Four-Sided Ground Contact Assembly

1. Field of the Invention

The present invention generally relates to electrical equipment and, more particularly, is concerned with a four-sided ground contact assembly for use in an electrical receptacle.

2. Description of the Prior Art

Heretofore, some electrical receptacles manufactured and marketed by Hubbell Incorporated of Orange, Conn., the assignee of the subject application, have employed a receptacle body with plug terminal contact receiving openings formed on its front side, a base body which mates with the receptacle body, a plurality of contact terminal assemblies fitted with cavities in the receptacle and base bodies, and an U-shaped mounting bridge provided with a base portion positioned adjacent a rear face of the base body and a pair of opposite leg portions extending forwardly from opposite ends of the base portion along opposite ends of the base and receptacle bodies, securing the receptacle and base bodies together in a mated relationship and capturing the contact terminal assemblies therein. The mounting bridge also has mounting tabs attached to the opposite leg portions and extending outwardly therefrom in opposite directions with holes on the mounting tabs for fastening the electrical receptacle to an external structure, such as a building wall, by the use of screws inserted through the holes and threaded into the structure.

While the above-described electrical receptacle has functioned satisfactorily under the range of conditions for which it was designed, as with any product certain drawbacks have been noted from time to time. One drawback particularly concerns the ground contacts provided on the mounting bridge. The ground contacts are formed by a pair of opposing beams so as to provide electrical contact with a ground pin on only two sides thereof. The opposing beams thus fail to fully securely capture the ground pin allowing it to work laterally in either direction and thereby reduce the effectiveness of the electrical connection therebetween.

Representative examples of prior art contact assemblies are found in U.S. Pat. No. 2,675,527 to Hartranft, U.S. Pat. No. 3,029,405 to Buchanan, U.S. Pat. No. 3,694,790 to Martin, U.S. Pat. No. 3,860,319 to Slater, U.S. Pat. No. 4,019,797 to Praml, U.S. Pat. No. 4,203,638 to Tansi, U.S. Pat. No. 4,271,337 to Barkas, U.S. Pat. No. 4,379,605 to Hoffman, U.S. Pat. No. 5,266,039 to Boyer et al., and U.S. Pat. No. 5,584,714 to Karst et al. However, none of these prior art patents appear to teach a contact assembly specifically applicable for overcoming the above-noted drawback.

Consequently, the inventors herein have perceived a need to provide further innovations which will overcome the above noted drawback.

The present invention provides a four-sided ground contact assembly designed to satisfy the aforementioned need. The four-sided ground contact assembly of the present invention overcomes the drawback of the prior art by advantageously providing four points of contact, such as by being substantially circumferentially spaced from one another approximately 90.degree. apart, on four sides of a ground pin of an electrical plug, which improves the physical connection as well as electrical contact of the contact assembly with the ground pin.

Accordingly, the present invention is directed to a four-sided ground contact assembly for use in an electrical receptacle. The four-sided contact assembly comprises: (a) a first contact element mounted to a mounting bridge of the electrical receptacle and having a pair of opposing contact leg portions; and (b) a second contact element mounted to the mounting bridge of the electrical receptacle and having a pair of opposing contact leg portions and such that the leg portions of the first and second contact elements are circumferentially spaced from one another and provide four points of contact on four sides of a ground pin of an electrical plug.

More particularly, the leg portions of the first contact element are approximately 180.degree. apart. The leg portions of the second contact element are approximately 180.degree. apart. Each leg portion of the first and second contact elements is approximately 90.degree. apart from an adjacent one of the leg portions of the first and second contact elements. Each of the first and second contact elements has a substantially U-shaped configuration. Each leg portion of the first and second contact elements has an upper end and a lower end and the point of contact of the leg portion is disposed closer to the upper end than to the lower end of the leg portion. One of the pair of leg portions of the first and second contact elements is spring biased toward the other of the pair of leg portions of the first and second contact elements. Each of the first and second contact elements has a base portion extending between and connected with the lower ends of the leg portions of the first and second contact elements. The base portion of the first contact element is integral with the mounting bridge and the base portion of the second contact element is disposed above and fastened to the base portion of the first contact element and thus to the mounting bridge.

These and other features and advantages of the present invention will become apparent to those skilled in the art upon a reading of the following detailed description when taken in conjunction with the drawings wherein there is shown and described an illustrative embodiment of the invention.

In the following detailed description, reference will be made to the attached drawings in which:

FIG. 1 is an exploded view of an electrical receptacle incorporating the features of the present invention as well as of the other inventions of the applications cross-referenced above.

FIG. 2 is a front plan view of the receptacle of FIG. 1 having a pair of four-sided ground contact assemblies which constitute the present invention.

FIG. 3 is a longitudinal sectional view of the receptacle taken along line 3--3 of FIG. 2 showing the four-sided ground contact assemblies mounted on a mounting bridge of the receptacle.

FIG. 4 is a front plan view of the bridge removed from the receptacle, showing on the bridge the four-sided ground contact assemblies of the present invention and the enhanced barbs which constitutes the invention of the second cross-referenced application.

FIG. 5 is a longitudinal sectional view of the bridge taken along line 5--5 of FIG. 4.

FIG. 6 is an enlarged side elevational view of a pair of auxiliary contacts in each four-sided ground contact assembly.

FIG. 7 is an end elevational view of the auxiliary contacts as seen along line 7--7 of FIG. 6.

FIG. 8 is an enlarged detailed view of a connecting portion of the auxiliary contacts enclosed by oval 8 of FIG. 7.

FIG. 9 is a side elevational view of an alternate mounting bridge for the receptacle having only the enhanced barbs on the bridge constituting the invention of the second cross-referenced application.

FIG. 10 is a front plan view of the bridge as seen along line 10--10 of FIG. 9.

FIG. 11 is a rear plan view of the bridge as seen along line 11--11 of FIG. 9.

FIG. 12 is an end elevational view of the bridge as seen along line 12--12 of FIG. 9.

FIG. 13 is an opposite end elevational view of the bridge as seen along line 13--13 of FIG. 9.

FIG. 14 is a fragmentary cross-sectional view of the bridge taken along line 14--14 of FIG. 9.

FIG. 15 is an enlarged detailed view of a portion of the bridge enclosed by oval 15 of FIG. 9 having one of the enhanced barbs thereon.

FIG. 16 is another enlarged detailed view of a portion of the bridge enclosed by oval 16 of FIG. 9 having another of the enhanced barbs thereon.

FIG. 17 is a rear perspective view of a receptacle body of the receptacle of FIG. 1.

FIG. 18 is a front plan view of the receptacle body of FIG. 17.

FIG. 19 is a longitudinal sectional view of the receptacle body taken along line 19--19 of FIG. 18.

FIG. 20 is a rear plan view of the receptacle body of FIG. 17.

FIG. 21 is a side elevational view of the receptacle body as seen along line 21--21 of FIG. 20.

FIG. 22 is a longitudinal sectional view of the receptacle body taken along line 22--22 of FIG. 20.

FIG. 23 is a cross-sectional view of the receptacle body taken along line 23--23 of FIG. 20.

FIG. 24 is a front plan view of the receptacle of FIG. 1 in assembled form in which the receptacle and base bodies are mated together and retained in the mated relationship by the mounting bridge and the multiple barbs thereon.

FIG. 25 is a longitudinal sectional view of the assembled receptacle taken along line 25--25 of FIG. 24.

FIG. 26 is a rear plan view of the assembled receptacle as seen along line 26--26 of FIG. 25.

FIG. 27 is a side elevational view of a back wired clamping arrangement constituting the invention of the first cross-referenced application which is incorporated in a contact terminal assembly of the receptacle of FIG. 1.

FIG. 28 is a front plan view of the back wired clamping arrangement as seen along line 28--28 of FIG. 27.

FIG. 29 is a perspective view of a contact terminal assembly having a pair of base plates of the back wired clamping arrangement of FIG. 27.

FIG. 30 is an exploded perspective view of the back wired clamping arrangement of FIG. 27.

FIG. 31 is an assembled perspective view of the back wired clamping arrangement of FIG. 30.

FIG. 32 is a side elevational view of the contact terminal assembly of FIG. 29.

FIG. 33 is a front plan view of the contact terminal assembly as seen along line 33--33 of FIG. 32.

FIG. 34 is a cross-sectional view of the contact terminal assembly taken along line 34--34 of FIG. 32.

FIG. 35 is a side elevational view of a clamp plate of the back wired clamping arrangement of FIG. 30.

FIG. 36 is a front plan view of the clamp plate as seen along line 36--36 of FIG. 35.

FIG. 37 is a rear plan view of the clamp plate as seen along line 37--37 of FIG. 35.

FIG. 38 is a side elevational view of the clamp plate as seen along line 38--38 of FIG. 35.

FIG. 39 is a perspective view of an enhanced terminal screw used in the receptacle of FIG. 1, the terminal screw having features constituting the invention of the third cross-referenced application.

FIG. 40 is a side elevational view of the screw of FIG. 36.

FIG. 41 is a top plan view of the screw as seen along line 41--41 of FIG. 40.

FIG. 42 is a bottom plan view of the screw as seen along line 42--42 of FIG. 40.

In the following description, like reference characters designate like or corresponding parts throughout the several views of the drawings. Also in the following description, it is to be understood that such terms as "forward", "rearward", "left", "right", "upwardly", "downwardly", and the like are words of convenience and are not to be construed as limiting terms.

In General

Referring to the drawings and particularly to FIG. 1, there is illustrated an electrical receptacle, generally designated 10, incorporating the features of the present invention as well as the features of the other inventions of the applications cross-referenced above. The electrical receptacle 10 basically includes a receptacle body 12, a base body 14, a pair of contact terminal assemblies 16, 18 and a U-shaped mounting bridge 20.

The receptacle body 12 of the receptacle 10 has a front side 12A with a pair of plug terminal contact receiving openings 22 formed therein, an opposite rear side 12B, and pairs of opposite ends 12C and sides 12D. The base body 14 of the receptacle 10 has opposite front and rear faces 14A, 14B and mates at its front face 14A with the rear side 12B of the receptacle body 12. The contact terminal assemblies 16, 18 of the receptacle 10 fit through respective cavities 24, 26 in the receptacle and base bodies 12, 14 such that the assemblies 16, 18 are aligned with pairs of the openings 22 of the receptacle body 12 for receiving therethrough and in electrically engagement with the assemblies 16, 18 the prongs of an electrical plug (not shown).

The mounting bridge 20 of the receptacle 10 has a base portion 28 for positioning adjacent the rear face 14B of the base body 14 and a pair of opposite leg portions 30 extending forwardly from opposite ends of the base portion 28 along opposite ends 12C of the receptacle body 12. The opposite ends 12C of the receptacle body 12 have lugs 31 with ramps 31A which snap fit within cutouts 30A defined in the opposite leg portions 30 of the mounting bridge 20 to secure the mounting bridge 20 to the receptacle body 12. The mounting bridge 20 also has pairs of arcuate-shaped wing portions 32 attached to the opposite leg portions 30 for inserting into slots 34 formed into the rear corners 12E of the receptacle body 12 and around the corners 14C of the base body 14 which fit within the rear corners 12E of the receptacle body 12. The mounting bridge 20 is thereby adapted to secure the receptacle and base bodies 12, 14 together in a mated relationship and captures the contact terminal assemblies 16, 18 therebetween. The bridge 20 also mounts ground contact assemblies 36 (FIGS. 9-11 and 14) which align with other of the openings 22 on the front side 12A of the receptacle body 12 for receiving a ground prong or pin of the electrical plug (not shown). The bridge 20 further has mounting tabs 38 attached to the opposite leg portions 30 and extending outwardly therefrom in opposite directions with eyelets 40 on the mounting tabs 38 and holes 38A through the tabs 38 for fastening the receptacle 10 to an external structure, such as a building wall, by the use of screws 42 inserted through the holes 38A and threaded into the structure.

Back Wired Clamping Arrangement

Referring now to FIGS. 1 and 27 to 38, there is illustrated a back wired clamping arrangement, generally designated 44, being the invention of the first application cross-referenced above. The back wired clamping arrangement 44 basically includes a base plate 46, a clamp plate 48 and a fastening means 50. The base plate 46 is connected to one of the contact terminal assemblies 16, 18 of the electrical receptacle 10. Each contact terminal assembly 16, 18 has a pair of base plates 46 connected thereto. The base plates 46 of each contact terminal assembly 16, 18 are interconnected and disposed in a side by side relationship to one another. Each contact terminal assembly 16, 18 receives a pair of clamp plates 48 such that each clamp plate 48 interfits with one of the base plates 46. Each contact terminal assembly 16, 18 utilizes a pair of fastening means 50. Each fastening means 50 secures a base plate 46 and a clamp plate 48 to one another.

The base plate 46 has a main body portion 52 with opposite side edges 54, a front edge 56 and a rear edge 58 together extending about and substantially surrounding the main body portion 52, and a pair of opposite forward side tabs 60 formed on the side edges 54. The main body portion 52 has a substantially flat configuration. The main body portion 52 of one base plate 46 is interconnected via a flange 62 to the main body portion 52 of the adjacent base plate 46 on the same contact terminal assembly 16, 18. The flange 62 extends between and is connected at the rear edges 58 of the base plates 46. Each forward side tab 60 extends outwardly from and along one of the side edges 54 from the front edge 56 to a point spaced from the rear edge 58. Each forward side tab 60 has a substantially rectangular configuration and is disposed in substantially perpendicular relation to the main body portion 52. The base plate 46 has a recess 64 defined in the front edge 56 thereof. The recess 64 is spaced an equal distance from each of the side edges 54. The recess 64 has a substantially three-sided U-shaped configuration. The base plate 46 also has a central passageway 66 defined through the main body portion 52 which is internally threaded and has a substantially circular configuration.

The clamp plate 48 has a main body portion 68 with opposite side edges 70, a front edge 72 and a rear edge 74 together extending about and substantially surrounding the main body portion 68, and a pair of opposite rearward side tabs 76 formed on the side edges 54 and a front tab 78 formed on the front edge 72. The main body portion 68 has a substantially flat configuration. Each rearward side tab 76 extends outwardly from and along one of the side edges 70 from the rear edge 74 to a point spaced from the front edge 72. Each rearward side tab 76 has a substantially rectangular configuration and is disposed in substantially perpendicular relation to the main body portion 68. The rearward side tabs 76 of the clamp plate 48 and the forward side tabs 60 of the base plate 46 are disposed in substantially parallel relation to one another. The rearward side tabs 76 of the clamp plate 48 and the forward side tabs 60 of the base plate 46 together form side walls. The front tab 78 extends outwardly from and along the front edge 72. The front tab 78 is spaced an equal distance from each of the side edges 70. The front tab 78 has a substantially rectangular configuration and is disposed in substantially perpendicular relation to the main body portion 68 and to the rearward side tabs 76 and to the forward side tabs 60. The front tab 78 inserts within the recess 64 of the base plate 46 and forms a front wall. With respect to their relative sizes, the area of each forward side tab 60 is greater than the area of the front tab 78 and less than the area of each rearward side tab 76. The clamp plate 48 has a central hole 80 defined through the main body portion 68. The central hole 80 has a substantially circular configuration. The central hole 80 is aligned with the central passageway 66 of the base plate 46.

The clamp plate 48 and the base plate 46 together define at least one and, preferably, a pair of channels 82. Each channel 82 is for receiving a multi-stranded wire 84 therethrough and such that the base and clamp plates 46, 48 substantially enclose and make electrical contact with the strands of the wire 84. The channels 82 are disposed in substantially parallel relation to one another. Each channel 82 is open at the front edges 56, 72 and at the rear edges 58, 74 of the base and clamp plates 46, 48. The side walls formed by the forward side tabs 60 of the base plate 46 and the rearward side tabs 76 of the clamp plate 48 and the main body portion 52 of the base plate 46 and the main body portion 68 of the clamp plate 48 all together provide each channel 82 with a substantially three-sided U-shaped configuration in transverse cross-section and such that the base plate 46 and the clamp plate 48 enclose and make electrical contact with the strands of the wire 84 on three sides. The front wall formed by the front tab 78 of the clamp plate 48 separates the channels 82 at the front edges 56, 72 of the base and clamp plates 46, 48. The front wall makes electrical contact with the strands of the wire 84 on a fourth side.

The fastening means 50 includes the central passageway 66 of the base plate 46, the central hole 80 of the clamp plate 48 and a screw 86. The screw 86 is any conventional type. The screw 86 is disposed through the central hole 80 of the clamp plate 48 and threadably inserted through the central passageway 66 of the base plate 46 and thereby secures the clamp plate 48 to the base plate 46. The screw 86 also makes electrical contact with the strands of the wire 84 on the fourth side. The screw 86 combines with the main body portions 52, 68 of the base and clamp plates 46, 48 and with one of the side walls formed by the forward side tabs 60 of the base plate 46 and the rearward side tabs 76 of the clamp plate 48 and with the front wall formed by the front tab 78 of the clamp plate 48 to enclose and make electrical contact with the strands of the wire 84 on four sides of the wire 84. The screw 86 separates the channels 82 at an intermediate point between the front edges 56, 72 and the rear edges 58, 74 of the base and clamp plates 46, 48. The screw 86 and the base and clamp plates 46, 48 securely bundle together the strands of the wire 84 during insertion into one of the channels 82 so as to prevent the strands of the wire 84 from spreading apart. The fastening means 50 may also include an anti-vibration washer 88 having an endless row of resiliently yieldable peripheral tabs 89 separated by slots 91. The washer 88 is disposed on the screw 86 such that its tabs 89 will apply pressure on the clamp plate 48 so as to retain the clamping action of the base and clamp plates 46, 48 on the wire 84 during vibration of the electrical receptacle 10.

Four-Sided Ground Contact Assembly

Referring now to FIGS. 1 to 8, there is illustrated the four-sided ground contact assembly, generally designated 90, of the present invention. The four-sided ground contact assembly 90 basically includes a first contact element 92 and a second contact element 94. Each of the first and second contact elements 92, 94 is mounted to the mounting bridge 20 of the electrical receptacle 10. The first contact element 92 has a pair of opposing contact leg portions 96 and a base portion 98. The second contact element 94 similarly has a pair of opposing contact leg portions 100 and a base portion 102. The leg portions 96, 100 of the first and second contact elements 92, 94 are circumferentially spaced from one another and provide four points of contact respectively on four sides of a ground prong or pin of an electrical plug (not shown).

The leg portions 96 of the first contact element 92 are spaced approximately 180.degree. apart. The leg portions 100 of the second contact element 94 are spaced approximately 180.degree. apart. Each leg portion 96, 100 of the first and second contact elements 92, 94 is spaced approximately 90.degree. apart from an adjacent one of the leg portions 96, 100 of the first and second contact elements 92, 94. Also, each of the first and second contact elements 92, 94 has a substantially U-shaped configuration. Each leg portion 96, 100 of the first and second contact elements 92, 94 has an upper end 96A, 100A and a lower end 96B, 100B. The points of contact of the leg portions 96, 100 are at 104. The point of contact 104 of the leg portion 96, 100 is disposed closer to the upper end 96A, 100A than to the lower end 96B, 100B of the leg portion 96, 100. Each leg portion 96 is made of a yieldable resilient material providing a spring bias of one leg portion 96 toward the other leg portion 96. Similarly, each leg portion 100 is made of a yieldable resilient material providing a spring bias of one leg portion 100 toward the other leg portion 100.

The base portion 98, 102 of the first and second contact elements 92, 94 extend between and connect with the lower ends 96B, 100B of the respective leg portions 96, 100 of the first and second contact elements 92, 94. The base portion 98 of the first contact element 92 is integral with the base portion 28 of the mounting bridge 20. The base portion 102 of the second contact element 94 is disposed above the base portion 98 of the first contact elements 92 and is mounted to the base portion 98 and thus to the mounting bridge 20 by a rivet 105 or the like. The base portion 102 of the second contact element 94 is slightly bowed upwardly such that the base portion 102 when secured by the rivet 105 to the mounting bridge 20 will contact the bridge 20 along the entire length of the base portion 102.

The points of contact 104 of each pair of leg portions 96, 100 of the first and second contact elements 92, 94 are disposed closer to one another than are the upper ends 96A, 100A or the lower ends 96B, 100B of the pairs of leg portions 96, 100. A portion of each leg portion 96, 100 between the point of contact 104 and the upper end 96A, 100A is arcuate shaped. A centerline C extends vertically between the pairs of the leg portions 96, 100 and represents the approximate location of the ground pin of the electrical plug. The upper end 96A, 100A of each leg portion 96, 100 is spaced from the centerline C approximately the same distance as the lower end 96B, 100B of each leg portion 96, 100.

Mounting Bridge With Enhanced Barbs

Referring now to FIGS. 1 and 9 to 26, there is illustrated a plurality of enhanced barbs, generally designated 106, being the invention of the second application cross-referenced above. The barbs 106 are provided on the mounting bridge 20 of the electrical receptacle 10. Each barb 106 is mounted on one of the arcuate-shaped wing portions 32 attached to the opposite leg portions 30 of the mounting bridge 20. The mounting bridge 20 preferably has four barbs 106. When the mounting bridge 20 is mated with the receptacle body 12 of the electrical receptacle 10, each barb 106 inserts into one of the slots 34 formed into the rear corners 12E of the receptacle body 12.

Each barb 106 basically includes an upright tab 108 and a plurality of teeth 110. The upright tab 108 of each barb 106 is mounted to one of the wing portions 32 of the mounting bridge 20. The teeth 110 are formed on the upright tab 108 and project outwardly therefrom in three directions such that the teeth 110 engage and bite into three sides of a respective one of the slots 34 of the receptacle body 12. The three directions which the teeth 110 project are orthogonal in relation to one another.

Each of the upright tabs 108 has a substantially rectangular configuration. The upright tab 108 has opposite side edges 108A and opposite inward and outward facing side surfaces 108B, 108C in relation to the mounting bridge 20. There are preferably two pairs or four teeth 110 associated with each tab 108. Each tooth 110 preferably has a substantially wedge-shaped three-dimensional configuration. One pair of the teeth 110 project from one of the opposite side edges 108A and the outward facing side surface 108C of the upright tab 108. The other pair of teeth 110 project from the other of the opposite edges 108A and the outward facing side surface 108C of the upright tab 108.

Terminal Screw With Impeller Wire Gripping Elements

Referring now to FIGS. 1 and 39 to 42, there is illustrated an enhanced terminal screw, generally designated 112, being the invention of the third application cross-referenced above. The screw 112 basically includes a shank 114, a head 116 and a plurality of impeller wire gripping elements 118. The shank 114 has opposite ends 114A, 114B. The head 116 is mounted to the opposite end 114A of the shank 114. The head 116 has an underside surface 120. The impeller wire gripping elements 118 formed on the underside surface 120 of the head 116 grip a wire (not shown) which partially surrounds the shank 114 and tends to more tightly wrap the wire radially inwardly toward the shank 114 as the screw 112 is tightened relative to the wire.

The impeller wire gripping elements 118 are spirally arranged on the underside surface 120 of the head 116. The impeller wire gripping elements 118 are symmetrically arranged about the shank 114. Each impeller wire gripping element 118 has an arcuate shape. The underside surface 120 of the head 116 defines a plurality of spaced apart grooves 122. The impeller wire gripping elements 118 are constituted by a plurality of lands 124 formed between the spaced apart grooves 122 on the underside surface 120 of the head 116. Each land 124 has opposite edges 126 adjacent to and spaced from such edges of other lands 124 by the widths of the grooves 122 so as to provide the gripping surfaces.

It is thought that the present invention and its advantages will be understood from the foregoing description and it will be apparent that various changes may be made thereto without departing from the spirit and scope of the invention or sacrificing all of its material advantages, the form hereinbefore described being merely preferred or exemplary embodiment thereof.