standby-saver module that reacts to a reduction in power consumption via one designated socket outlet to turn off others plugged in the module or in the serial chain;
• an automatic or manually controlled standby-saver module for reducing power consumption of appliances plugged in the module or in the serial chain, and which is controllable by remote control through wired, wireless, radio, infra-red, universal serial bus or other, to allow remote control over the module driving one or more subsequent system components or power outlets to respond;
• a dedicated AC or DC outlet module that provides multiple low voltage power outlets for such devices as wired or wireless personal computer peripherals and wireless communication devices, or any other low-voltage AC or DC powered device or rechargeable device normally employing a raw AC or DC source, often but not exclusively in the range of 3v to 12v;
• a USB charger module with a series of USB sockets and an internal 5V supply, such that devices that have a USB interface can be plugged in and charged from it; • a charger module for "walkie talkie" radios and other communications devices, data loggers and other similar devices that may provide multiple dedicated recharging sites within the module, often employing some control over the charging function;
5
• a power meter module, consisting of a female end and male end with a power meter in between;
• a dog-leg power feed module with adjacent sockets and pins, which allows o connection of two parallel system components, wherein the presented pins in this device may be insulated or unpowered for safety reasons;
• a dog-leg power link module often, but not exclusively used in association with the dog-leg power feed module, to provide electrical continuity from a5 powered module to an adjacent or parallel module;
• a turn-around power link or feed module, allowing a strip of modules to be placed alongside another, the turn-around module linking power between the two ends through 180 degrees; 0
• a networking module, including circuitry to allow the communication of data signals to and from a computing device connected to the module, across the mains power circuit;
5 • any of the above modules fitted with a display device employing an LED, neon, CFL, EL, LCD or other display technology to indicate ON/OFF status, process information or other data useful to the user;
• a cover unit that fits over a single module or any arrangement of multiple o modules, having cable passages and preventing dust accumulating on the system components so-covered, and made from an opaque material, for instance injection-moulded and optionally provided with a latching mechanism; • a cover as described above but transparent or partially transparent to allow visual access to any displays within the system;
• a cover having one or more user - editable or user - writable portions, for instance in proximity to sockets or cable passages, and either by writing directly on the portion or portions, the portion or portions having a pre - prepared surface, or by securing pre - printed or write - on labels to the portion or portions, the securing being adhesive, magnetic, static, mechanical or any suitable alternative.

Claims

Claims
1. A power supply module for supplying mains power to a modular mains power distribution system, comprising :
5 a body;
means for connecting to a mains power source,
o connecting means at an extremity of the body, for connecting the module to a second module to which to supply mains power;
the connecting means comprising electrically conducting means and mechanically engaging means respectively for defining an electrical path between5 connected modules and mechanically engaging modules with one another, and
the connecting means being defined by a female socket-like element.
2. A termination module for a modular mains power distribution system, comprising:
a body;
connecting means at an extremity of the body, for connecting the module to a second module from which to receive mains power;
the connecting means comprising electrically conducting means and mechanically engaging means respectively for defining an electrical path between connected modules and mechanically engaging modules with one another, and
the connecting means being defined by a male plug-like element.
3. An in-line module for a modular mains power distribution system, comprising
a body;
5 first connecting means at a first extremity of the body, for connecting the module to a second module from which to receive mains power;
second connecting means at a second extremity of the body, for connecting o the module to a further module to which to supply mains power;
the connecting means comprising electrically conducting means and mechanically engaging means respectively for defining an electrical path between connected modules and mechanically engaging modules with one another, 5 the first connecting means being defined by a male plug-like element, and
the second connecting means being defined by a female plug-like element.
4. A module according to claim 1 or 2, wherein the connecting extremity is shaped for registration with a connecting extremity of another module.
5. A module according to claim 3, wherein each connecting extremity is shaped for registration with a connecting extremity of another module.
6. \ A module according to claim 4 or 5, wherein the connecting extremity includes a stepped surface, for registering with a complementary stepped surface at an extremity of another module.
7. A module according to claim 6 when depending on claim 5, wherein the stepped surfaces are asymmetrical relative to one another.
8. A module according to any of claims 1 to 7, wherein the male plug- like element is defined by a plurality of shrouded pins or turrets, and wherein the female socket-like element is defined by a plurality of recesses adapted to receive the shrouded pins or turrets.
5
9. A module according to claim 8, wherein the shrouded pins or turrets extend at a vertical angle relative to the top surface of the module main.
10. A module according to claim 8 or 9, wherein the shrouded pins or o turrets and the recesses are tapered.
11. A module according to any preceding claim, wherein, in use, an earth terminal of a first module connects to an earth terminal of a second module, a live terminal of the first module connects to a live terminal of the second module5 and a neutral terminal of the first module connects to a neutral terminal of the second module.
12. A module according to any of claims 1 to 11, wherein the connecting means further includes releasable latching means, for releasably securing o modules to one another.
13. A module according to claim 12, wherein the latch is a manually releasable latch.
5 14. A module according to 13, wherein the latch is a resiliently deformable latch.
15. A module according to claim 14, wherein the latch includes a resiliently deformable member shaped substantially as an arrow and maintained 0 between guiding pins, wherein simultaneous compression of both tips of the arrow
- shaped member causes the tip to withdraw between the guiding pins into a recess defined in the body, for unlatching latched parts.
16. A module according to claim 1 or any of claims 4 to 15 when dependent on claim 1 , wherein the means for connecting to a mains power source is a cable having a length comprised between 1 meter and 5 meters.
17. A module according to claim 16, further comprising a residual current circuit device or ELCB for protection against earth leakage or shock to system components and devices connected to them.
18. A module according to any preceding claim, further including a user
- activated switch for switching current from a first module to a second module, after connecting the first and second modules.
19. A module according to any preceding claim, wherein the module is a programmable module for controlling the ON/OFF timings of all subsequent system modules and connected loads.
20. A module according to any preceding claim, further comprising a power monitor.
21. A module according to any preceding claim, further comprising a single noise filter or individual electrical noise filters.
22. A module according to claim 2, 3 or any of claims 4 to 21 when depending on claims 2 or 3, wherein the module is a dedicated AC or DC outlet module providing multiple low voltage power outlets for such devices as wired or wireless personal computer peripherals and wireless communication devices, or any other low-voltage AC or DC powered device or rechargeable device normally employing an AC or DC supply.
23. A module according to claim 2, 3 or any of claims 4 to 21 when depending on claims 2 or 3, wherein the module is a recharger module for "walkie talkie" radios and other communications devices, data loggers and other similar devices that may provide multiple dedicated recharging sites within the module.
24. A module according to claim 3 or any of claims 4 to 23 when 5 dependent on claim 3, further comprising a residual current circuit device or ELCB for protection against earth leakage or shock to system components and devices connected to them.
25. A module according to any preceding claim, wherein the module is a i o distribution module comprising at least two main power sockets.
26. A module according to claim 25, wherein each socket comprises an individual switch.
15 27. A module according to claim 25, further comprising a single switch for any amount of sockets.
28. A module according to any of claims 25 to 27, wherein sockets are arranged at an angle relative to the main axis of the module. 0
29. A module according to claim 28, wherein the angle is 45 degrees.
30. A module to claim 3 or any of claims 4 to 29 when depending on claim 3, further comprising an automatic or manually controlled standby-saving 5 module reacting to a reduction in power consumption of one designated socket to turn off others in the serial chain.
31. The module of claim 30, adapted to react to a reduction in power consumption via any of a plurality of socket outlets to turn off others in the serial 0 chain.
32. The module of claim 30 or 31 , adapted to be controllable by remote control through RFID, wireless, infra-red or other controlling signal, to allow remote control over the master device driving one or more subsequent system components or power outlets to respond.
33. A module according to any of claims 1 to 32, wherein the module is fitted with a display device selected from the group comprising LED, neon, CFL, EL, LCD or other, for indicating ON/OFF status, process information and/or other data useful to the user.
34. A module according to any of claims 1 to 33, wherein the module comprises a plurality of lateral screw mounting bosses.
35. A module according to claim 3 or any of claims 4 to 15 when depending on claim 3, wherein the module is a dog-leg module, having first and second extremities substantially adjacent to one another.
36. A module according to claim 35, further comprising means for connecting to a mains power source, wherein the first connecting means defined by a male plug-like element remain unpowered
37. A modular mains power distribution system, comprising at least a power supply module according to claim 1 and a second module according to claim 2 or 3.
38. A modular mains power distribution system, comprising at least a module according to claim 36 and a second module according to claim 3.
39. The system according to claim 38, further comprising a module according to claim 35 and a further module according to claim 3, wherein the second and further modules are disposed parallel to one another.
40. The system according to claim 39, further comprising a removable link component adapted to mechanically link the at least two adjacent modules, the link component comprising peg-like members connected by a joining member, each peg-like member being adapted to engage a respective lateral screw
5 mounting boss of an adjacent module.
41. The system of claim 40, wherein each peg-like member further comprises deformable ribs to achieve an interference fit in the screw mounting boss. 0
42 The system of claim 40 or 41 , wherein, in use, a surface of the joining member opposite the two peg-like members sits flush with the top face of the adjacent modules. 5
43. The system of any of claims 37 to 42, further comprising a cover for a or each module, wherein the cover is opaque, substantially translucent or partially translucent.
44. The system of claim 43, wherein the cover includes a window. 0
45. The system of claim 43 or 44, wherein the cover further comprises a latching mechanism.
46. The system of any of claims 43 to 45, wherein the cover further 5 comprises at least one user - editable or user - writable portion.
47. The system of claim 46, wherein the portion is a pre - prepared surface, or a pre - printed or write - on label secured to the portion area, the securing being selected from the group comprising adhesive, magnetic, static and o mechanical securing.
48. The system of any of claims 43 to 47, wherein the module is for receiving at least one appliance plug, the cover having at least one lateral slot for permitting the passage of the appliance cable trailing the appliance plug.
49. The system of any of claims 43 to 47, wherein the module is for receiving a plurality of appliance plugs, the cover having a plurality of lateral slots respectively for permitting the passage of the appliance cable trailing each appliance plug.
50. The system of any of claims 37 to 49, further comprising a removable foot component adapted to engage a through lateral screw mounting boss in the underside of a module.
51. The system of claim 50, wherein the foot component is manufactured from a resilient material, having a shore A hardness in the range of
Shore A 40 to Shore A 80
52. The system of claim 51 or 52, wherein the foot component comprises a shank portion having annular ribs for providing an interefrence fit within the screw mounting boss, and a conical shape extending away from the module base for concentrating the module weight at the cone tip.
53. A power supply module for supplying mains power to a modular mains power distribution system substantially as hereinbefore described, with reference to and as shown in the accompanying drawings.
54. A termination module for a modular mains power distribution system substantially as hereinbefore described, with reference to and as shown in the accompanying drawings.
55. An in-line module for a modular mains power distribution system substantially as hereinbefore described, with reference to and as shown in the accompanying drawings.
56. A modular mains power distribution system substantially as hereinbefore described, with reference to and as shown in the accompanying drawings.
PCT/GB2010/000428 2009-03-10 2010-03-10 Modular mains power distribution system WO2010103272A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB0904098.1 2009-03-10
GB0904098A GB2468495A (en) 2009-03-10 2009-03-10 Inter-engaging electrical socket blocks

Publications (1)

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WO2010103272A1 true WO2010103272A1 (en) 2010-09-16

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GB2468495A (en) 2010-09-15

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