WIRING DEVICE WITH KEYING FEATURES

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] The present disclosure is based on and claims benefit from co-pending U.S. Provisional Patent Application Serial No. 62/694,659 filed on July 6, 2018 entitled“Electrical Plug Connector and Wiring Device with Keying Features” the contents of which are incorporated herein in their entirety by reference.

BACKGROUND

Field

[0002] The present disclosure relates to electrical wiring devices and electrical plug connector assemblies providing easy connection of electrical conductors to the electrical wiring devices. More particularly, the present disclosure relates to electrical wiring devices and electrical plug connector assemblies rated for one voltage with keying features to prevent electrical plug connector assemblies from being plugged into electrical wiring devices that are not rated for the same voltage.

Description of the Related Art

[0003] To facilitate connecting electrical wires to an electrical wiring device, such as an electrical receptacle, some electrical wiring devices have an aperture in their rear face for receiving an electrical plug connector terminating a plurality of wires. The wires terminated by the electrical plug connector are connected to the existing power wires in a known manner. Thus, once the plug connector assemblies are wired, an electrician is not required to connect the electrical plug connector to the electrical wiring device.

[0004] When connecting an electrical plug connector to the electrical wiring device, precautions are desired to reduce the possibility that an electrical plug connector rated for one voltage, e.g., 250 volts, is not inadvertently installed in an electrical wiring device rated for a different voltage, e.g., 120 volts.

SUMMARY

[0005] The present disclosure provides exemplary embodiments of wiring device assemblies that include an electrical wiring device and electrical plug connector assembly that permit easy connection of electrical conductors to the electrical wiring device via the electrical plug connector assembly. The wiring device assemblies according to the present disclosure include keying features, such as keys and keyways, to prevent electrical plug connector assemblies rated for one voltage from being plugged into electrical wiring devices that are rated for a different voltage.

[0006] In an exemplary embodiment, the electrical plug connector assembly includes a connector housing, at least one key and at least one keyway. The connector housing has a body portion and a plug portion. The plug portion is configured to fit within an aperture in a rear face of a body of the electrical device. The at least one key is disposed on the plug portion of the connector housing and is configured to interact or mate with at least one keyway associated with the aperture of the electrical device. The at least one keyway is disposed in the plug portion of the connector housing and is configured to interact or mate with at least one key in the aperture of the electrical device. In an exemplary embodiment, the at least one key on the plug portion of the connector housing is a rib extending from the plug portion of the connector housing, and the at least one keyway in the plug portion of the connector housing is a groove in the plug portion of the connector housing.

[0007] An exemplary embodiment of an electrical device assembly includes electrical wiring device and a plug connector assembly. The electrical wiring device has a body with an aperture in a rear face of the body. The plug connector assembly is configured to mate with the aperture in the rear face of the body of the electrical device. The plug connector assembly includes a connector housing, at least one key and at least one keyway. The connector housing has a body portion and a plug portion that is configured to fit within the aperture in the rear face of the body. The at least one key is disposed on the plug portion of the connector housing and is configured to interact or mate with at least one keyway in the rear face of the body and associated with the aperture. The at least one keyway is disposed in the plug portion of the connector housing and is configured to interact or mate with at least one key in the aperture of the electrical device. In an exemplary embodiment, the at least one key on the plug portion of the connector housing is a rib extending from the plug portion of the connector housing, and the at least one keyway in the rear face of the body is a groove that can receive the rib. The at least one key way in the plug portion of the connector housing is a groove in the plug portion of the connector housing, and the at least one key in the aperture of the electrical device is a rib that is received in the groove.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] A more complete appreciation of the present disclosure and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:

[0009] Fig. 1 is a rear perspective view of an exemplary embodiment of a wiring device assembly according to the present disclosure, illustrating a plug connector assembly connected to an electrical wiring device;

[0010] Fig. 2 is a rear perspective view of the wiring device assembly of Fig. 1, illustrating the plug connector assembly disconnected from the electrical wiring device;

[0011] Fig. 3 is a rear elevation view of the electrical wiring device of Fig. 1, illustrating keying features within an aperture of the electrical wiring device; [0012] Fig. 4 is a front perspective view of an exemplary embodiment of the plug connector assembly of Fig. 1, illustrating keying features on a plug portion of the plug connector assembly;

[0013] Fig. 5 is a rear perspective view of the plug connector assembly of Fig. 4;

[0014] Fig. 6 is another rear perspective view of the plug connector assembly of Fig. 4;

[0015] Fig. 7 is a cross-sectional view of the plug connector assembly of Fig. 4 taken from line 7-7; and

[0016] Fig. 8 is an enlarged view of a portion of the wiring device assembly of Fig. 1 taken in cross section from line 8-8 to illustrate the latching of the plug connector assembly connected to the electrical wiring device.

DETAILED DESCRIPTION

[0017] The present disclosure provides exemplary embodiments of wiring device assemblies that include an electrical wiring device and electrical plug connector assembly that provide easy connection of electrical conductors to the electrical wiring device. The wiring device assemblies according to the present disclosure are configured to operate at a common voltage rating and include keying features to ensure the electrical wiring devices are configured to mate with electrical plug connector assemblies rated for the same voltage. For example, the electrical wiring device may be rated for 250 volts and the keying features are provided so that electrical plug connector assemblies rated for 250 volts can mate with the electrical wiring device. Thus, for example, the keying features can be used to prevent electrical plug connector assemblies rated for 250 volts from being plugged into electrical wiring devices rated for 120 volts.

[0018] As used in the present disclosure, the terms "front," "rear," "upper," "lower," "upwardly," "downwardly," and other orientational descriptors are intended to facilitate the description of the electrical wiring devices and the electrical plug connector assemblies, and are not intended to limit the structure of the electrical wiring devices and the electrical plug connector assemblies to any particular position or orientation. For ease of description, the wiring device assemblies may be referred to herein as the“device assembly” in the singular and the“device assemblies” in the plural. Similarly, the electrical wiring devices according to the present disclosure may be referred to as the“device” in the singular and the“devices” in the plural. The electrical wiring devices contemplated include any type of electrical wiring device suitable for insertion into an electrical box. Non-limiting examples of electrical wiring devices contemplated by the present disclosure include single receptacles, duplex receptacles, single pole switches, multi-pole switches, etc. The electrical plug connector assemblies according to the present disclosure may be referred to as the“connector assembly” in the singular and the“connector assemblies” in the plural.

[0019] Referring to Figs. 1-4, an exemplary embodiment of a device assembly 10 is shown. In the exemplary embodiment shown, the device assembly 10 includes a device 20 and a connector assembly 50. The device 20 includes a body or housing 22, a front cover 24 and a yoke 26 used to secure the device 20 to an electrical box as is known. The body 22 has a rear surface 22a that includes an aperture 28 providing access to components within the body 22. Within the aperture 28 are one or more contact members 30, 32 and 34, which are also known as blades or prongs. The one or more contact members 30, 32 and 34 supply electrical power to the device 20 as is known. The body 22 has a first overhang 36 and a second overhang 38 that interact with latch members 104 and 114, seen in Fig. 7, on the connector assembly 50 to releasably connect or secure the connector assembly 50 to the device 20 as described below. The body 22 and the aperture 28 also include keying features that interact with keying features on the connector assembly 50 to ensure that connector assemblies rated for one voltage are mated with devices rated for the same voltage. The keying features are described in more detail below.

[0020] Referring now to Figs. 2 and 4-7, an exemplary embodiment of a connector assembly 50 according to the present disclosure is shown. The connector assembly 50 includes a connector housing 52, which for reference purposes is divided into a body portion 54 and a plug portion 56, seen in Fig. 2. The plug portion 56 of the connector housing 52 is configured to fit within the aperture 28 in the device 20. The connector housing 52 is preferably unitarily or monolithically formed as a one-piece member. However, the connector housing 52 may be made of individual components, e.g., the body portion 54 and the plug portion 56, or an upper half and a lower half, that are secured together by welds, e.g., sonic welds, adhesives, mechanical fasteners, snap-fit connections or other known methods.

[0021] Referring to Figs. 1, 2, and 4-6, the connector housing 52 has a front surface 52a, a rear surface 52b disposed opposite the front surface 52a, an upper surface 52c, a bottom surface 52d disposed opposite the upper surface 52c, and first and second side surfaces 52e and 52f that extend between the upper surface 52c and the bottom surface 52d. The front surface 52a of the connector housing 52 includes a plurality of slots 58, 60 and 62, as seen in Figs. 4 and 7. The bottom surface 52d of the connector housing 52 includes one or more wire openings 66, 68, and 70, seen in Fig. 6, that permit electrical wires, e.g., wires 300, 302 and 304, to enter the interior of the housing 52 as described below. In the embodiment shown, there are three wire openings, 66, 68 and 70. However, any suitable number of wires may be used with the connector assembly 50 as required by the device 20 with which the connector assembly 50 is to be mated. Wires, e.g., wires 300, 302 and 304, seen in Fig. 2, are connectable to the building wiring, e.g., hot, neutral and ground wires, within an electrical box to which the device assembly 10 is to be mounted as is known. Each slot 58, 60 and 62 in the front surface 52a of the connector housing 52 corresponds to a wire opening in the bottom surface 52d of the connector housing, and a passageway is formed between the slot and the wire opening. For example, in the embodiment shown in Figs. 6 and 7, slot 58 corresponds to wire opening 66 and passageway 72 is formed between the slot 58 and the wire opening 66. Slot 60 corresponds to wire opening 68 and passageway 74 is formed between the slot 60 and the wire opening 68. Similarly, slot 62 corresponds to wire opening 70 and passageway 76 is formed between the slot 62 and the wire opening 70. First, second and third contact members 80, 82 and 84 are disposed in the first, second and third passageways 72, 74 and 76, respectively. The contact members 80, 82 and 84 are connected to the wires 300, 302 and 304 respectively, and are configured to connect to or contact the contact members 34, 32 and 30, seen in Fig. 3, when the connector assembly 50 is connected to the device 20.

[0022] As noted, the connector assembly 50 is configured to be connected to a device 20 to supply electrical power to the device. In some instances, it may be desirable to latch the connector assembly 50 to the device 20 so that the connector assembly 50 does not inadvertently or accidentally disconnect from the device 20. Referring to Figs. 2, 4, 7 and 8, to latch the connector assembly 50 to the device 20, the connector housing 52 may include one or more latch assemblies. For example, in the exemplary embodiment shown, the connector housing 52 includes two latch assemblies, namely a first latch assembly and a second latch assembly.

[0023] Continuing to refer to Figs. 2, and 4-8, the first latch assembly includes a first latching arm 100 and a first latch member 104. The first latch assembly may also include a first deflecting member 102. The first latching arm 100 extends substantially parallel to the first side surface 52e of the connector housing 52. The first latching arm 100 is movable, e.g., pivotable or deflectable, relative to the body 22 of the device 20 to facilitate connecting the connector housing 52 to and disconnecting the connector housing from the device 20. In the exemplary embodiment shown, the first latching arm 100 includes the first latch member 104 and the first deflecting member 102. The first latch member 104 extends inwardly from a forward end lOOa of the first latching arm 100, as seen in Fig. 7. The first latch member 104 is configured to engage the first overhang 36, seen in Fig. 2, in the body 22 of the device 20, similar to that seen in Fig. 8, to releasably connect the connector assembly 50 to the device 20. The first deflecting member 102 is disposed at a rearward end lOOb of the first latching arm 100, as seen in Fig. 7, and is used to move, e.g., pivot, the first latching arm 100 when disconnecting the connector housing 50 from the device 20, as described below. A first connecting arm 106 connects the first latching arm 100 to the first side surface 52e of the connector housing 52, as seen in Fig. 7, at a point between the forward end lOOa and the rearward end lOOb of the first latching arm 100.

The first connecting arm 106 preferably extends substantially perpendicularly to the first side surface 52e of the connector housing 52. The first connecting arm 106 allows the first latching arm 100 to move, e.g., flex, rotate or pivot, about the connecting arm 106 so that the first latch member 104 can engage with or disengage from the first overhang 36 of the body 22 of the device 20, similar to that seen in Fig. 8.

[0024] Continuing to refer to Figs. 2, and 4-8, the second latch assembly includes a second latching arm 110 and a second latch member 114. The second latch assembly may also include a second deflecting member 112. The second latching arm 110 extends substantially parallel to the second side surface 52f of the connector housing 52. The second latching arm 110 is movable, e.g., pivotable or deflectable, relative to the body 22 of the device 20 to facilitate connecting the connector housing 52 to and disconnecting the connector housing from the device 20. In the exemplary embodiment shown, the second latching arm 110 includes the second latch member 114 and the second deflecting member 112. The second latch member 114 extends inwardly from a forward end 1 lOa of the second latching arm 110, as seen in Fig. 7. The second latch member 114 is configured to engage the second overhang 38 in the body 22 of the device 20, as seen in Fig. 8, to facilitate releasably connecting the connector assembly 50 to the device 20. The second deflecting member 112 is disposed at a rearward end lOOb of the second latching arm 110, as seen in Fig. 7, and is used to move, e.g., pivot, the second latching arm 110 when disconnecting the connector housing 50 from the device 20, as described below. A second connecting arm 116 connects the second latching arm 110 to the second side surface 52f of the connector housing 52, seen in Fig. 7, at a point between the forward end 1 lOa and the rearward end 1 lOb of the second latching arm 110. The second connecting arm 116 preferably extends substantially perpendicularly to the second side surface 52f of the connector housing 52. The second connecting arm 116 allows the second latching arm 110 to move, e.g., flex, rotate or pivot, about the connecting arm 116 so that the second latch member 114 can engage with or disengage from the second overhang 38 of the body 22 of the device 20, as seen in Fig. 8.

[0025] The connector housing 52 also includes a first set of barriers 120 and a second set of barriers 122 provided to limit and possibly prevent wires 300 and 302 and other objects from accidentally or inadvertently causing the latching arms 100 and 110 from disconnecting from their respective overhang 36 or 38. In the exemplary embodiment shown in Figs. 5-7, the first set of barriers includes first and second barriers 120 and 122, seen in Fig. 6. The first and second barriers 120 and 122 extend outwardly from the first side surface 52e of the connector housing 52 and along the first side surface 52e so as to shield the first deflecting member 102 to limit and possibly prevent wires 300 and 302 and other objects from inadvertently or accidentally causing the first latching arm 100 to disconnect from the first overhang 36 of the body 22 of the device 20. The second set of barriers includes third and fourth barriers 124 and 126, seen in Figs. 5 and 6. The third and fourth barriers 124 and 126 extend outwardly from the second side surface 52f of the connector housing 52 and along the second side surface 52f so as to shield the second deflecting member 112 to limit and possibly prevent wires 300 and 302 and other objects from inadvertently or accidentally causing the second latching arm 110 to disconnect from the second overhang 38 of the body 22 of the device 20.

[0026] As noted above, the present disclosure provides exemplary embodiments of wiring device assemblies that include keying features to ensure the devices 20 connect to connector assemblies 50 rated for the same voltage. The keying features include a key 40, seen in Fig. 2, and corresponding keyway 42 used to prevent electrical plug connector assemblies rated for one voltage from being plugged into electrical wiring devices rated for a different voltage. In the exemplary embodiment shown in Figs. 2-4, the device 20 includes one or more device keys 40 and one or more device keyways 42, and the connector housing 52 includes one or more connector keys 130 and one or more connector keyways 132.

[0027] In the exemplary embodiment shown in Figs. 2 and 3, the device keys 40 are ribs extending into the aperture 28 in the body 22 of the device 20. However, the device key 40 may be any structure sufficient to block entry of an incompatible connector assembly 50into the aperture 28 of a device 20. In the exemplary embodiment shown, the device keyways 42 are grooves, notches or channels in the body 22 of the device 20 which are associated with, adjacent to or part of the aperture 28. However, the device keyways 42 may be any structure sufficient to receive a key of a compatible connector assembly 50 into the device 20. The device key 40 may be aligned with the device key way 42 as shown in Fig. 3. However, the device key 40 may be positioned relative to the aperture 28 at any location on the aperture 28, which may differ from the location of the device keyway 42. In the exemplary embodiment shown in Figs. 2 and 4, the connector keys 130 are ribs extending from the plug portion 56 of the connector housing 52. However, the connector keys 130 may be any structure sufficient to block entry of a connector assembly 50 into an incompatible device 20. The connector keys 130 can extend from the upper surface 52c, the bottom surface 52d or one of the side surfaces 52e and 52f of the connector housing 52. In the embodiment shown, the connector keys 130 extend from the upper surface 52c. The connector keyways 132 are grooves, notches or channels in the plug portion 56 of the connector housing 52 that are accessible from the front surface 52a of the connector housing 52. However, the connector keyways 132 may be any structure sufficient to receive a key from a compatible device 20. The connector key 130 may be aligned with the connector key way 132 as shown in Fig. 4. However, the connector key 130 may be positioned relative to the front surface 52a of the connector housing 52 at any location, which may differ from the location of the connector keyway 132.

[0028] In operation, to connect the connector assembly 50 to the device 20, the plug portion 56 of the connector housing 52 is inserted into the aperture 28 of the body 22 of the device 20.

When the plug portion 56 is inserted into the aperture 28, if the connector assembly 50 is compatible with the device 20, the device key 40 is received in the connector key way 132 and the connector key 130 is received in the device key way 42.

[0029] If the connector assembly 50 is incompatible with the device 20, the device key 40 and the connector key 130 block entry of the connector assembly 50 into the aperture 28 of the device 20. If the connector assembly 50 is compatible with the device 20, when the plug portion 56 of the connector housing 52 is inserted into the aperture 28, the contact members 30, 32 and 34 of the device 20 slide into respective slots 62, 60 and 58 in the connector housing 52 so that the contact members 30, 32 and 34 engage corresponding contact members 84, 82 and 80 within the connector housing 52. In addition, as the plug portion 56 is inserted into the aperture 28, the first latching arm 100 flexes so that the first latch member 104 slides past the first overhang 36 in the body 22 of the device 20 and engages the first overhang 36. Similarly, as the plug portion 56 is inserted into the aperture 28, the second latching arm 110 flexes so that the second latch member 114 slides past the second overhang 38 in the body 22 of the device 20 and engages the second overhang 38, as seen in Fig. 8. As a result, the first and second latching arms 100 and 110 releasably secure the connector assembly 50 to the device 20. To remove the connector assembly 50 from the device 20, the first and second deflecting members 102 and 112 are deflected inwardly against the biasing of the integral hinges provided by the connecting arms 106 and 116 such that the first and second latch members 104 and 114 move, e.g., pivot, outwardly to disengage first and second latch members 104 and 114 from the respective overhangs 36 and 38 allowing the connector assembly 50 to be withdrawn from the aperture 28 of the device 20.

[0030] When the connector assembly 50 is connected to the device 20, the electrical contact members 84, 82 and 80 within the connector housing 52 are in electrical contact with contact members 30, 32 and 34 within the device 20 so that electrical power is transmitted through the connector assembly 50 to the device 20 to supply power to a load. For example, in instances where the device 20 is a receptacle, electrical power would be transmitted through the connector assembly 50 to the receptacle 20 to supply power to a load plugged into the receptacle 20.

[0031] It will be understood that various modifications can be made to the embodiments of the present disclosure without departing from the spirit and scope thereof. Therefore, the above description should not be construed as limiting the disclosure, but merely as embodiments thereof. Those skilled in the art will envision other modifications within the scope and spirit of the invention as defined by the claims appended hereto.