Electrical power load switch with connection sensor

• US 10,177,507 B2
• Filed: 02/09/2017
• Issued: 01/08/2019
• Est. Priority Date: 02/12/2016
• Status: Active Grant

• Current Assignee: Norman R. Byrne
• Original Assignee: Norman R. Byrne
• Inventors: Byrne, Norman R., Burdi, Roger D., Li, Shixiong
• Primary Examiner(s): Cavallari, Daniel
• Application Number:
  US15/428,276
• Publication Number:
  US 20170237206A1
• Time in Patent Office: 698 Days
• Field of Search: None
• CPC Class Codes: G01R 33/07 Hall effect devices
• CPC Class Codes: G05B 11/01 electric
• CPC Class Codes: H01R 13/6205 Two-part coupling devices held in engagement by a magnet
• CPC Class Codes: H01R 13/6675 with built-in power supply
• CPC Class Codes: H01R 13/6683 with built-in sensor
• CPC Class Codes: H01R 13/703 operated by engagement or disengagement of coupling parts, e.g. dual-continuity coupling partH01R13/71 takes precedence
• CPC Class Codes: H01R 13/7038 making use of a remote controlled switch, e.g. relais, solid state switch activated by the engagement of the coupling parts
• CPC Class Codes: H01R 13/73 Means for mounting coupling parts to apparatus or structures, e.g. to a wall
• CPC Class Codes: H01R 24/76 with sockets, clips or analogous contacts and secured to apparatus or structure, e.g. to a wall

Abstract

An electrical power coupler is configured to convey electrical power upon detecting that a compatible other coupler is properly aligned and no undesirable operating conditions are detected. The power coupler includes a first ferromagnetic metal adjacent a first magnet, a hall sensor for detecting a magnetic field in the first ferromagnetic metal, and at least two first electrical contacts. A control unit is in electrical communication with the power conductors, and includes an electrical switch operable to selectively allow a flow of electricity from a power source through the associated power conductors when the hall sensor detects the magnetic field, such as when the first electrical contacts are in contact with at least two second electrical contacts of another electrical power coupler. The second electrical contacts make contact with the first electrical contacts upon proper alignment of a correspondingly configured other electrical power coupler.

Claims

1. An electrical power coupler comprising:

a first ferromagnetic metal adjacent to a first magnet, a hall sensor operable to detect a magnetic field in the first ferromagnetic metal, and at least two first electrical contacts, each first contact coupled to a respective one of at least two power conductors that are coupled to a power source;

a control unit in electrical communication with said power conductors, said control unit comprising an electrical switch associated with at least one of said power conductors and operable to selectively allow a flow of electricity through said power conductors when said hall sensor detects said magnetic field;

wherein said hall sensor detects said magnetic field when said first electrical contacts are in contact with at least two second electrical contacts of an other electrical power coupler, and wherein the second electrical contacts make contact with said first electrical contacts when said first magnet is aligned with a second ferromagnetic metal of the other electrical power coupler and when a second magnet of the other electrical power coupler is aligned with said first ferromagnetic metal.

2. The electrical power coupler claimed in claim 1, wherein said hall sensor is further operable to output a signal to said control unit when said magnetic field is above a threshold level.

3. The electrical power coupler claimed in claim 2, wherein said magnetic field is above said threshold when the second electrical contacts are axially aligned with said first electrical contacts.

4. The electrical power coupler as claimed in claim 1, further in combination with the power source, wherein said power source is operable to provide direct current (DC) power.

5. The electrical power coupler as claimed in claim 1, wherein said control unit is operable to measure a current in said power conductors and to selectively prevent said flow of electricity through said power conductors when a measured current is above a current threshold.

6. The electrical power coupler as claimed in claim 1, wherein said electrical power coupler is configured for installation in one of a wall or an article of furniture.

7. An electrical power distribution system comprising:

a first power coupler comprising a first ferromagnetic metal adjacent to a first magnet, a first hall sensor operable to detect a first magnetic field in the first ferromagnetic metal, and at least two first electrical contacts, each first contact coupled to a respective one of at least two first power conductors that are coupled to a power source;

a first control unit in electrical communication with said first power conductors, said first control unit comprising a first electrical switch associated with at least one of said first power conductors and operable to selectively conduct a flow of electricity through said first power conductors when said first hall sensor detects said first magnetic field; and

at least one power cable assembly comprising a second power coupler having at least two second electrical contacts and a second ferromagnetic metal adjacent to a second magnet, said second power coupler at an end portion of said power cable assembly;

wherein said first hall sensor detects said first magnetic field when said second electrical contacts are in contact with said first electrical contacts, and wherein contacting said second electrical contacts with said first electrical contacts axially aligns said first magnet with said second ferromagnetic metal and said second magnet with said first ferromagnetic metal.

8. The electrical power distribution system as claimed in claim 7, wherein said first hall sensor is further operable to output a signal to said first control unit when said first magnetic field is above a first threshold level.

9. The electrical power distribution system as claimed in claim 8, wherein said first magnetic field is above said first threshold when said second electrical contacts are axially aligned with said first electrical contacts.

10. The electrical power distribution system as claimed in claim 7, wherein said power cable assembly further comprises at least two second power conductors coupled to said second electrical contacts, and an accessory power outlet operable to supply power to personal electronic devices via said second power conductors.

11. The electrical power distribution system as claimed in claim 7, wherein said power source is operable to provide direct current (DC) power.

12. The electrical power distribution system as claimed in claim 7, wherein said power cable assembly further comprises a third power coupler at an opposite end portion of said power cable assembly from said second power coupler, wherein said third power coupler comprises at least two third electrical contacts, a third ferromagnetic metal adjacent to a third magnet, and a third hall sensor operable to detect a magnetic field from said third ferromagnetic metal.

13. The electrical power distribution system as claimed in claim 7, wherein said first power coupler comprises said first control unit.

14. The electrical power distribution system as claimed in claim 10, wherein said second power coupler further comprises a second hall sensor and a second control unit, wherein said second hall sensor is operable to detect a second magnetic field from said second ferromagnetic metal, and wherein said second control unit is further operable to selectively allow a flow of electricity through said second power conductors via an electrical switch associated with at least one of said second power conductors when said second hall sensor detects said second magnetic field.

15. The electrical power distribution system as claimed in claim 7, wherein said first control unit is further operable to measure a current in said first power conductors and further yet operable to selectively prevent said flow of electricity through said first power conductors when a measured current is above a current threshold.

16. The electrical power distribution system as claimed in claim 7, wherein said power cable assembly is integrated into an article of furniture.

17. A method for selectively powering an electrical power distribution system, the method comprising:

aligning a first ferromagnetic metal and a first magnet of a first power coupler to a second magnet and a second ferromagnetic metal, respectively, of a second power coupler;

measuring, with a hall sensor, a first magnetic field strength in the second ferromagnetic metal;

comparing, with a control unit, the first magnetic field strength to a first threshold, wherein the hall sensor is communicatively coupled to the control unit; and

with the control unit, selectively connecting power via a power source to two second electrical contacts of the second power coupler when the first magnetic field strength is above the first threshold.

18. The method as claimed in claim 17, wherein said selectively connecting power to the second electrical contacts comprises connecting at least two power conductors from the power source to the second electrical contacts via an electric switch.

19. The method as claimed in claim 18, wherein the first magnetic field strength is above the first threshold when the second electrical contacts of the second power coupler are axially aligned with at least two first electrical contacts of the first power coupler.

20. The method as claimed in claim 19, wherein the first electrical contacts of the first power coupler are in electrical contact with the second electrical contacts of the second power coupler when the first magnet and the first ferromagnetic metal are aligned with the second ferromagnetic metal and second magnet, respectively, and wherein the electrical contacts of the second power coupler are in electrical communication with the power source via the power conductors when the power source is selectively connected to the second power coupler.

21. The method as claimed in claim 17, wherein measuring the first magnetic field strength is performed by the hall sensor positioned adjacent to the second ferromagnetic metal.

22. The method as claimed in claim 17 further comprising measuring a current in the power conductors and selectively disconnecting the power to the second electrical contacts when a measured current in the power conductors is above a current threshold.