Plug and cord connector set with integrated circuitry

• US 20060270250A1
• Filed: 05/26/2006
• Published: 11/30/2006
• Est. Priority Date: 05/26/2005
• Status: Active Grant

• Current Assignee: Fiber Optic Designs Incorporated
• Original Assignee: Fiber Optic Designs Incorporated
• Inventors: Allen, David
• Granted Patent: US 7,377,802 B2
• Time in Patent Office: Days
• US Class Current: 439/43
• CPC Class Codes: F21S 4/26 of rope form, e.g. LED lighting ropes, or of tubular form
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: H01R 13/6658 on printed circuit board H01R13/6666 - H01R13/6691 take precedence
• CPC Class Codes: H01R 13/6666 with built-in overvoltage protection
• CPC Class Codes: H01R 13/6675 with built-in power supply
• CPC Class Codes: H01R 2103/00 Two poles
• CPC Class Codes: H01R 24/66 with pins, blades or analogous contacts and secured to apparatus or structure, e.g. to a wall
• CPC Class Codes: H01R 29/00 Coupling parts for selective co-operation with a counterpart in different ways to establish different circuits, e.g. for voltage selection, for series-parallel selection, programmable connectors

Abstract

A plug and/or a plug and cord connector set that is easily mass produced and includes integrated circuitry for use with decorative lighting products such as Christmas lights and rope lights. The integrated circuitry included in the plug and/or plug and cord connector combination can serve to reduce or limit current, provide full-wave AC to DC rectification, provide overload protection, reduce voltage, protect against voltage spikes, add blinking or flashing functions, or any combination thereof. An optional intermediate circuit is included for the manufacture of light strings employing multiple series connections.

Claims

1. A connector assembly for an LED lighting chain, comprising:

an inner component housing;

a pair of conductor blade symmetrically secured to said inner component housing;

a circuit board housing electrical components of a current altering circuit, said circuit board being a modular unit that is mounted to said inner component housing;

a protective outer housing adapted to insulate and protect said inner component housing and said circuit board;

at least one LED serial set electrically connected to said conductor blades through conductor wires.

2. The connector assembly of claim 1, wherein said current altering circuit defines a rectifier circuit.

3. The connector assembly of claim 1, further comprising a female receptacle adapted to received a second set of conductor blades to define a stackable plug connector.

4. The connector assembly of claim 1, wherein said circuit board draws inbound electrical alternating current from said conductor blades through an overload protection device.

5. The connector assembly of claim 1, wherein said conductor blades are polarized such that the blades are different widths.

6. The connector assembly of claim 1, wherein said inner component housing comprises at least one fuse compartment for receiving at least one fuse adapted to electrically connect said conductor blade with said wires.

7. The connector assembly of claim 1, wherein said inner component housing comprises at least one locking tab for locking said inner compartment housing to said outer housing.

8. The connector assembly of claim 1, wherein the inner component housing and said circuit board as a modular assembly are affixed to said outer housing by a snap-fit connection.

9. The connector assembly of claim 1, wherein said inner component housing comprises slots for mounting the conductor blades.

10. The connector assembly of claim 1, wherein said circuit board is configured to accommodate through-hole or surface mount electronic components and microelectronic circuits.

11. The connector assembly of claim 1, wherein said circuit board is sealed to protect the electrical components.

12. The connector assembly of claim 1, wherein said circuit board houses a plurality of series resistors, conductor wires connections and connector blade contact pads.

13. The connector assembly of claim 1, wherein said circuit board houses rectifying diodes and at least one resistor.

14. The connector assembly of claim 13 wherein said circuit board further houses a capacitor connected in parallel across DC terminals of said rectifying diodes in order to smooth DC ripples.