GB2468495A - Inter-engaging electrical socket blocks - Google Patents

Abstract

This invention relates to a modular trailing socket mains extension system that employs stepped mechanical interlocking features 3, 8 between modules with vertical electrical conductors 4, mechanical guidance 5 and a releasable latch 7. Optional components include a dust and protective cover (22, Fig 12), non-slip feet (Fig 19) and system components such as dogleg connectors (32, 33, Fig 17) allowing alternative serial and parallel layout arrangements with removable interlocking pegs (31, Fig 15). Multiple modules with different characteristics may be inserted in serial connectivity to provide control, monitoring or other features to subsequently connected socket arrays.

Description

An extendable multiway trailing mains distribution system

Background to the Invention

When powering household electrical devices there are rarely enough wall mounted mains power sockets available. For this reason many people buy free trailing multi-way extension power outlets that are plugged into a normal wall socket to provide more outlets via an extension cable. Secondly, many electrical devices are not conveniently close to a wall mounted power socket, so extension leads and multiple cables directly connected to the devices are run across the floor.

Problem Multiple multi-way extension power outlets are often connected in parallel from two or more wall mounted power outlets or, more often in series, plugging into each other in daisy-chain fashion. This has several disadvantages, the main one being that when serially connected, one extension socket is lost to use by plugging-in the next multi-way outlet along the chain. A second disadvantage is the untidiness and safety issues relating to the trip hazard of loose cables lying on the floor.

In families with younger children there is always a concern about access to mains plugs and unused sockets for reasons of electrical safety. Multi-way mains extension sockets are often located on the floor and in places easily accessible to young children.

When located on the floor, as is often the case, muRi-way outlets gather dust and are difficult to clean, particularly when populated with plugs.

Many households now use timers, power monitors, controllers or protection systems for their mains powered electrical equipment and other plug-in devices that use-up power sockets that may otherwise be employed to power the main equipment in use, necessitating pro-rata provision of extra extension sockets, compounding the quantity of daisy-chained socket outlet blocks and cables.

Conventional multi-way power outlets tend to slide on carpets or other smoother surfaces so rarely stay in place.

Multiple loose cables may present a trip-hazard

Description

This invention concerns the modular design of a free trailing multi-outlet mains power distribution block and a range of associated accessories that provide 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, filter blocks and other devices may be daisy-chain serially connected together as required by the user are also disclosed. Additional components may be added or removed at any time to the serial chain without physically disconnecting the equipment plugs from their current sockets. No conventional mains sockets within the disclosed modules are used up by the interconnection and power distribution means. A cover system is described that provides a tidier appearance and improves ceanng.

List of Figures Figure 1 shows a four-way distribution b'ock top % view with mate pins Figure 2 shows a four-way distnbution block iower 3/4 view with female socket Figure 3 shows the detai' of two modular units at the point of mating Figure 4 shows the detai' of two modular units after mating Figure 5 shows a power feed modular unit top 3/4 view Figure 6 shows a power feeder unit tower 3/4 view Figure 7 shows a power feeder unit at the point of mating top % view Figure 8 shows a power feeder unit at the point of mating ower % view Figure 9 shows a power feeder unit mated to a modu'ar distribuUon block Figure 10 shows a 3/4 top view of a typca one-piece deformabe atch component Figure 11 shows an underside 3/4 view of a typical deformable latch component fitted within a housing Figure 12 shows a % view of a cover about to be fitted to a popu'ated four-way distribution block Figure 13 shows a 3/4 view of a cover fitted to a popu'ated four-way distribution block Figure 14 shows a % view of a mounting screw-boss that also acts as a link registration point for joining modu'es together Figure 15 shows a 3/4 view of a sink component Figure 16 shows the detaU of a % view of a ink component fitted between two back-to back distribution b'ocks Figure 17 shows an exploded top % view of an array of two back-to-back four-way distribution bbcks, a °dog-leg power feed unit and a dog-leg power link unit, with two link components Figure 18 shows a top % view of an array of two back-to-back four-way distribution blocks, a dog-'eg power feed unit and a dog-leg power link unit mated together Figure 19 shows a 3/4 view of a manuaUy insertable conical rubber foot Figure 20 shows an inverted � view of a four-way distribution block fitted with three conical feet with a fourth about-to-be inserted.

Figure 21 shows a � view of a typical system configuration with a power feeder unit and two 4-Way distribution blocks

Description of Figures

Referring to the Figi is a mains distribution block that in this illustration contains four UK mains sockets 2 arrayed in the top face of the block. In this iUustration the sockets are disposed at 45° to the axes to reduce size of the block and provide a smoother exit for the appliance cables, more in-line with the main axis of the block. Conventional 90° or other orientations or other array configurations may be accommodated by this general design with any other number of sockets within the total power handling capability of the system may be envisaged. 3 is a step in the block that 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 neutra' power connections disposed either side 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 mandatory 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 ensure prevention of finger-access when the electrical connections are formed, but before the components are fuy mated. A preferred embodiment would use a shuttered shielding arrangement although this is not a mandatory requirement under current UK regulations.

The provided power pins 4 distribute electricity to the sockets 2 by conventional buss bars or other common electrical connectivity methods as are standard in the industry and known to those skied in the art. 5 is one of a pair of symmetricay placed guide and registration turrets provided to ensure that a mating power supply block or other adapter or module within the system is prevented from being mated at an excessive angle to the power pins and provides a mechanical register to prevent any lateral forces being transferred to the power pins or shrouds during insertion or in normal everyday use if kicked or otherwise impacted.

The illustrated pin and socket forms 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 12R losses of the contact forms and the requirement for the earth pin making first -before the live and neutral pins make electrical contact, also these forms are demonstrated as capable of distributing a fu I 3A 250v AC to a subsequent load. However, as regulatory bodies consider the pin forms in particular as being oversized with a significant factor of safety, reduced pin and socket dimensions may also be employed without compromising system function and 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 latch 7 for easy separation.

Referring to Fig 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 and improved registration as the parts become fully mated.

Sprung-loaded latch 7 cooperates with a mating détente 13 in the next module such that once the registration turrets 5 and sockets 11 are fully engaged, the latch prevents unintended separation.

An overlapping end projection 10 cooperates with the power pin step 3 of a connected modu'e.

Referring to Fig 3 this shows two modular blocks of the system approaching a mated condition with the arrow showing the direction of mate.

Referring to Fig 4, this shows two component modules fully mechanically and electrically mated with the parts fitting together to present good contour and feature alignment.

The mu Ri-way modular power outlet shewn in Figs 1 through 4 provide mains power distribution but as shewn are essentiay passive, in that there is no direct connection to the mains. To provide electrical power connectivity a Power Supply module is required that feeds mains power to the first module of the daisy chain of any interconnected distribution units and other devices described herein.

Referring to Fig 5 this is a Power Supply Module block 14 connected via a free mains cable 16 that in the UK would consist of a 3 core double insulated 13A 2301250v AC capable cable manufactured to approved standards for connection to the mains supply through a conventional free mains plug (not shewn) with a moulded or otherwise effected strain relief 15. The Power Supply Module has finger grips 18 that assist in plugging this onto the 4-way adaptor as shown is Figs 1 to 4 or any other module described herein employed as the first device in any daisy chained configuration of the system components. In a similar way to the previously described interlocking features, the power module includes tapered sockets 17 and latch détente 13 to engage with the connected module turrets as described elsewhere. 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.

Also a switch button may be included to provide control over the series of daisy-chained devices attached. Any ON display indicator may be incorporated into the switch or as a separate component.

Fig 6 shows an underside view of the Power Module as described in Fig 5 with a socket arrangement 12 in this case employing insulated shrouded electrical contacts for connection with the first modular device in the daisy chain through the electrical connector pins 4 as shown in Fig 1.

Fig 7 shows the Power Supply Module ready to mate with, in this case, a four-way distribution block with shrouded electrical connections Fig 8 shows an underside view of a Power Supply Module nearly mated with a four-way distribution block Fig 9 shows a fully mated Power Module displaying the alignment of profile features exhibited through the common design concept carried through each component of the system.

Fig 10 shows a one-piece latching mechanism with side buttons. When the buttons are pressed-together in directions 19 the central latch tongue withdraws in direction 20. Releasing the buttons allows the resilient material to recover its original shape and the latch tongue returns to its latched projecting position.

Fig 11 shows an inverted view of the one piece latch Fig 10 located within a housing with other parts removed to reveal the positioning of the latch with guide pins 21. Registration and location are provided by the button and latch holes in the housing and the guide pins 21.

Fig 12 shows a cover 22 being apped to a populated socket strip 23 in dftection 24.

Fig 13 shows cover 22 n-situ on a populated socket strip 23 depicting slots 25 providing access for cables 26 Fig 14 shows the position of a mounting screw boss 27 of which there may be one or more located a'ong each side of the illustrated 4-way free socket or other system components thsposed so as to align with other system components when placed in "back to back" 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 face and is also recessed into the side of the unit to allow dose side by side positioning of adjacent system components.

Fig 15 shows a resilient, often elastomeric, link component 31 that may be manuaUy pushed into any unpopulated mounting holes of adjacent system components to provide mechanical registration and interlocking between parallel parts. Deformable gripping ribs 28 are provided to ensure good retention, whi'e upstanding grippable bosses 29 are flush with the top face of the system components when fully pressed home into their intended mounting position.

Fig 16 shows a pair of socket strips connected together back to back with a link component depicted in Fig 15, showing the flush face mounting of the top face of boss 29.

Fig 17 shows an exploded view of two back to back oriented 4-way distribution blocks 30, two link components 31, a dual width power feed module that links the dog-leg ends of the 4-way distribution blocks and a second dog-leg adapter 32 that provides electrical connectivity through to the second module. Note that by feeding the assemblage from the female socket electrical connectors in the power-feed module, the subsequent 4-way distribution block then mates to this with pins and presents power to its opposite end that then presents intrinsically safe power sockets that may be shrouded or preferably shuttered, for connection to the adapter 32. Again, this adapter has electrical connection pins that mate into the powered 4-way distribution block and at the other end presents a set of intrinsically safe sockets that feed the second 4-way distribution block in the same manner as the first module is powered.

Finally, the socketed end of the second 4-way distribution block is plugged into the power feed module. NB. 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 facitate this action.

The interlocking nk parts may then be pushed into the central, adjoining holes for added security.

Fig 18 shows a fully assembled set of components comprising two 4-way socket modules 30, two link parts 31, a dog-leg power feed module 32 and dog-leg joining part 33. This assembly may be screwed down to a wall or bench or used as a free trailing assembly Fig 19 shows a foot component manufactured from an elastomeric material with a shank feature provided with deformable ribs 34 and a pointed end feature 35. This may be typically manufactured from Viton or other synthetic rubber type often with a Shore A hardness in the range of 40 to 80 and preferably of a Shore A 60 grade material.

Fig 20 shows an inverted view of three of the foot components depicted in Fig 19 inserted into of a 4-way distribution block and one foot component about to be inserted in the direction of arrow 36. The ribs provide a gripping function in the unused screw-mounting bosses with the user hand push-fitting the foot in place. The conical head feature of the foot 35 provides a broader flanged end to limit insertion and a point that when the assembly is oriented normally allows the weight of the 4-way 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 we as engaging in tufted pe or woven materials such as carpets to retain the distribution block or other so-fitted system component.

Figure 21 shows a 3/4 view of a power feeder unit 31 plugged into a 4-Way distribution block 30 with a second 4-way distribution block 30a plugged onto the end of the first unit to provide 8 accessible mains sockets in a linear arrangement.

Examples

Components of the system mate together both mechanically and electrically, employing separate mechanical features to provide each function and this provides rugged connection through interlocking conical turrets and recesses which separate mechanical stresses from the electrica' connection pins and sockets during everyday use.

A latching mechanism is provided to retain system components together that in the preferred embodiment may be manually un'atched through the action of side buttons requiring the grip between typically the thumb and first finger of one hand.

A preferred embodiment employs a one-piece deformable latch, so formed as to limit the number of components employed, reduce cost and size of parts and maintain a compact product profile with minimal unnecessary wasted space, a'though other forms of latch may be envisaged and applied providing they provide easy engagement and disengagement of the system components.

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 at no time are live pins presented to the user. This is effected by having all unused available power positions as female sockets whilst the mating parts that provide power continuity into a module are male pins.

Several embodiment forms may be envisaged for the socket and pin arrangement with the preferred embodiment using vertically arranged pins and sockets disposed in the same plane as the provided mains outlets whilst the modules within the system are arrayed at right angles to the pin and socket p'ane and disposed at one end of a feed or termination module or at both ends of an in-line module. In the preferred embodiment, the pin and socket forms may follow conventional UK mains plug and socket dimension and shape conventions to easily meet UK technical and approvals requirements, however, as these are signiflcanty larger than is deemed strictly necessary, particularly by non-UK approvals boards and mains interconnect design requirements, smaller pins and sockets may easily be accommodated without compromising functionality or statutory regulations for these components.

Mechanical strength is imparted to any arrangement of system components by several features of the design.

One feature providing mechanical strength is an overlapping stepped mating feature asymmetrically placed at each end of an in-line module or employing only the opposite mating feature in a single-ended, non extendable module, wherein are located the pins and sockets normally used for electrical connection, although in some components these may be insulated or electrically unconnected pins for reasons of safety.

A second feature providing mechanical strength is a pair of conical tapered turrets located on one system component and cooperating with conical tapered female recesses in the mating component, both physically disposed toward the outer side edges of the mating system components.

By provision of a conical form, when at the initiation of mating during user assembly of two system components, there is initially a large clearance between male and female turret features, allowing early angular and positional misalignment, with the parts being progressively drawn together until tightly constrained when fully mated. In the mid-mate condition the electrical connection pins and sockets are thus essentially aligned to allow easy initiation of insertion of these parts. The mating turrets engage before the electrical connections and thus provide a secondary function of alignment for simple assembly by the user.

The third mechanical strengthening feature is a latch connecting between mating system components. In the preferred embodiment this is spring-loaded such that it engages automatically upon mating of any pair of system components and ensures that the conical mating turrets and most importantly the electrical connections cannot become inadvertently separated. A preferred location is in the vertical face of abutting system components to provide a arge width of latch feature to ensure strength of the parts and resufting atching function.

In the preferred embodiment the latch is manuaUy operable for disengagement of system components and may be of one-piece design as described elsewhere and in the Description of Figures.

A typical minimal system wiU consist of a Power Feed Module connected to a 4-way distribution block as depicted in the Figures, afthough any number of sockets may be incorporated in a single distribution block, 4 and 6-way versions are expected to provide good commercial potential.

ft not screwed-down in position but left trailing, the system may be kept in position by use of inserted conical rubber feet as is also described in the Figures, with sub populations in excess of four feet, one disposed in each corner of the system, being the expected normal minimal configuration.

Screw mounting bosses may be provided on any system module that extends beyond pin and socket-mounting steps described elsewhere and 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.

When extending the 4-Way or other population distribution block or other system components the option is provided to connect additional modules in a linear direction to make the system long and narrow for typical location along a skirting board or bench, or in a parallel configuration back-to-back to reduce length and increase width where this fits better into the users intended location for the system.

Other expected system components that provide additiona' functiona'ity are described b&ow, but the system may expand to indude many other extant or yet to be invented features as are deemed useful in a trailing socket mains distribution app'ication: A multiway distribution block fitted with individua'ly switched outlets A multiway distribution block fitted with a single switch for all outlets A mutiway distribution b'ock incorporating a sing'e or individual eectrica noise fiRers as typicay emp'oyed to provide dean" power to PCs and other sensitive electronic equipment A power feed module with Power ON/OFF switch to aU seria'ly connected ouflets A power feed or in-tine modu'e with an ELCB to protect against earth leakage/shock protection to aU system components and devices connected to them A power feed module hard wired to a free cable acting as the primary unit within a system with or without an ELCB or other control device and provided with one or more socket ouliets A programmable module that is a'so a power feed module or an in-line Module that controls the ON/OFF timings of all subsequent system modules and loads applied A power feed or in-line module containing a power monitor An automatic or manually controlled master standby-saver module that reacts to a reduction in power consumption via one designated socket outlet to turn off others in the serial chain or is controUable by remote control through RFID, Wireless, infra-red or other means to allow remote control over the master device driving one or more subsequent system components or power outlets to respond A dedicated AC or DC ouflet module that provides multiple low voltage power outlets for such items as USB hard disk drives, mobile phone chargers, rechargeable wireless PC mice and other pointing 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 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 -often employing some control over the charging function A dog-'eg power feed module with adjacent sockets and pins provided with associated mechanical step, turret and latch features that allows connection of two parallel system components back-to-back. For safety reasons the presented pins in this device will be insulated or unpowered.

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 a powered module to a parallel adjacent module.

Any of the above modules fitted with a display device employing an LED, Neon CFL, EL, LCD or other display technology to provide ONJOFF status, process nformaton or other data useful to the user A cover unit that fits over a single or multiple arrangement of modules providing cable exits whilst preventing dust accumulating on the system components so-covered. In the simplest embodiment this may be effected from an opaque material often injection moulded to form and provided with a simple latching function.

A cover as described above but transparent or partially transparent to allow visual access to any displays within the system A cover that provides locations for user marking of populated sockets or for other purposes either by writing directly on a section of the cover in a specified and pre-prepared area or by fitment of pre-printed or write-on labels, adhesive, slide-in or otherwise retained Cams

Claims (9)

1. An electrical socket bbck comprises; a body with a cable and at least one socket for receiving a plug, the socket block has mechanical and electrical connectors which are adapted to inter-engage with mechanical and electrical connectors of a second socket block, so as simultaneously to connect the first and second socket blocks mechanicaUy, one to another, and define an electrical path from the first socket block to the second socket block; wherein the mechanical and electrical connectors are defined by turrets, extending generay at right angles from the body of the first socket block to be received by shaped recesses, defined in the body of the second socket block.

2. An electrical socket block according to claim 1 wherein the mechanical connector has a latch preventing inadvertent separation of the socket blocks.

3. An electrical socket block according to claim 2 wherein the latch is a manually releasable latch.

4. An electrical socket block according to claim 2 or 3 wherein the latch includes a resiliently deformable latch.

5. An electrical socket block according to any of claims 2 to 4, wherein the latch includes an arrow head resiliently deformable member, such that when located in a housing, simultaneous compression of both tips of the arrow head member causes a latch tongue to withdraw into a recess defined in a housing so as to permit previously latched parts to be unlatched.

6. An electrical socket block according to any preceding claim wherein the turrets are tapered and the recesses are tapered.

7. An electrical socket block according to claim 6 wherein the tapered male turrets are located at a at first end of the block and recesses are located at a second end of a second block.

8. An electrical socket block according to any preceding daim includes a safety fitting which is adapted to ensure correct orientation of the blocks so that, in use, an earth terminal of the first block connects to an earth terminal of the second block, a live terminal of the first block connects to a live terminal of the second block and a neutral terminal of the first block connects to a neutral terminal of the second block.

9. An electrical socket block according to any preceding claim includes a dedicated power supply.lOAn electrical socket block according to any preceding claim includes a switch that is activated by a user to switch current from the first block to the second block, following interconnection of the blocks.11.An electrical socket block according claim 10 wherein the switch is located beneath a cover.12.An electrical socket block according to any preceding claim includes a An electrical socket block according to any preceding claim includes an opaque or translucent cover component provided with side slots such that when clipped over a populated or part populated socket block or other modules, allows a cable that is fitted to an appliance to exit via said slot.13. An electrical socket block according to claim 13 includes a window.14.A removable link component that fits into mounting holes otherwise normally used for screws or other fasteners that comprises of interlinked resilient plastic parallel cylinders with peg features that may be inserted manually from the normally top face of a pair or more of parallel system components as described in the previous claims.The link component pegs are retained by deformable ribs and the top face of the component is designed to fit flush with the normal top face of the described system components such that insertion of a plug is still possible and in event of an overlap if the p'ug housing and the link component, this prevents the link part from being removed.15.A dogleg staggered component to the system described in the other claims providing, with an incoming mains feed power cable, power via female electrical socket connectivity to the first unit in the chain with a dummy set of unpowered pins adjacent to them to provide added rigidity to a fully assembled suite of parts.16. A similar set of body shell mouldings or major component parts described in C'aim may be employed without the mains power feed cable, but in this component al pins are electrically connected to permit power transfer to second, reversed orientation 4-way mains socket module or other similarly sized system component mounted in paralleL 17.A removable foot components manufactured from a resilient material, typically an elastomer or rubber type material such as Viton, typically with a Shore A hardness often in the range of Shore A 40 to Shore A 80 but often Shore A 60 and provided with annular ribs to provide grip such that it may be inserted into an unused screw mounting hole from the normal underside of a system component described in previous claims. The foot feature comprises a conical shape that concentrates weight at the tip such that it prevents slippage of the main component so-fitted when located on a smooth surface and engages with the pile of a carpet to prevent movement if so located.