Electrical Connector And Method Of Manufacturing Same

• US 20090258508A1
• Filed: 06/24/2009
• Published: 10/15/2009
• Est. Priority Date: 04/20/2007
• Status: Active Grant

• Current Assignee: Belkin International Incorporated (Hon Hai Precision Industry Co., Ltd.)
• Original Assignee: Belkin International Incorporated (Hon Hai Precision Industry Co., Ltd.)
• Inventors: Wadsworth, John
• Granted Patent: US 7,850,458 B2
• Time in Patent Office: Days
• US Class Current: 439/21
• CPC Class Codes: H01R 13/652 with earth pin, blade or socket
• CPC Class Codes: H01R 2103/00 Two poles
• CPC Class Codes: H01R 24/30 with additional earth or shield contacts
• CPC Class Codes: H01R 35/04 Turnable line connectors with limited rotation angle with frictional contact members
• CPC Class Codes: H01R 39/64 Devices for uninterrupted current collection
• CPC Class Codes: Y10T 29/49204 Contact or terminal manufacturing
• CPC Class Codes: Y10T 29/532 Conductor

Abstract

Embodiments of electrical connectors and related methods of manufacture are described herein. Other embodiments and related methods are also disclosed herein.

Claims

1. An electrical connector comprising:

two or more conductors, each conductor of the two or more conductors has an inner radius and an inner surface along the inner radius;

two or more electrical prongs, each prong of the two or more electrical prongs contacts and is electrically coupled to the inner surface of a different one of the two or more conductors; and

a housing having a first portion and enclosing the two or more conductors and a first portion of each of the two or more electrical prongs,

wherein;

a second portion of each of the two or more electrical prongs is capable of being inserted into an electrical outlet;

the two or more electrical prongs extend out of the first portion of the housing and are rotatable about an axis substantially perpendicular to the first portion of the housing;

the two or more conductors are substantially stationary relative to the axis when the two or more electrical prongs are rotated;

the two or more conductors comprise;

a first conductor comprising a first portion of a ring;

a second conductor comprising a second portion of the ring; and

a third conductor comprising a third portion of the ring.

2. The electrical connector of claim 1, wherein:

the first portion of the housing and the two or more electrical prongs are configured to rotate about the axis relative to a second portion of the housing and the two or more conductors.

3. The electrical connector of claim 1, further comprising:

a cable comprising two or more electrical wires,

wherein;

a portion of the cable is enclosed by the housing; and

each conductor of the two or more conductors is electrically coupled to a different one of the two or more wires.

4. The electrical connector of claim 1, wherein:

a first prong of the two or more electrical prongs comprises;

a first arm having;

a first distal end at the second portion of the first prong; and

a first proximal end at the first portion of the first prong;

and

a first flange at the first proximal end of the first arm, wherein the first flange and the first arm are a first single piece;

a second prong of the two or more electrical prongs comprises;

a second arm having;

a second distal end at the second portion of the second prong; and

a second proximal end at the first portion of the second prong;

and

a second flange at the second proximal end of the second arm, wherein the second flange and the second arm are a second single piece;

and

a third prong of the two or more electrical prongs comprises;

a third arm having;

a third distal end at the second portion of the third prong; and

a third proximal end at the first portion of the third prong;

and

a third flange at the third proximal end of the third arm, wherein the third flange and the third arm are a third single piece.

5. The electrical connector of claim 4, wherein:

the first flange of the first prong contacts the inner surface of the first conductor;

the second flange of the second prong contacts the inner surface of the second conductor; and

the third flange of the third prong contacts the inner surface of the third conductor.

6. The electrical connector of claim 4, wherein:

the first arm of a first prong comprises a first length; and

the second arm of the second prong comprises a second length different from the first length.

7. The electrical connector of claim 6, wherein:

the third arm of the third prong comprises the first length.

8. The electrical connector of claim 1, wherein:

the housing comprises;

a first outer portion;

a second outer portion comprising a main face, the main face having an aperture; and

a plug face portion adjacent to the aperture in the main face of the second outer portion;

and

the first portion of the housing comprises the plug face portion.

9. The electrical connector of claim 8, further comprising:

a cable coupled to the two or more conductors,

wherein;

the first outer portion of the housing forms a first portion of a cable receiving aperture;

the second outer portion of the housing forms a second portion of the cable receiving aperture; and

a portion of the cable is located within the cable receiving aperture.

10. The electrical connector of claim 1, wherein:

the two or more prongs are configured to rotate at least approximately one hundred and twenty degrees about the axis.

11. The electrical connector of claim 1, wherein:

the two or more electrical prongs comprise;

a first prong contacting the inner surface of the first conductor of the two or more conductors;

a second prong contacting the inner surface of the second conductor of the two or more conductors; and

a third prong contacting the inner surface of the third conductor of the two or more conductors.

12. The electrical connector of claim 1, wherein:

a first prong of the two or more electrical prongs contacts a first portion of the inner surface of the first conductor;

the first prong of the two or more electrical prongs contacts at least a second portion of the inner surface of the first conductor when the two or more electrical prongs are rotated about the axis;

a second prong of the two or more electrical prongs contacts a first portion of the inner surface of the second conductor; and

the second prong of the two or more electrical prongs contacts at least a second portion of the inner surface of the second conductors when the two or more electrical prongs are rotated about the axis.

13. The electrical connector of claim 1, wherein:

the two or more conductors define a plane through the housing; and

the planes is substantially perpendicular to the axis.

14. An electrical connector comprising:

a housing comprising;

a first outer section;

one or more protrusions coupled to the first outer section; and

a second outer section configured to couple with the first outer section;

a rotatable section coupled at least partially between the first and second outer sections of the housing;

a first conductor coupled to a first part of the one or more protrusions of the housing and comprising a first innermost surface along a first portion of a ring perimeter;

a second conductor coupled to a second part of the one or more protrusions of the housing and comprising a second innermost surface along a second portion of the ring perimeter;

a third conductor coupled to a third part of the one or more protrusions of the housing and comprising a third innermost surface along a third portion of the ring perimeter;

a first electrical prong coupled to the rotatable section and to the first innermost surface of the first conductor;

a second electrical prong coupled to the rotatable section and to the second innermost surface of the second conductor;

a third electrical prong coupled to the rotatable section and to the third innermost surface of the third conductor;

wherein;

the first and second outer sections of the housing enclose the first, second and third conductors and proximal portions of each of the first, second, and third electrical prongs;

distal portions of the first, second, and third electrical prongs are configured to extend past the housing to couple with an electrical outlet;

the rotatable section is rotatable along with the first, second, and third electrical prongs about an axis substantially perpendicular to the first outer section of the housing; and

the two or more conductors are substantially stationary relative to the axis when the rotatable section is rotated.

15. The electrical connector of claim 14, wherein:

the proximal portion of the first electrical prong comprises a first flange configured to remain in contact with the first innermost surface of the first conductor when the rotatable section is rotated;

the proximal portion of the second electrical prong comprises a second flange configured to remain in contact with the second innermost surface of the second conductor when the rotatable section is rotated; and

the proximal portion of the third electrical prong comprises a third flange configured to remain in contact with the third innermost surface of the third conductor when the rotatable section is rotated.

16. The electrical connector of claim 15, wherein:

the first flange is formed integrally with the first prong;

the second flange is formed integrally with the second prong; and

the third flange is formed integrally with the third prong.

17. The electrical connector of claim 15, wherein:

the rotatable section comprises;

a first aperture through which the distal portion of the first electrical prong extends past the housing;

a second aperture through which the distal portion of the second electrical prong extends past the housing;

a third aperture through which the distal portion of the third electrical prong extends past the housing;

a first slot configured to at least partially enclose the first flange of the first prong;

a second slot configured to at least partially enclose the second flange of the second prong; and

a third slot configured to at least partially enclose the third flange of the third prong.

18. The electrical connector of claim 15, wherein:

the rotatable section comprises a stopper; and

the housing comprises a notch configured to accommodate the stopper of the rotatable section;

wherein;

the stopper traverses along the notch when the rotatable section is rotated; and

opposite ends of the notch bound the stopper and restrict rotation of the rotatable section to approximately one hundred twenty degrees.

19. A method comprising:

providing a housing of an electrical connector, the housing comprising one or more internal protrusions;

coupling a first conductor to a first part of the one or more internal protrusions to comprise a first portion of a conductor ring;

coupling a second conductor to a second part of the one or more internal protrusions to comprise a second portion of the conductor ring;

coupling a third conductor to a third part of the one or more internal protrusions to comprise a third portion of the conductor ring;

providing a rotatable section at least partially enclosed within the housing;

providing a first electrical prong coupled to the rotatable section and comprising a first flange in contact with a first innermost surface of the first conductor;

providing a second electrical prong coupled to the rotatable section and comprising a second flange in contact with a second innermost surface of the second conductor; and

providing a third electrical prong coupled to the rotatable section and comprising a third flange in contact with a third innermost surface of the third conductor.

20. The method of claim 19, wherein:

providing the rotatable section comprises;

providing first, second, and third apertures in the rotatable section towards an exterior of the housing; and

providing first, second, and third slots within the rotatable section;

providing the first electrical prong comprises;

routing a distal portion of the first electrical prong through the first slot towards the exterior of the housing; and

securing the first flange of the first electrical prong with one or more walls of the first slot;

providing the second electrical prong comprises;

routing a distal portion of the second electrical prong through the second slot towards the exterior of the housing; and

securing the second flange of the second electrical prong with one or more walls of the second slot;

and

providing the third electrical prong comprises;

routing a distal portion of the third electrical prong through the third slot towards the exterior of the housing; and

securing the third flange of the third electrical prong with one or more walls of the third slot.

21. The method of claim 19, wherein:

providing the housing comprises;

providing a notch within the housing;

and

providing the rotatable section comprises;

providing a stopper coupled to a surface of the rotatable section; and

coupling the stopper within opposite ends of the notch of the housing to restrict rotation of the rotatable section to approximately one hundred twenty degrees.

22. The method of claim 19, wherein:

coupling the first, second, and third conductors comprises;

coupling the first, second, and third conductors along a plane parallel to a surface of the housing and substantially perpendicular to distal portions of the first, second, and third electrical prongs.