A SYSTEM FOR COUPLING A DEVICE TO AN ELECTRICAL SUPPLY

Field

One aspect of the present invention relates to a system for coupling a device to an electrical supply, and in one illustrative arrangement such a system comprises an electrical plug (for example an electrical plug of the type disclosed herein), a cable and a cover.

Another aspect of the present invention relates to electrical plugs, particularly but not exclusively to reconfigurable electrical plugs that can be manipulated between a smaller storage configuration and a larger in-use configuration.

Yet another aspect of the present invention relates to a method of manufacturing an electrical plug- particularly, but not exclusively, to a method of manufacturing a three- pin electrical plug for coupling electrical appliances to a source of electrical power Background

A first aspect of the present invention is concerned with issues surrounding the fact that it is commonplace nowadays for users to travel with a number of different portable devices, and in many instances these devices each require a separate charger and in some cases bespoke cables for coupling those devices together. For example, a user who is travelling with an iPod™ or iPhone™ and a computer, such as a MacBook Air™, may also carry a charger for that computer, a cable for coupling their iPod™ or iPhone™ to the computer, and a plug that they can plug the cable into in situations where they wish to charge their iPod™ or iPhone™ directly from the mains (and not from their computer). Typically users will carry all these items around in a bag, and if the cables are not tidied away when they are put into the bag they can easily be jumbled up, whereupon it can be difficult and time consuming for the user to subsequently take out the right cable for the particular task in hand.

It is also generally the case that electronic devices tend to steadily decrease in size as technology progresses. For example, portable computers from a few years ago tended to be an inch or more in thickness, whereas newer portable computers are significantly thinner. In fact, with the advent of the MacBook Air™ and iPad™, it is now possible for consumers to purchase portable computers that are significantly less than an inch thick.

However, whilst devices such as computers have decreased in size, the electrical plugs that are typically provided as part of the power supply for such computers have changed little in size over the years. The ultimate illustration of this is the three-pin plug that is used in countries such as the UK (inter alia). This plug is roughly 1.75 inches thick at its thickest point (from the rear of the plug to the tip of the earth pin), or in other words three times thicker than an iPad™, for example.

Clearly it would be advantageous if the thickness of such plugs could be reduced, and one aspect of the present invention seeks to address this problem.

Another aspect of the present invention is concerned with the issue that a traditional three-pin plug, for example, carried in a bag with an electronic device may knock against that device and damage it. A particular concern is that the plug may rub against and scratch the screen of that device. It would be advantageous, therefore, if a means could be devised to reduce the chance of a plug inadvertently scratching a computer or other device whilst the plug and computer, for example, are being carried together by a user, for example in a bag.

Yet another aspect of the present invention seeks to provide simple and cost- effective methods for assembling plugs, in particular foldable plugs - for example of the type described in UK patent no. 2467644 (the entire contents of which are incorporated herein by reference).

The plugs disclosed in this patent can readily be reconfigured between smaller storage configurations and larger in-use configurations.

It is anticipated that such plugs will be popular with consumers, and the extent of their popularity will depend to a greater or lesser extent on the retail cost of the plugs. One important factor that will affect the retail cost of the plugs is the ease with which they can be manufactured, and one aspect of the present invention seeks to provide a simple and cost-effective method for assembling plugs, in particular foldable plugs - for example of the type described in the aforementioned granted UK patent (the entire contents of which are incorporated herein by reference).

Summary

One aspect of the present invention provides a system for coupling an electrical device to an electrical supply, the system comprising: an electrical plug having a plurality of electrical pins, a cable having a first end that is connectable to the plug and a second end that is connectable to an electrical device to which electricity is to be supplied; and a cover that defines an internal void for storage of the cable when the cable is not connected to the plug, the cover being configured for coupling to the plug.

In one implementation the plug further comprises a plug main body, and first and second wings coupled to said body so that the wings can pivot relative to said body from a storage position where the wings are generally linearly aligned with the plug, to a deployed position where the wings are generally perpendicular to the plug.

In an envisaged arrangement, the cover may be configured to be coupled to the plug when the wings are in the storage position. The electrical pins may be wholly enclosed when the cover is coupled to the plug. The cover may cooperate with the wings to wholly enclose the electrical pins.

Preferably the cable is located between the plug and the cover when the cable is not in use and the cover is fitted to the plug. The cover and plug may cooperate to enclose the cable in said void.

The cable may be provided with a first connector or socket at its first end and the plug may have a complementary socket or connector respectively.

Preferably the cable has a second connector or socket at its second end.

The first and second connectors or sockets may be of the same kind, or different kinds, of connectors and sockets respectively.

Preferably, at least one of the first and second connectors or sockets is a USB type connector or socket respectively.

Another aspect of the invention relates to a method of manufacturing an electrical plug, the method comprising: providing an arm having a first face and a second face, the first face having a pair of electrical pins extending generally in parallel therefrom, and the second face having first and second electrical contacts, the electrical contacts each being coupled to the respective electrical pins; providing a chassis and fitting first and second electrical connectors thereinto; fitting the arm to the chassis so that the electrical pins extend outwardly from the chassis, and so that the arm can rotate between a stowed position in which the arm is generally linearly aligned with the chassis and an operative position in which the arm is generally perpendicular to the chassis; coupling the first and second electrical contacts to the first and second electrical connectors in the chassis respectively; and fitting a cover to the chassis.

The first and second electrical connectors may comprise part of a printed circuit board, and the step of fitting the first and second electrical connectors to the chassis may include fitting the circuit board to the chassis.

Preferably, the first and second electrical contacts are coupled to the first and second electrical connectors in the chassis via first and second electrical cables respectively.

The method may comprise the steps of: mounting first and second electrical contact connectors to the arm or the chassis and coupling them to the first and second electrical contacts, or the first and second electrical connectors respectively; and

mounting first and second electrical connector pins to the other of the chassis and the arm and coupling them to the first and second electrical connectors, or the first and second electrical contacts respectively; wherein

the electrical contact connectors are configured to engage the first and second electrical connector pins respectively when the arm is fitted to the chassis, thereby coupling the first and second electrical contacts to the first and second electrical connectors in the chassis respectively.

Preferably the first and second electrical connector pins or the first and second electrical contact connectors are coupled to the first and second electrical connectors, or the first and second electrical contacts, via first and second electrical conduits respectively.

The first and second electrical connectors may be fitted in a recess defined by the chassis.

The first electrical connector may comprise a first fuse connector and a second fuse connector engageable with respective ends of a fuse.

The method may comprise the step of mounting a fuse carrier to the chassis. The cover may be welded to the chassis.

The method may comprise the steps of: mounting a third electrical pin to the chassis; and coupling a third electrical connector to the third electrical pin.

The chassis may be provided with an electrically insulating fixed pin extending therefrom.

The electrical connectors fitted within the chassis may partially project from within the chassis.

The method may comprise the step of coupling the electrical connectors to respective electrical conductors of an electrical supply line.

The method may comprise the step of providing an electrically insulating layer over at least part of the electrical plug. The electrically insulating layer may be provided over at least part of the electrical supply line.

The method may comprise the step of coupling first and second wings to the chassis so that the wings can pivot relative thereto from a first position where the arm and the wings are generally linearly aligned with the chassis, to a second position where the arm and wings are generally perpendicular to the chassis. The wings may at least partially cover the electrical pins when in the first position. The arm and chassis may be snap-fitted in rotatable connection to each other.

The arm may be rotatably fitted to the chassis by inserting a peg protruding from the arm or the chassis through a receiving aperture in the other of the arm and the chassis, and inserting a circlip into a circumferential groove in the peg.

The arm or the chassis may be provided with a clip and a receiving aperture, and the arm may be rotatably fitted to the chassis by inserting a peg, protruding from the other of the arm and the chassis, through the receiving aperture into engagement with the clip. The clip may engage a circumferential groove in the peg.

The arm and chassis may further comprise respective parts of a two-part rotation limiting mechanism configured to limit rotation of the arm relative to the chassis.

Another aspect of the invention provides an electrical plug comprising: a chassis; and an arm having first and second electrical pins extending from a face thereof, the arm being coupled to the chassis by means of a push-fit coupling mechanism that retains the arm on the chassis and allows the arm to rotate relative to the chassis between a first position where the arm is generally linearly aligned with the chassis and a second position where the arm is generally perpendicular to the chassis, the arm and chassis further comprising respective parts of a two-part rotation limiting mechanism configured to limit relative rotation of the arm and chassis.

The arm and chassis may comprise respective parts of a two-part snap-fit mechanism, the arm and chassis being snap-fitted in rotatable connection to each other.

The arm or the chassis may comprise a plurality of outwardly barbed tabs which protrude into an opening in the other of the arm and the chassis.

The arm or the chassis may comprise a peg with an enlarged end portion, and the peg extends through a deformable peg receiving portion adjacent an opening in the other of the chassis and the arm.

The arm or the chassis may define a cavity and is provided with a clip therewithin and an opening extending thereinto; and the other of the arm and the chassis may comprise a peg protruding therefrom; wherein the peg extends through the opening into engagement with the clip.

The arm and chassis may further comprise respective parts of a two-part rotation limiting mechanism configured to limit rotation of the arm relative to the chassis.

Another aspect of the invention relates to an electrical plug that comprises: a chassis into which first and second electrical connectors have been fitted; an arm fitted to the chassis, the arm having a first face with a pair of electrical pins extending generally in parallel therefrom, and a second face having a pair of electrical contacts which are coupled to the respective electrical pins and to the first and second electrical connectors in the chassis respectively; and a cover fitted to the chassis; wherein: the arm is fitted to the chassis so that the electrical pins extend outwardly from the chassis, and so that the arm can rotate between a stowed position in which the arm is generally linearly aligned with the chassis and an operative position in which the arm is generally perpendicular to the chassis.

The first and second electrical connectors may comprise part of a printed circuit board which has been fitted to the chassis.

The electrical plug may comprise first and second electrical conduits for coupling the first and second electrical contacts to the first and second electrical connectors in the chassis respectively.

The electrical plug may comprise first and second electrical contact connectors mounted to the arm or to the chassis which are coupled to the first and second electrical contacts, or the first and second electrical connectors respectively; and first and second electrical connector pins mounted to the other of the chassis and the arm which are coupled to the first and second electrical connectors, or the first and second electrical contacts respectively; wherein: the electrical contact connectors engage the first and second electrical connector pins respectively, thereby coupling the first and second electrical contacts to the first and second electrical connectors respectively.

Preferably the first and second electrical connector pins or the first and second electrical contact connectors, are coupled to the first and second electrical connectors, or the first and second electrical contacts, via first and second electrical conduits respectively.

The electrical contact connectors may be at least partially mounted within, and the electrical connector pins may extend into, the space between a peg and a retention flange which may both extend from the arm or the chassis.

The retention flange may comprise two slots through which the first and second electrical contact connectors respectively extend.

In one implementation, the arm or the chassis may have a peg extending therefrom which defines an opening; an exterior and an interior surface of the peg may comprise first and second electrically conducting portions respectively, which are in connection with the respective electrical pins on the arm, or the respective electrical connectors within the chassis; the other of the chassis and the arm may have a receiving flange and pin, which are in connection with the respective electrical connectors within the chassis, or the respective electrical pins on the arm; and the first and second electrically conducting portions on the peg may engage the receiving flange and peg respectively, thereby connecting the electrical pins to the respective electrical connectors.

The arm and chassis may further comprise respective parts of a two-part rotation limiting mechanism configured to limit rotation of the arm relative to the chassis.

The chassis and arm may comprise a plurality of tabs and limiting flanges respectively, which are brought into engagement when the arm and chassis are at first and second rotational positions relative to one another.

The first and second electrical connectors may be fitted in a recess defined by the chassis.

The first electrical connector may comprise a first fuse connector and a second fuse connector engageable with respective ends of a fuse.

The electrical plug may comprise a fuse carrier fitted to the chassis.

The cover may be welded to the chassis.

The electrical plug may comprise a third electrical pin mounted to the chassis; and a third electrical connector coupled to the third electrical pin.

The chassis may have an electrically insulating fixed pin extending therefrom. The electrical connectors fitted within the chassis may partially project from within the chassis.

The electrical plug may comprise a plurality of electrical conductors of an electrical supply line each respectively coupled to the electrical connectors comprising the plug.

The electrical plug may comprise an electrically insulating layer provided over at least part of the electrical plug. The electrically insulating layer may be provided over at least part of the electrical supply line.

The electrical plug may comprise first and second wings coupled to the chassis so that the wings can pivot relative thereto from a first position where the arm and the wings are generally linearly aligned with the chassis, to a second position where the arm and wings are generally perpendicular to the chassis.

In an envisaged implementation the wings may at least partially cover the electrical pins when in the first position.

The arm or the chassis may comprise a plurality of outwardly barbed tabs which protrude into an opening in the other of the arm and the chassis.

The arm or the chassis may comprise a peg with an enlarged end portion, and the peg may extend through a deformable peg receiving portion adjacent an opening in the other of the chassis and the arm. The arm or the chassis may comprise a peg protruding therefrom and the other of the arm and the chassis may define a receiving aperture, wherein the peg extends through the receiving aperture and has a circlip fitted into a circumferential groove therein.

In one envisaged arrangement the arm and chassis may each carry complementary parts of an interengagement mechanism, for example a two-part interengagement mechanism.

The arm or the chassis may define a cavity and comprise a clip therewithin and an opening extending thereinto; and the other of the arm and the chassis may comprise a peg protruding therefrom; wherein the peg extends through the opening into engagement with the clip. The clip may engage a circumferential groove in the peg.

Another envisaged implementation of the teachings of the invention provides a component for an electrical plug, the component comprising:

an arm having first and second electrical pins extending from a face thereof, the arm being capable of being coupled to a chassis by means of a coupling mechanism that retains the arm on the chassis whilst allowing the arm to rotate relative to the chassis between a first position where the arm is generally linearly aligned with the chassis and a second position where the arm is generally perpendicular to the chassis.

In a preferred implementation, the arm and chassis further comprise respective parts of a two-part rotation limiting mechanism that is operable to limit relative rotation of the arm and chassis.

The arm and chassis may comprise respective parts of a two-part snap-fit mechanism, the arm and chassis being snap-fitted in rotatable connection to each other. For example, the arm or the chassis may comprise a plurality of outwardly barbed tabs which protrude into an opening in the other of the arm and the chassis.

In another implementation, the arm or the chassis may comprise a peg with an enlarged end portion, the peg extending through a deformable peg receiving portion adjacent an opening in the other of the chassis and the arm.

In a particularly preferred implementation, the arm or the chassis defines a cavity and is provided with a clip therewithin and an opening extending thereinto; and the other of the arm and the chassis comprises a peg protruding therefrom; wherein the peg extends through the opening into engagement with the clip.

In general terms, in accordance with another aspect of the invention, protection is claimed for any of the features herein disclosed, in isolation or in combination. A particularly preferred implementation provides an arm for a foldable electrical plug, the arm comprising a first part of a two-part coupling mechanism, a second part of said mechanism being carried by another part of said foldable electrical plug, wherein said coupling mechanism is configured to couple the arm to said other part whilst permitting said arm to rotate relative thereto..

In this implementation, the arm may further comprise a first part of a two-part rotation limiting mechanism that operates to limit the extent to which the arm may be rotated relative to said other part of said plug.

In another arrangement, the teachings of the invention provide a method of manufacturing an electrical plug, the method comprising: providing an arm having a first face and a second face, the first face having a pair of electrical pins extending generally in parallel therefrom, and the second face having first and second electrical contacts, the electrical contacts each being coupled to the respective electrical pins; providing a chassis and fitting first and second electrical connectors thereto; fitting the arm to the chassis so that the electrical pins extend outwardly from the chassis, and so that the arm can rotate between a stowed position in which the arm is generally linearly aligned with the chassis and an operative position in which the arm is generally perpendicular to the chassis; coupling the first and second electrical contacts to the first and second electrical connectors in the chassis respectively; and fitting a cover to the chassis.

In an envisaged arrangement, fitting the arm to the chassis causes the first and second electrical contacts to couple to the first and second electrical connectors.

The chassis may comprise multiple chassis portions.

The step of providing a chassis may comprise coupling said multiple chassis portions together to form said chassis.

The step of fitting first and second electrical connectors to said chassis may comprise fitting electrical connectors to one or more of said chassis portions.

In another illustrative implementation of the teachings of the invention, there is provided an electrical plug comprising: first and second chassis parts fittable together to form a chassis, one said part functioning as a carrier for a plurality of electrical connectors, and the other said part functioning as a carrier for a first part of a two-part arm engagement mechanism; an arm having a face from which first and second electrical pins extend generally in parallel, said arm further comprising first and second electrical connectors coupled to respective electrical pins, and a second part of said two- part arm engagement mechanism; and first and second wings that are capable of being coupled to said chassis so that the wings are moveable from a first position where the wings are generally parallel to said chassis and a second position where the wings extend generally perpendicularly to said chassis; wherein the two-part arm engagement mechanism is configured to enable said arm to rotate relative to said chassis in a plane that is generally orthogonal to said chassis; and the arm and chassis are configured so that the electrical connectors coupled to said electrical pins electrically connect with the electrical connectors in said one chassis part when the arm is coupled to the chassis by means of said two-part arm engagement mechanism.

In one envisaged arrangement, said one chassis part is configured to support said electrical connectors in a predetermined configuration.

One part of said two-part arm engagement mechanism may comprise a cylindrical rod having an enlarged head, and the other part of said two-part arm engagement mechanism may comprise a socket configured to receive said rod.

At least part of said socket may be resiliently outwardly deformable to allow said enlarged head to pass therethrough. The resiliently outwardly deformable portion of said socket may be configured to snap behind said enlarged head to retain said rod in said socket.

At least said enlarged head of said rod may beresiliently inwardly deformable to allow said enlarged head to pass through said socket. The resiliently inwardly deformable portion of said rod may be configured to snap over a part of said socket to retain said rod therein.

In one implementation said rod extends from a face of said arm, and said socket is carried by said second chassis part.

Another aspect relates to a method of manufacturing an arm which is configured to be pivotally connected to the chassis of an electrical plug, the method comprising the steps of: providing an electrical pin; forming an arm body around a part of the electrical pin; coupling an electrical conductor to the pin; and covering at least part of the arm body and at least part of the electrical conductor.

Yet another aspect relates to a method of manufacturing an arm which is configured to be pivotally connected to the chassis of an electrical plug, the method comprising the steps of: providing an electrical pin; coupling an electrical conductor to the pin to form a conductor/pin assembly; coupling the conductor/pin assembly to an arm body; and covering at least part of the arm body and at least part of the electrical conductor.

Other features, advantages and objects of the invention will be apparent from the detailed description provided hereafter.

Brief Description of the Drawings

Various aspects of the teachings of the present invention, and arrangements embodying those teachings, will hereafter be described by way of illustrative example with reference to the accompanying drawings, in which:

Fig. 1 is a front perspective view of a plug embodying the teachings of the invention when in a stowed configuration;

Fig. 2 is a front perspective view of the plug in Fig. 1 in a deployed, in-use, configuration;

Fig. 3 is an exploded view of a component part of the plug shown in Fig. 2;

Fig. 4 is a bottom perspective view of the arm shown in Fig. 3

Fig 4a is schematic perspective view of another arm configuration;

Fig. 5 is a another bottom perspective view of the arm in Fig. 3;

Fig. 6 is a side perspective view of a chassis and an earth pin before the earth pin is mounted in the chassis;

Fig. 7 is a side perspective view of the chassis and earth pin of Fig. 6 after the earth pin has been mounted in the chassis;

Fig. 8 is a side perspective view of the arrangement in Fig. 7 before a first fuse connector is mounted in the chassis;

Fig. 9 is a side perspective view of the arrangement in Fig. 8 after the first fuse connector has been mounted in the chassis;

Fig. 10 is a side perspective view of the arrangement in Fig. 1 1 before a second fuse connector and a neutral connector are mounted in the chassis;

Fig. 11 is a side perspective view of the arrangement in Fig. 10 after the second fuse connector and the neutral connector have been mounted in the chassis;

Fig. 12 is a side perspective view of the arrangement in Fig. 1 1 before a fuse carrier and fuse are mounted in the chassis;

Fig. 13 is a side perspective view of the arrangement in Fig. 14 after the fuse carrier has been mounted in the chassis, but before an arm - for example of the type shown in Fig. 5 - has been mounted in the chassis;

Fig. 14 is a side perspective view of the arrangement in Fig. 13 after the arm has been mounted in the chassis;

Fig. 15 is a topside perspective view of the chassis in Fig. 14;

Fig. 16 is a side perspective view of the arrangement in Fig. 14 before a cover is mounted on the chassis;

Fig. 17 is a side perspective view of the arrangement in Fig. 16 after the cover has been mounted to the chassis, but before an earth connector is coupled to the earth pin;

Fig. 18 is a side perspective view of the arrangement in Fig. 17 after the earth connector has been mounted on the chassis cover; Fig. 19 is a side perspective view of the arrangement in Fig. 18 after the bottom half of the chassis has been over moulded;

Fig. 20 is a side perspective view of the arrangement in Fig. 19 before a pair of wings are mounted to the chassis;

Fig. 21 is a front elevation of the electrical components of a plug of the type shown in Figs. 1 & 2;

Fig. 22 is a rear elevation of the electrical components shown in Fig. 21 ;

Fig. 23 is a topside perspective view of another arm receiving aperture;

Fig. 24 is an underside perspective view of the arm receiving aperture in Fig. 23;

Fig. 25 is a cross-sectional view of the arm receiving aperture in Fig. 23;

Fig. 26 is a perspective view of an another illustrative arm configuration;

Fig. 27 is a perspective view of the arrangement in Fig. 26;

Fig. 28 is a rear plan view of the arm in Fig. 26;

Fig. 29 is a side schematic view of another arm;

Fig. 30 is a rear perspective view of the arm of Fig. 29 after it has been received in the arm receiving aperture;

Fig 31 is a perspective view of another arm and complementary connector;

Fig. 32 is a perspective view of another arm and cooperating circlip;

Fig 33 is a perspective view of another arrangement;

Fig. 34 is a rear exploded view of a USB power plug;

Fig. 35 is a front exploded view of the USB power plug in Fig. 34;

Fig. 36 is a front partially exploded view of a USB power plug;

Fig. 37 is a rear partially exploded view of the USB power plug of Fig 36;

Fig. 38 is a rear exploded view of part a USB power plug;

Fig. 39 is a front partially exploded view of a USB power plug;

Fig. 40 is a rear perspective view of a USB power plug into which a USB connector cable has been plugged;

Fig. 41 is a front perspective view of the USB power plug in Fig. 40 when in a stowed configuration;

Fig. 42 is a perspective view of a cable housing;

Fig. 43 is a perspective view of an assembled system for coupling an electrical device to an electrical supply;

Fig. 44 is a perspective view of another arm arrangement;

Fig. 45 is a perspective view of connector configured to co-operate with the arm of Fig. 44;

Fig. 46 is an exploded view of another arrangement; Fig 47 is a first perspective view of the arrangement in Fig. 46 in assembled form;

Fig. 48 is a second perspective view of the arrangement in Fig. 46;

Fig. 49 is an exploded perspective view of the components of a foldable plug; Fig. 50 is an exploded view of the components to be assembled in a first step of an illustrative plug manufacturing process;

Fig. 51 is a perspective view of the components shown in Fig. 50 when assembled together;

Fig. 52 is an exploded view of the components to be assembled in a second step of an illustrative plug manufacturing process;

Fig. 53 is a perspective view of the components shown in Fig. 50 when assembled together;

Figs. 54 and 55 depict, schematically, the assembly of the components shown in Figs. 51 and 53;

Fig. 56 is a schematic perspective view of a finished plug;

Figs. 57(a) to 57(d) depict, schematically, an illustrative process for manufacturing a pivot arm for use in a foldable plug, for example the plug of Fig. 56;

Figs. 58(a) to 58(d) depict, schematically, another illustrative process for manufacturing a pivot arm for use in a foldable plug, for example the plug of Fig. 56; and Figs. 59(a) to 59(d) depict, schematically, yet another illustrative process for manufacturing a pivot arm for use in a foldable plug, for example the plug of Fig. 56.

Detailed Description

Illustrative implementations of the teachings of the invention will now be described with particular reference to a three-pin electrical plug of the type that is commonly found in the United Kingdom. However, it should be remembered that this particular implementation is merely illustrative, and that the teachings of the present invention may equally be applied to other types of electrical plugs (for example to other types of three-pin plug or to a two-pin plug, for example of the type commonly found throughout the remainder of Europe) without departing from the spirit and scope of the invention.

With the above proviso in mind, reference will now be made to Figs. 1 & 2 of the accompanying drawings, in which there is depicted an electrical plug 10 having three electrical pins, namely earth 16, live 18, and neutral 20 pins. More specifically, the live and neutral pins 18, 20 are mounted to an arm 14 which is rotatably coupled to the plug body 1 1. In particular, the arm 14 is configured such that it is able to rotate between a stowed position (not visible in Fig. 1) and a deployed position (shown in Fig. 2). The plug 10 also has a pair of wings 12 rotatably coupled to the plug body 1 1. These wings, like the arm 14, are also configured to rotate between a stowed wing position (shown in Fig. 1) where the wings 12 are generally linearly aligned with the plug body and a deployed wing position (shown in Fig. 2) where the wings extend generally perpendicularly from the plug body 1 1.

With reference to Fig. 1 , when the arm 14 is in the stowed position it is generally linearly aligned with the plug body 11 and the electrical pins 16, 18, 20 are generally in alignment with one another. In this configuration the wings 12 are able to rotate relative to the plug body 1 1 to the aforementioned stowed position such that they at least partially cover (and in one envisaged arrangement, wholly cover) the aligned electrical pins 16, 18, 20 and are also generally linearly aligned with the plug body 1 1. In this position the wings provide some protection to the pins 16, 18, 20 when the plug 10 is not in use and also reduce the likelihood of the pins 16, 18, 20 scratching another object, such as the screen of a mobile phone, if the plug 10 should be carried with the phone in a bag when the phone and plug are not in use.

With reference to Fig. 2, when the arm 14 is in the deployed position it is generally perpendicular to the plug body 11 and the electrical pins 16, 18, 20 are not in alignment with each other. In order for the arm 14 to move from the stowed position into the deployed position, the wings 12 are first rotated from the aforementioned stowed wing position so that they move apart to a deployed wing position where the wings are generally perpendicular to the plug body 1 1. In this configuration (i.e. when the arm 14 and wings 12 are each in their respective deployed positions), the plug 10 can be inserted into the openings of a three-pin electrical socket of the kind commonly used throughout the UK.

A method of manufacturing a plug 10 of the kind shown in Figs. 1 & 2 will now be described - although it should again be emphasised that this method is merely illustrative, and that the teachings of the present invention may equally be applied to other types of electrical plugs such as a two-pin plug of the type commonly found throughout the remainder of Europe or other three-pin plugs. It should also be noted that the various steps of the method described hereafter need not necessarily be undertaken in the particular order disclosed herein as many steps can be interchanged with other steps, or indeed omitted altogether.

Fig. 3 shows an arm 14 (of the kind shown in Fig. 2) to which live and neutral electrical pins 18, 20 can be mounted. The electrical pins 18, 20 can, in turn, be coupled to respective electrical cables 22, 24 once the pins have been mounted in the arm. As shown in Fig. 3, the electrical cables 22, 24 each include an electrical contact 54 that is configured for attachment to a contact portion 50 of each electrical pin 18, 20.

As shown in Fig. 4, the arm 14 is configured to define a recess 26 in its underside (i.e. that side which is closest to the plug body 11 when the arm is coupled thereto), and to define two pin receiving portions 30 that extend from the arm's upper surface (i.e. that surface opposite the underside of the arm).

The pin receiving portions 30 have respective pin receiving apertures 32, and hollow interiors that each open to the recess 26 in the underside of the arm 14. As shown in Fig. 4, the live and neutral electrical pins 18, 20 are inserted into respective pin receiving portions 30 so that the pins each partially extend into the recess 26, whereupon the pins are each coupled to a respective electrical cable 22, 24.

In the context of a UK three-pin plug, each pin receiving aperture 32 has a substantially rectangular cross sectional shape. In other envisaged arrangements the pins may have a different shape (for example, they may be at least partly circular in cross-section), and in such cases the pin receiving apertures 32 will each have a shape that is complementary to that of the pins.

The arm 14 also includes a first part of a two-part coupling mechanism, the plug body including the second part of this two-part coupling mechanism. As will later be described, the first and second parts of the coupling mechanism co-operate to couple the arm 14 to the plug body 1 1.

In this particular arrangement, the first part of the coupling mechanism comprises an attachment member 34 that projects from the recess 26 of the arm 14 and includes, at a point distal from the arm 14, a pair of outwardly barbed tabs 38. In other arrangements a fewer or greater number of barbed tabs 38 may be provided. For example, as shown in Fig. 4a, the attachment member could comprise four outwardly barbed tabs 38.

In this particular implementation (or indeed in other implementations), the attachment member 34 includes two grooves 35 which extend along its major axis on opposite sides thereof. The grooves 35 are configured to at least partially receive and guide (as shown in Fig. 5) a portion of the electrical cables 22, 24 so that at least those portions of the electrical cables 22, 24 are held in a fixed position relative to the arm 14 as it rotates (thereby reducing the likelihood of the electrical cables 22, 24 becoming entangled as the arm 14 rotates relative to the plug body 1 1). In a particularly preferred arrangement the grooves 35 each include a plurality of (optionally, deformable) ribs 40 (shown in Fig. 4) extending along the length of each groove so that the electrical cables 22, 24 are gripped by the attachment member 34. The attachment member 34 also includes a first part 42 of a two-part rotation limiting mechanism that cooperates with a second part of the mechanism (carried by the plug body 11) to restrict the degree to which the arm 14 can rotate relative to the plug body 1 1. In this arrangement, the first part of the rotation limiting mechanism comprises a pair of projections 42 that protrude from opposite sides of the attachment member 34.

After the live and the neutral electrical pins 18, 20 have been inserted into the pin receiving portions 30 of an arm 14, the electrical contacts 54 of the live and neutral electrical cables 22, 24 are connected to respective contact portions 50 of the electrical pins 18, 20 (as shown in Fig. 5). In a preferred implementation the cables are soldered to the pins, but in principle the cables may be joined to the pins by any of a number of known mechanisms.

Once the electrical cables have been coupled to the contact portions 50 of the electrical pins 18, 20, at least part of the cables are each pushed into a respective groove 35 in the attachment member (as shown in Fig. 5). In a particularly preferred arrangement, a single wind is introduced into the electrical cables 22, 24 at a point beyond the attachment member 34. Such a wind allows the electrical cables 22, 24 to be of sufficient length to enable rotation of the arm 14 relative to a plug body 11 whilst reducing the chance of the cables 22, 24 from getting tangled up with one another and restricting such rotational movement.

Once the arm/pin/cable configuration shown in Fig. 5 has been assembled it is then inserted into a chassis 56 (shown in Fig. 6) that comprises part of the plug body 1 1 (as shown in Fig 2). The chassis 56 comprises a first chassis part 53 that is at least partly obscured (and most probably wholly obscured) in the final plug (as shown in Fig. 2), and a second chassis part 52 that is at least partly visible when the plug has been assembled and is in the deployed position ready for use.

With reference to Fig. 6, the first chassis part 53 has a peripheral wall 59 that cooperates with an internal wall 61 to define first and second recesses 63, 62. In an envisaged implementation, the chassis 56 may be formed by means of an injection moulding process.

The second chassis part 52 includes an earth pin receiving aperture 64 that extends through the second chassis part to the first recess 63. An earth electrical pin 16 is inserted into the earth pin receiving aperture 64 and pushed through the second chassis part 52 until a base part of the earth electrical pin 16 is located in the first recess 63 (as shown in Fig. 7).

With reference to Fig. 8, an electrically conducting first fuse connector 68 is also mounted in the chassis 56. In the particular arrangement shown in Fig. 8 the first fuse connector 68 has a (kinked) bent portion 74 part-way along its length. Towards one end of the connector 68 on one side of the bent portion 74 a first pair of wings 72 extend in the same direction from either side of the first fuse connector 68. Towards the other end of the connector 68 on the other side of the bent portion 74 a live cable connector 73 extends from the first fuse connector 68 in the opposite direction to the wings 72. In use, the wings 72 electrically contact a fuse within the plug 10 and the live cable connector 73 is connected to the live pin 18 of such a plug 10 via the live electrical cable 22 (shown in Fig. 5).

As shown in Figs. 9 and 12, the second chassis part 52 includes a fuse carrier opening 104 that extends through the second chassis part 52 and opens at an opening 75 to the second recess 62. The fuse carrier opening 104 is configured (as shown in Fig 12) to accept a fuse carrier 108 and carried fuse 110.

As shown in Figs. 8 and 9, the first fuse connector 68 is mounted in the first chassis part 53 by inserting the first pair of wings 72 into the aforementioned opening 75 and fitting the cable connector 73 of the first fuse connector 68 into a first connector compartment 70 defined by upstanding walls within the second recess 62 of the first chassis part 53.

With reference to Fig. 10, a second fuse connector 76 is also mounted within the chassis 56. In the particular arrangement shown, the second fuse connector 76 comprises a first part 77 that terminates at respective ends in first and second bent portions 80, 82. A second pair of wings 86 extend in the same direction from either side of the first bent portion 80, and a live device connector 84 extends from the second bent portion 82 in an opposing direction to the wings 86.

As in the case of the first fuse connector 68, the second pair of wings 86 are configured to make electrical contact with the fuse 110 within the plug 10 when the fuse carrier 108 and fuse 1 10 are inserted into the fuse carrier opening 104.

A neutral connector 78 is also mounted within the chassis 56, and comprises a (kinked) bent portion 88 part-way along its length. One end of the neutral connector 78 on one side of the bent portion 88 terminates in a neutral cable connector 92 that fits into a second connector compartment 96 (Fig. 11) defined by upstanding walls within the second recess 62 of the first chassis part 53. A neutral device connector 94 extends from the other end of the neutral connector 78 on the other side of the bent portion 88. In use the neutral cable connector 92 is connected to the neutral pin 20 of a plug 10 via the neutral electrical cable 24 (shown in Fig. 5).

The live and the neutral device connectors 84, 94 each respectively comprise, as shown in Fig. 11 , a hook 85, 95 that are each configured to hook over the peripheral wall 59 of the first chassis part 53 and locate behind respective wall tabs 98, 102 when the second fuse connector 76 and the neutral connector 78 are mounted within the chassis 56.

As shown in Fig. 1 1 , when the second fuse connector 76 is mounted within the chassis 56 the aforementioned first part 77 locates in a channel 100 formed between the chassis peripheral wall 59 and the aforementioned connector compartments 70, 96.

Referring now to Fig. 12, once the first and second fuse connectors 68, 76 and the neutral connector 78 have been fitted into the first chassis part 53, a fuse 1 10 is fitted into the fuse carrier 108 and pushed through the second chassis part 52 via the aforementioned fuse carrier opening 104. Once inserted, the fuse 1 10 electrically couples the second pair of wings 86 to the first pair of wings 72, and in a preferred arrangement the wing pairs are configured to securely hold the fuse in the plug once the fuse has been inserted.

The second part of the chassis 52 also includes a pair of wing mounts 1 14 (only one of which is visible), one mount being provided at either end of the chassis. Each wing mount 1 14 comprises a generally circular projection that has a central depression, and the wing mounts 1 14 are configured so that a pair of wings 12 may be rotatably coupled to the chassis 56 (as shown in Figs. 1 & 2).

Once the electrical connectors 68, 76, 78 and the fuse carrier 108 have been inserted into the chassis, the next step in the assembly process is to couple the assembled arm 14 (shown in Fig. 5) to the chassis 56 in such a way that the arm 14 can be rotated relative to the chassis.

To couple the assembled arm to the chassis, free ends of the live and neutral cables are first inserted into an arm receiving aperture 116 in the second chassis part 52 (see Fig. 13), which arm receiving aperture 1 16 extends through the second chassis part 52 and opens to the second recess 62. Next, the aforementioned attachment member 34 is pushed into the arm receiving aperture, whereupon the barbed tabs 38 bear against the periphery of the arm receiving aperture 1 16 and resiliently flex in an inward direction to enable the attachment member 34 (whose diameter is slightly smaller than that of the arm receiving aperture) to pass into and through the second chassis part 52.

As will be appreciated, once the barbs of the tabs have passed through the second chassis part 52 and into the second recess 62, the tabs move outwardly to their original position whereupon the barbs will bear on the underside of the arm 14 in the event that an attempt should be made to decouple the arm 14 from the second chassis part 52. In effect, the barbed tabs form the first part of the aforementioned two-part coupling mechanism, and the second chassis part 52 forms the second part of the aforementioned two-part coupling mechanism.

Referring now to Fig. 15, in an envisaged implementation the arm receiving aperture 1 16 comprises a pair of ledges 1 18 that increase the diameter of the aperture 1 16 compared with a narrower portion 120 of the aperture that extends through the second chassis part 52. The ledges 1 18 are separated from one another by two projections 122 which are, in the preferred arrangement, diametrically opposite one another.

The ledges 1 18 each accommodate a single projection 42 on the attachment member when the arm is fitted to the chassis. The ledges 1 18 cooperate with the projections 42 on the attachment member 34 to limit the extent to which the arm 14 can rotate relative to the plug body 1 1. In a preferred implementation, the ledges are sized so that the arm 14 can only rotate through substantially 90 degrees between the aforementioned stowed and deployed arm positions. In effect, the ledges form the second part of the aforementioned two-part rotation limiting mechanism.

In the aforementioned embodiment, the barbed tabs extend into the second recess and the barbs of the tabs bear against the underside of the arm if one should attempt to remove the arm from the plug body. In an alternative arrangement the barbs on the tabs 38 may locate in a circumferential groove formed inside the second chassis part 52. In another envisaged implementation a pair of such grooves may be provided to limit the extent to which the arm can rotate, and in this implementation the ledges 118 and projections 42 may be omitted.

Once the arm 14 has been fitted to the second chassis part 52, the live and neutral electrical cables 22, 24 are connected to the live and the neutral cable connectors 73, 92 respectively. To facilitate this, the live and neutral cables may terminate with a connector that is capable of mating with the live and neutral cable connectors 73, 92.

Once the cables have been coupled to the connectors, the live and the neutral device connectors 84, 94 are electrically coupled to the live and the neutral electrical pins 18, 20 respectively.

In the next step of the assembly process, depicted schematically in Fig. 16, a cover 124 is fitted over the electrical connectors in the first chassis part 53, following which the cover 124 may be secured to the first chassis part 53 (for example by means of an adhesive, a snap-fit or a welding process (such as ultrasonic welding)). As shown in Fig 16, the cover 124 includes a window 126 that aligns with a connection point 66 in the earth pin 16 when the cover 124 is fitted to the first chassis part 53. The cover window 126 allows an earth connector 128 to be electrically coupled to the earth pin 16 (see Figs. 17 & 18).

The earth connector depicted in Figs. 17 and 18 comprises an eyelet 132 at one end, and an earth device connector 134 at the other. The earth connector 128 may be coupled to the earth pin by any of a number of different arrangements. For example, the earth connector 128 could be welded or soldered to the earth pin 16 or coupled thereto by means of a rivet or fastener 135 that can be inserted through the eyelet 132 at one end of the earth connector 128 and engaged with the connection point 66 of the earth pin 16.

When the earth connector is fitted over the cover, part of the connector locates behind a third wall tab 136 (Fig. 17), and the earth device connector 134 projects from the chassis 56.

With reference to Fig. 18, when the assembled arm 14 has been mounted to the fully assembled chassis 56, the earth, live and neutral device connectors 134, 84, 94 (which are in electrical connection with the earth, live and neutral electrical pins 16, 18, 20 respectively) are then connected to respective electrical cables 138 of a power supply cable, for example a cable that is or may be coupled to an electrical device. This provides that such an electrical device is in electrical connection with the pins 16, 18, 20 and allows electricity to be provided to the device when the pins 16, 18, 20 are inserted into an electrical socket.

With reference to Fig. 19, after the electrical wires 138 have been connected as described above, the first chassis part 53 is over moulded with an electrically insulating material (such as a plastics or rubber material) thereby encapsulating the internal electrical components of the plug 10 within an electrically insulating shell.

In the next step of the assembly process, depicted schematically in Fig. 20, a pair of wings 12 are coupled to the plug body 11 , in particular to the wing mounts 114 carried by the second chassis part 52. The wings 12 comprise an inner wing 140 and an outer wing 142. The inner wing comprises a pair of annular tabs 144 sized to fit around the circular wing mounts 114. The outer wing also comprises a pair of tabs 146, but in this case the tabs 146 each include a projecting pin 148 that is sized to locate within the central depression formed in the circular wing mounts 114. As shown in Fig. 20, in the preferred arrangement, the wing tabs are configured so that the outer wing tabs can move over the inner wing tabs (or vice versa), and each wing tab is capable of being flexed so that the wings can be snap-fitted to the chassis 56. As will be appreciated by persons skilled in the art, the abovedescribed mechanism by which the wings are coupled to the plug chassis 56 could be reversed so that the pins are carried by the plug chassis and locate in depressions formed in circular projections that extend inwardly from the outer wing tabs - the annular inner wing tabs fitting over the circular projections carried by the outer wing.

The arrangement of the electrical components of a plug 10 (according to the particular arrangement hereinbefore described) is shown in Figs. 21 & 22. However, in various envisaged alternative embodiments the shapes of the electrical components (such as the first fuse connector 68, the second fuse connector 76, the neutral connector 78, and the earth connector 128 for example) may be different to those shown in the accompanying figures provided that such components are electrically connected in the same configuration. Furthermore, in such alternative arrangements, the chassis 56 may have a different shape provided that it is configured to receive such differently shaped components therewithin and allow them to be mounted thereto. It is also envisaged that the plug 10 may be used without a fuse 1 10, and in such an arrangement there would be no need for a fuse carrier and the first fuse connector would comprise a single component. In certain circumstances it may also not be necessary for the earth pin to be capable of carrying an electrical current. For example, if the plug were to include a transformer the earth pin could simply comprise a dummy pin that functions only to enable the live and neutral pins of the plug to be inserted into a UK socket.

It will also be remembered that the teachings of the present invention may be applied to different plug configurations for use in countries other than the UK, and in such circumstances there may be no need for an earth pin to be provided.

In another envisaged implementation of the plug 10, as shown in Figs. 23-25, each ledge separating projection 122 of the arm receiving opening 1 16 in the second chassis part 52 is provided with an electrically conducting pin 150 that extends entirely through the second chassis part 52 and protrudes from either side thereof (as shown in Fig. 25). In this configuration the live and neutral electrical cables 22, 24 (connected to the live and the neutral cable connectors 73, 92 respectively) can be connected to that part of the appropriate pin 150 that protrudes from the underside of the second chassis part 52 (i.e. that side which lies adjacent the first chassis part 53).

An arm 14 configured for use with this particular arrangement of arm receiving opening 1 16 is illustrated in Figs. 26, 27 & 28 (note that the attachment member 34 shown in Figs. 26 & 28 has been shortened to avoid obscuring pertinent features of the arm, and that in principle any of the various attachment members described herein may be employed). With particular reference to Fig. 28, the arm 14 comprises an annular peripheral flange 152 that has a diameter greater than that of the attachment member 34. The annular flange 152 further defines two slots 154, one each adjacent the respective contact portions 50 of the live and neutral electrical pins 18, 20. As before, the attachment member 34 includes two projections 42 that locate in ledges 1 18 (one of which is shown in Fig. 25) formed in the second chassis part 52 to limit the extent to which the arm can rotate relative to the chassis 56.

A pair of recesses 155 are defined between the flange and attachment member 34, and each said recess extends between and is bounded at opposite ends by the attachment member projections 42. An electrical connector 153 located in one of said recesses 155 extends through one of the aforementioned slots 154 to the contact portion 50 of the live pin, and a second electrical connector 153 located in the other of said recesses 155 extends through the other of the aforementioned slots 154 to the contact portion 50 of the neutral pin.

Each electrical connector 153 includes a curved portion 156 that follows - at least generally - at least part of the perimeter of each said recess, and each said curved portion 156 functions as an electrically conducting keep within which one of the aforementioned conducting pins 150 can move whilst continuously maintaining electrical contact between the pin and connector.

When the attachment member 34 of the arm 14 shown in Figs. 26 & 28 is inserted into the arm receiving aperture 116 depicted in Fig. 23, the attachment member 34 rotatably couples the arm 14 to the second chassis part 52 (for example by means of a snap-fit as previously described in connection with Figs. 4, 5 and 13, or indeed by any of the other arrangements herein described).

In this position the pins 150 (protruding outwardly from the chassis 56 towards the arm 14) extend into and inside the curved keep portions 156 of the electrical connectors 153 provided in the recesses 155 to make electrical contact with those portions 156 of the connectors. As will be appreciated, when the arm is rotated relative to the chassis, the pins wipe round the inside of the curved keep portions 156 of the electrical connectors 153 and thereby continuously electrically connect the live and neutral pins of the plug to the components within the chassis 56.

As will be appreciated by persons skilled in the art, this arrangement can readily be reversed so that the electrical pins extend from the arm and engage with curved keep portions of electrical connectors provided in the second chassis part 56.

In further envisaged implementations of the plug 10, the arm 14 need not necessarily be rotatably fitted to the chassis 56 using the snap-fit mechanism already described, but may instead be coupled to the chassis by another coupling arrangement - three illustrative examples of which will now be described.

In the arrangement depicted in Fig. 29 a distal part of the arm attachment member 34 is provided with a circumferential groove 158 that is configured to accept a generally C-shaped split washer 160 (commonly known as a circlip). The washer 160 can be slid into the groove 158 (as shown in Fig. 30), once the attachment peg 34 of the arm 14 has been pushed through the arm receiving opening 1 16 in the second chassis part 52 to securely couple the arm 14 to the chassis 56 whilst still allowing the arm 14 to rotate relative thereto.

In another arrangement shown in Fig. 31 , the attachment member 34 of the arm

14 may be provided with an enlarged head portion 155 (which is preferably located at the end of the attachment member 34 distal from the arm). A plurality of resilient flexible tabs 157 (in this instance, four flexible tabs) extend from the second chassis part 52 towards the first chassis part (not shown in Fig. 31) to define a channel 159 that has a smaller diameter than the arm receiving opening 116 in the second chassis part 52.

As the attachment member 34 of the arm 14 is pushed into the opening 1 16, the head portion 155 bears upon the tabs 157 and causes the tabs 157 to resiliently deform in an outward direction (i.e. to increase the diameter of the channel 159). Once the head portion has been inserted beyond the tabs 157, the tabs 157 snap behind the head portion 155 to secure the arm to the second chassis part 52..

In an implementation of this concept, the attachment member may comprise a rod and the enlarged head portion may be shaped and configured to resemble the head of a mushroom that extends from the rod towards the second chassis part 52.

In another arrangement, depicted schematically in Fig. 32, the arm attachment member 34 (preferably a portion thereof distal from the arm) comprises a circumferential groove 158 and a clip 159 may be located in the groove once the arm has been pushed through the opening 116 in the second chassis part 52. As will be appreciated, when the clip 159 engages the groove 158, the arm is coupled to the chassis whilst still being able to rotate relative to the chassis 56.

In one arrangement the clip 159 may extend from the chassis cover 124 so that the clip 159 engages the groove 158 when the cover 124 is fitted to the first chassis part 53. In another envisaged arrangement, the clip 159 may be inserted into the chassis 56 once the attachment peg 34 has been pushed through the arm receiving opening 116 in the second chassis part 52. Fig. 33 shows one such arrangement where the second chassis part 52 is provided with a slot 161 into which a clip 159 can be inserted once the attachment member 34 of the arm 14 has been pushed into the chassis 56. In this particular arrangement, the slot 161 is covered by a door 163 that can be sealed shut once the clip has been inserted (for example by welding, or by overmoulding) to prevent the clip from being withdrawn to release the arm from the chassis.

As with previously mentioned arrangements, it is envisaged that the components shown in Figs. 29 to 32 may readily be swapped around so that those components shown as being carried by the chassis are carried by the arm, and vice versa. For example, in the case of the first described snap-fit mechanism, the chassis 56 may instead have a pair of outwardly barbed tabs 38 and the arm 14 may have a receiving opening 1 16 (for receiving such barbed tabs). In reverse arrangements of the other arm- chassis attachment mechanisms disclosed herein the attachment peg 34 may instead protrude from the chassis 56 (not the arm 14) to engage with an appropriate formation in the arm, and the other arm attachment feature (such as the arm receiving aperture 116 or clip 159) may be located on the arm 14 (rather than in or on the chassis 56).

The teachings provided hereinbefore are particularly suitable for use with a USB power plug 162 of the type depicted in Figs. 34 & 35. Such a USB power plug 162 comprises an arm 14, and a chassis that comprises a first chassis part 164 and a second chassis part 168. In this particular implementation the first and second chassis parts are separately formed, and subsequently coupled together. The first chassis part 164 comprises a rod-like body from which the earth pin extends and to which the arm 14 is coupled. The second chassis part 168 comprises a casing that is, in this implementation, formed as a one-piece unit. In other implementations a rear wall or one or more side walls may be separately formed from the remainder of the casing and subsequently joined to it.

The arm 14 is rotatably coupled to the first chassis part 164 by means of any of the attachment arrangements described herein (for example by means of a snap-fit coupling (e.g as shown in Figs. 36, 37), by means of a circlip 160 (e.g. as shown in Fig. 38) or by means of a clip 159 (e.g. as shown in Fig. 39).

It should also be noted that whilst the USB power plug 162 shown in Fig. 34 comprises an arm 14 and an arm receiving aperture 1 16 of the type depicted in Figs. 26 & 23 respectively, the USB power plug 162 could incorporate an arm 14 and an arm receiving aperture 116 of the type depicted in Figs. 5 & 15 respectively.

Figs. 36-39 show, merely by way of illustration, a number of envisaged implementations for the USB power plug 162. Figs. 36 & 37 show one envisaged arrangement in which the attachment member 34 on the arm 14 has a number of outwardly barbed tabs that effect a snap-fit coupling with the body 164. Fig. 38 shows another envisaged arrangement in which the arm 14 is coupled to the body 164 by means of a circlip 160 that locates in a circumferential groove 158 on the attachment member 34. Lastly, Fig. 39 shows yet another envisaged implementation in which the attachment member 34 on the arm 14 has a circumferential groove 158 into which a clip 159 on a cover portion 160 of the casing 168 extends when the attachment member 34 has been inserted into the arm receiving aperture 1 16, and the cover portion 160 is coupled to the remainder of the casing 168.

Referring again to Fig. 34, it will be appreciated that to function as a USB power plug the casing 168 will house a printed circuit board (PCB - not shown) that carries those (known) components for providing power to a USB interface 170.

In one envisaged implementation the PCB may be installed in the housing in such a way that fitting the second chassis part 134 to the first chassis part 168 causes the pins 150 extending from the second chassis part 134 to abut against and thereby electrically contact appropriate electrical contacts on the PCB (thereby avoiding having to physically interconnect (for example, by means of a soldered connection) the pins 150 to the PCB).

In another envisaged implementation, the USB power plug includes an arm and complementary receiving aperture of the type shown in Figs. 5 and 15 respectively, the printed circuit board may be electrically connected to live and neutral electrical cables 22, 24 extending from the contact portions 50 of the respective pins 18, 20.

In the particular embodiment shown in Fig. 34, the earth pin 16 is a "dummy" earth pin and is formed as part of the body 164 (which is preferably made of insulating material). Alternatively however the earth pin may be made of electrically conducting material and electrically connected to the PCB.

As with other implementations, a pair of wings 12 are mounted to the wing mounting portions 1 14 at either end of the body 164. Such an arrangement is shown in Figs. 40 & 41 where both the arm 14 and wings 12 are shown to be in the deployed and stowed positions respectively. For illustrative purposes a USB connector is shown to be inserted in the opening 170 of the casing 168 in Fig. 40.

Another aspect of the present invention relates to a system 180 for coupling an electrical device to an electrical supply, and such a system is depicted schematically in Figs. 42 and 43.

As aforementioned, a problem with existing plugs and cables is that when a number of cables are carried together, those cables can easily become entangled and if this should happen a user may have to take out and untangle all of the cables in their bag to retrieve the particular cable they need at that time. There is also the problem that conventional plugs carried in a bag may scratch devices that are also carried in that bag, and whilst the foldable plug described herein significantly reduces the likelihood of this occurring (when the plug is in the folded stowed configuration), the earth pin may still project slightly from the wings and hence there is at least a theoretical chance that damage might occur.

To address this issue, as well as the cable entanglement issue, the system 180 comprises a USB power plug 162 of the type described herein, a cable 173 that is provided with a USB connector 173a at one end and another connector 173b (which may also be a USB connector or another type of connector, for example a bespoke connector for coupling to a particular type or model of electronic device) at the other end, and a cover 172.

The cover 172 has an opening 169, and around the periphery of that opening there are provided a number of internal ribs 171. The opening is sized to allow the cover to engage with the wing-end of a folded plug 162 of the type described herein, and the internal ribs form an interference fit with the wings of the plug to couple the plug to the cover. The ribs also limit the extent to which the plug can be inserted into the cover, so that an internal void is provided between the cover and the plug when the cover is attached thereto.

As shown in Fig. 42, the internal void is sized to accommodate the aforementioned cable 173 so that the system, when assembled, provides a means for storing a cable (to prevent that cable from becoming entangled with any other cables) as well as a means for fully enclosing the pins of the plug. As will be appreciated from Fig. 43, the system is particularly compact and provides an attractive way for users to carry plugs and electrical cables.

As aforementioned, the USB power plug 162 may in principal include any type of connector (not solely a USB connector), and may carry either a male or female connector (at least one end of the cable carrying the complementary connector).

Referring now to Figs. 44 & 45 of the accompanying drawings, there is depicted yet another envisaged arrangement whereby live and neutral electrical pins 18, 20 on a rotatable arm 14 may be electrically coupled to the live and neutral cable connectors 73, 92 within a chassis 56, or to a printed circuit board within a USB power plug 162.

In this arrangement, the attachment member 34 of the arm (preferably a distal end thereof) comprises a first electrical conductor 174 that extends circumferentially around the periphery of the attachment member 34. The attachment member 34 also has an opening 176 extending into its distal end, and the internal surface of that opening is provided with a second electrical connector 178 that extends circumferentially around that surface. The first electrical conductor 174 is electrically connected to one of the neutral and live electrical pins 20, 18 on the arm 14, and the second electrical conductor is electrically connected to the other.

In this arrangement the chassis 56 of the plug 10, or the body 164 of the adaptor 162, is provided with a complementary electrical connector 180 (see Fig. 45) that comprises an electrical pin 184 which is configured to electrically couple to the second connector 178, and an annular connector 182 surrounding the pin 184 that is configured to electrically couple to the first electrical connector 174. The pin 184 is electrically coupled to one of the live and neutral cable connectors 73, 92 within the chassis 56, and the annular connector 182 is coupled to the other. In another implementation the pin and annular connectors may be coupled to the printed circuit board within the USB power plug 162.

As with earlier mentioned arrangements, the connectors depicted in Fig. 44 may be reversed so that the connector shown in Fig. 45 is provided on the arm and the connector shown in Fig. 44 is provided on the chassis.

It will be appreciated that whilst various aspects and embodiments of the present invention have heretofore been described, the scope of the present invention is not limited to the particular arrangements set out herein and instead extends to encompass all arrangements, and modifications and alterations thereto, which fall within the spirit or scope of the invention.

For example, in another envisaged arrangement the plug 10 in Figs 1 and 2 (or

USB power plug 162 in Fig. 34) may include a substantially planar chassis 56 or body 164 that is provided with a cut-away portion 186 that includes a hollow cylinder 188. A pair of windows 190 are provided, one on either side of the chassis or body 164, (n.b. only one window is visible in Fig. 46) into which respective electrical spring contacts 192 may be fitted. The windows 190 provide access to the hollow interior of the cylinder 188 and enable the electrical contacts 192 to make contact with curved electrical contacts 194 on the attachment member of the arm 14 (one contact 194 being connected to one of the pins 18, 20, and the other contact 194 being connected to the other).

As shown in Fig. 46, the attachment member 34 of the arm 14 includes a pair of outwardly barbed tabs 38 that flex inwardly as the attachment member 34 is pushed into the hollow cylinder 188 of the chassis 56 or body 164 until the tabs 38 latch over a top edge 191 of the cylinder 188 (as shown in Figs. 47 and 48) to securely and rotatably couple the arm 14 to the chassis 56 or body 164.

Further illustrative embodiments of the teachings of the invention will now be described in the context of a manufacturing method for a foldable plug. The following description will refer, for convenience, to sequential steps of the method, but it will be appreciated and should be noted that the order in which the steps are accomplished may be varied at will without departing from the scope of the present invention.

With the above proviso in mind, reference will now be made to Fig. 49 in which there is depicted a schematic exploded perspective view of an illustrative foldable plug 201.

The plug 201 comprises a chassis 203 that is comprised of a first chassis part 203a and a second chassis part 203b. In this particular arrangement the first chassis part 203a has been formed, for example moulded, around an earth pin 205, but it will be appreciated that in some jurisdictions an earth pin may not be required, and further that the earth pin may in some embodiments be configured as a dummy earth pin rather than an electrically conducting earth pin.

Live 207 and neutral pins 209 are carried by a pivot arm 211 that can be coupled to the first chassis part 203a. In the preferred arrangement the pivot arm has a first face from which the live and neutral pins 207, 209 extend and a second face from which a rod 213 projects. The rod 213 includes an enlarged head that is capable of snap-fitting (in the manner described above) in a socket formed in the first chassis part 203a. As described above, the rod 213 may be wholly or partly hollow.

First and second wings 215, 217 snap fit to one another, and to the first chassis part 203a so that the wings may pivot from a closed configuration where they extend in parallel to one another and enclose at least a major portion of the earth pin, to an open configuration where the wings are linearly aligned and extend generally perpendicularly from the first chassis part 203a.

Live, earth and neutral conductors 219, 221 and 223 fit within the second chassis part 203b and are coupled to respective live, earth and neutral electrical connectors 225, 227 and 229. Once the conductors are located in the second chassis part 203a, the second chassis part 203b can be fitted, preferably snap-fitted, to the first chassis part 203a to enclose the conductors within the chassis 203. Once the chassis has been fitted together, a chassis cap 231 can be fitted to the second chassis part to close off a channel 233 through the chassis 203 into which a fuse holder 235 can be inserted.

In a final step, the chassis 203 is at least partly covered by a chassis cover 237 that includes an integral cable 239 through which the aforementioned electrical connectors extend.

Referring now to Fig. 50, in one stage of the assembly process the arm 21 1 carrying the live and neutral pins 207, 209 is push-fitted, preferably snap fitted, to the first chassis part 203a, following which the wings 215, 217 are coupled one to the other and then to the first chassis part 203a. In another arrangement, the wings could be fitted to the chassis part before the arm is push-fitted thereto. Fig. 51 is a perspective view of the first chassis part 203a with the arm fitted thereto and orientated so as to be generally linearly aligned with the chassis part 203a, and the wings 215, 217 in the aforementioned closed configuration (where the wings 215, 217 enclose at least part of the earth pin 205).

Referring now to Fig. 52, in a second stage of the assembly process the aforementioned live, neutral and earth conductors 219, 221 , 223 are coupled to their respective connectors 225, 227, 229 and then fitted within the second chassis part 203b (Note that the live conductor comprises a first part 219a that is configured to make contact with one end of the fuse in the fuse holder 235, and a second part 219b that is configured to make contact with the other end of the fuse in the fuse holder 235, each of the parts 219a, 219b being separated inside the second chassis part 203b so as to avoid short-circuiting the fuse). Once the conductors and connectors have been installed in the second chassis part 203b (as shown in Fig. 53), the aforementioned chassis cap 231 may be fitted to the chassis part 203b to close off the bottom of the channel 233 into which the fuse holder 235 can be inserted.

Once the first and second chassis parts 203a, 203b have been assembled, as described above, the second chassis part is fitted into the first chassis part, as shown in Figs. 54 and 55 of the drawings. In one envisaged arrangement, the second chassis part 203b may be arranged to snap-fit in the first chassis part. In another envisaged arrangement, the second chassis part may simply locate in the first chassis part.

In either event, the first and second chassis parts are configured so that once the second chassis part has been fitted to the first chassis part the first part 219a of the live conductor and the neutral conductor 221 each make electrical contact with contacts carried by the arm 21 1 that are coupled to the live and neutral pins - thereby electrically coupling the live and neutral pins to the live and neutral connectors 225, 227. When the first and second chassis parts have been fitted together, as shown in Fig. 55, the earth connector can be electrically coupled - for example, riveted - to the earth pin 205.

Once the first and second chassis parts 203a, 203b have been fitted together, the cover 237 can be fitted over at least part of the chassis 203, as shown in Fig. 56, so that the cover 237 obstructs access to the chassis and the connectors housed therein. In an envisaged implementation the cover can conveniently be formed by overmoulding the assembly depicted in Fig. 55. In another envisaged arrangement the cover 237 could be separately formed and then joined to the chassis, for example by welding or by means of an adhesive.

The cover may be of one material, or in another envisaged arrangement, the cover may include regions of higher grip that enable a user to more easily grip the plug and extract the plug from a socket. The cover may only, as shown, cover part of the chassis, or in another envisaged arrangement the cover may cover substantially all of the chassis up to the point where the wings are attached.

Referring now to Figs, 57(a) to 57d), 58(a) to 58(d) and 59(a) to 59(d), there are depicted three illustrative methods for forming the pivot arm 211 that is fitted to the first chassis part 203a.

In the first of these methods, depicted schematically in Figs. 57(a) to 57(d), a pair of electrical pins 205, 207 (one of which is shown in Fig. 57(a)) are provided. Each pin is electrically conducting, and in this particular implementation part of the pin is sheathed in non-conducting material 241. The pin 207 terminates at one end in a peg 243, and is shaped at the other to facilitate insertion of the pin into a socket.

As shown in Fig. 57(b), in a first step of the process, the aforementioned pair of pins 205, 207 are coupled to a body 245 that forms the principal component of the pivot arm 211. The pins may be inserted into a pre-formed body, or in a particularly preferred arrangement the body 245 may be moulded around the pins. In either event, the body is configured to provide a recessed region 247 into which the pin pegs 243 project, and from which the aforementioned rod 213 projects. As shown in Fig. 57(c), a pair of electrical conductors 249 are fitted into the recessed region 247 and coupled, for example by means of rivets, to respective pin pegs 243. As is described in more detail above the electrical conductors 249 each include a part that fits around the rod 213, and the conductors function to electrically couple the live and neutral pins 205, 207 to corresponding conductors provided in the chassis when the arm is pivotally coupled thereto.

Once the conductors 249 have been fitted into the channel 247 and coupled to the pin pegs 243, the channel is then closed (as shown in Fig. 57(d)) by means of a cap 251 that is then joined to the body 245 (for example by means of a welding process or by an adhesive). The cap may be a discrete component, or in another envisaged implementation the cap 251 may be formed by filling the channel 247 (for example by overmoulding) of the assembly depicted in Fig. 57(c) to close the channel 247 and thereby obstruct access to the conductors 249.

Figs. 58(a) to 58(d) show an alternative method for forming the pivot arm 211 of the plug. In this case the pin 205, 207 depicted in Fig. 58(a) has a shank that includes a portion 253 of reduced diameter. In this arrangement, the pins 205, 207 are insert moulded into a pivot arm body component 255 (shown in Fig. 58(b)) and this moulding process forms the aforementioned non-conducting sleeves 241 over the pin portions 253 of reduced diameter. As with the arrangement depicted in Figs. 57(a) to (d), the pivot arm body component 255 includes a recessed region that comprises, in this particular arrangement, a channel 257 into which the aforementioned conductors 249 are fitted (as shown in Fig. 58(c) before being coupled (for example, riveted) to the pins. The conductors, as with the previous arrangement, function to electrically couple the pins to the connectors when the pivot arm 21 1 is coupled to the chassis 203.

As shown in Fig. 58(b) and (c), the body also includes a cylinder 259 that extends from the recessed region of the body and forms part of the rod 213 of the final arm 211 , when the assembly of Fig. 58(c) has been over moulded to close the channel 257 and enclose the conductors within the arm, and to form the remainder 261 of the rod 213.

Referring now to Figs. 59(a) to (d), there is depicted another method for forming the pivot arm 211 of the plug. In this arrangement, a pivot arm body component 263 is formed that has an upstanding cylinder 265 which forms part of the rod 213 in the finished arm, and a pair of notches 267 (one at either end) into each of which a pin/conductor assembly can be fitted.

Fig. 59(b) shows one such pin/conductor assembly 269, and as shown the assembly comprises a conductor 249 that has been fixed, for example riveted, to a peg 243 projecting from the pin 205, 207. As with the arrangement shown in Figs. 58(a) to (d), the pin of this arrangement also comprises a portion 253 of reduced diameter.

Once the pins and conductors have been assembled, one of each assembly is fitted into each of the aforementioned notches 267. Fig. 59(c) is a view of part of the body component 263 showing a pin/conductor assembly fitted into one of the notches.

Once the pin/conductor assembles have been fitted into the notches 267, the entire assembly is overmoulded to form the aforementioned non-conducting sheaths 241 on the pins 205, 207, to enclose the conductors 249, and to from the remainder 261 of the pivot arm rod 213.

It will be appreciated that whilst various aspects and embodiments of the present invention have heretofore been described, the scope of the present invention is not limited to the particular arrangements set out herein and instead extends to encompass all arrangements, and modifications and alterations thereto, which fall within the spirit or scope of the invention.

For example, whilst in certain arrangements described above the arm body is formed around the pins, it will be appreciated that the arm body could be formed separately and then the pins could be inserted into and through the arm body. To facilitate this, a head portion of the pin from which the peg extends could be larger than the remainder of the pin (especially that bit of the pin that is configured to be inserted into a socket).

It should also be noted that whilst the accompanying claims set out particular combinations of features described herein, the scope of the present invention is not limited to the particular combinations hereafter claimed, but instead extends to encompass any combination of features herein disclosed. In particular, the scope of the present invention includes any of the features herein disclosed in isolation, or in combination with any of the other features herein disclosed.