ELECTRICAL CONNECTOR AND METHOD OF MANUFACTURING SAME

• US 20110065290A1
• Filed: 11/19/2010
• Published: 03/17/2011
• 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 8,002,554 B2
• Time in Patent Office: Days
• US Class Current: 439/18
• 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 innermost radius and an innermost surface along the innermost radius;

two or more electrical prongs, each prong of the two or more electrical prongs being in contact the innermost surface of a different one of the two or more conductors;

and

a housing comprising a rotatable 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 configured to be inserted into an electrical outlet;

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

the two or more conductors comprise;

a first conductor comprising at least a first portion of a first ring; and

a second conductor comprising at least a second portion of a second ring different than the first ring.

2. The electrical connector of claim 1, wherein:

the rotatable 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 to the two or more conductors.

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

a cable comprising;

a first wire coupled to the first conductor; and

a second wire coupled to the second conductor;

wherein a portion of the cable is enclosed by the housing.

4. The electrical connector of claim 1, wherein:

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

a first arm comprising;

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

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

and

a first flange extending from the first arm proximal end;

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

a second arm comprising;

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

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

and

a second flange extending from the second arm proximal end;

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

a third arm comprising;

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

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

and

a third flange extending from the third arm proximal end;

and

the two or more conductors further comprise;

a third conductor comprising at least a third portion of a third ring different than the first and second rings.

5. The electrical connector of claim 4, wherein:

the first arm of the first prong is substantially parallel to the axis;

the first flange of the first prong extends substantially normal to the first arm;

the second arm of the second prong is substantially parallel to the axis;

the second flange of the second prong extends substantially normal to the second arm;

the third arm of the third prong is substantially parallel to the axis; and

the third flange of the third prong extends substantially normal to the third arm.

6. The electrical connector of claim 4, wherein:

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

the second arm of the second prong comprises a second length different than the first length; and

the third arm of the third prong comprises a third length different than the first and second lengths.

7. The electrical connector of claim 4, wherein:

the rotatable portion comprises a plug face;

the first portion of the first prong comprises a first length from the plug face to the first flange;

the second portion of the second prong comprises a second length from the plug face to the second flange;

the third portion of the third prong comprises a third length from the plug face to the third flange; and

the first, second, and third lengths are different from each other.

8. The electrical connector of claim 4, wherein:

the rotatable portion comprises at least one of;

a first projection extending from an end of the rotatable portion and configured to maintain the first flange coplanar with the first conductor;

or

a second projection extending from the end of the rotatable portion and configured to maintain the second flange coplanar with the second conductor.

9. The electrical connector of claim 4, wherein:

the first prong comprises the first arm and the first flange as a first unitary structure;

the first flange of the first prong directly contacts the innermost surface of the first conductor;

the second prong comprises the second arm and the second flange as a second unitary structure;

the second flange of the second prong directly contacts the innermost surface of the second conductor;

the third prong comprises the third arm and the third flange as a third unitary structure; and

the third flange of the third prong directly contacts the innermost surface of the third conductor.

10. The electrical connector of claim 4, wherein:

the first conductor is continuous along a complete perimeter of the first ring and non-cradling with respect to the first flange of the first prong;

the second conductor is continuous along a complete perimeter of the second ring and non-cradling with respect to the second flange of the second prong;

the third conductor is continuous along a complete perimeter of the third ring and non-cradling with respect to the third flange of the third prong; and

the first, second, and third conductors are parallel and non-coplanar relative to each other.

11. The electrical connector of claim 1, wherein:

the housing comprises;

a first outer portion;

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

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

and

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

12. The electrical connector of claim 11, 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 secured within the cable receiving aperture.

13. The electrical connector of claim 1, wherein:

the two or more prongs are configured to rotate at least three hundred and sixty degrees about the axis.

14. The electrical connector of claim 1, wherein:

when the rotatable portion is rotated about the axis;

the first prong decouples from a first portion of the innermost surface of the first conductor and contacts a second portion of the innermost surface of the first conductor; and

the second prong decouples from a first portion of the innermost surface of the second conductor and contacts a second portion of the innermost surface of the second conductor.

15. An electrical connector comprising:

a housing comprising;

a 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 within the housing and comprising a first innermost surface along a first ring perimeter;

a second conductor within the housing and comprising a second innermost surface along a second ring perimeter;

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

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

wherein;

the first and second conductors are substantially parallel and non-coplanar relative to each other;

the first electrical prong comprises;

a first arm comprising;

a first arm distal end external to the rotatable section; and

a first arm proximal end internal to the rotatable section;

and

a first flange extending substantially perpendicular to the first arm from the first arm proximal end;

the first flange is unitary with the first arm of the first electrical prong and in direct contact with the innermost surface of the first conductor;

the second electrical prong comprises;

a second arm comprising;

a second arm distal end external to the rotatable section; and

a second arm proximal end internal to the rotatable section;

and

a second flange extending substantially perpendicular to the second arm from the second arm proximal end;

the second flange is unitary with the second arm of the second electrical prong and in direct contact with the second innermost surface of the second conductor;

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

the first and second conductors are substantially stationary relative to the axis when the rotatable section is rotated;

the first innermost surface of the first conductor is substantially continuous throughout the first ring perimeter;

the second innermost surface of the second conductor is substantially continuous throughout the second ring perimeter;

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

the second arm of the second electrical prong comprises a second length different than the first length.

16. The electrical connector of claim 15, wherein:

the rotatable section comprises;

a plug face;

first and second apertures at the plug face;

first and second internal projections; and

first and second slot mechanisms;

the first arm of the first prong comprises a first internal length from the plug face to the first flange;

the second arm of the second prong comprises a second internal length from the plug face to the second flange;

the first and second internal lengths are different from each other;

the first arm distal end extends through the first aperture past the housing;

the first slot mechanism engages the first flange at a first contact distance from the plug face and orients the first flange for contact with the first conductor;

the second arm distal end extends through the second aperture past the housing;

the second slot mechanism engages the second flange at a second contact distance from the plug face and orients the second flange for contact with the second conductor;

the first internal projection extends from an end of the rotatable portion and is abutted against the first flange of the first electrical prong to maintain the first flange in the first slot mechanism at the first contact distance from the plug face;

the first plane is separated from the plug face by the first contact distance;

the second internal projection extends from the end of the rotatable portion and is abutted against the second flange of the second electrical prong to maintain the second flange in the second slot mechanism at the second contact distance from the plug face;

the second plane is separated from the plug face by the second contact distance;

the first and second contact distances are different from each other; and

the rotatable section further comprises the plug face, the first and second apertures, and the first and second slot mechanisms, in a single piece of material.

17. The electrical connector of claim 16, further comprising:

a third conductor within the housing and comprising a third innermost surface along a third ring perimeter; and

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

wherein;

the housing encloses the third conductor and a proximal portion of the third electrical prong;

a distal portion of the third electrical prong is configured to extend past the housing to couple with the electrical outlet;

the third conductor is substantially stationary relative to the axis when the rotatable section is rotated;

the third innermost surface of the third conductor is continuous throughout the third ring perimeter;

the third electrical prong comprises;

a third arm comprising;

a third arm distal end external to the rotatable section; and

a third arm proximal end internal to the rotatable section;

and

a third flange extending substantially perpendicular to the third arm from the third arm proximal end;

the third flange is unitary with the third arm of the third electrical prong and in direct contact with the third innermost surface of the third conductor;

the first, second, and third flanges are uncradled by the two or more conductors;

the third arm of the third electrical prong comprises a third length different than the first and second lengths;

the first, second, and third conductors are substantially parallel and non-coplanar relative to each other;

a width of the first arm is greater than or equal to a width of the first flange; and

a width of the second arm is greater than or equal to a width of the second flange.

18. A method comprising:

providing a housing of an electrical connector;

providing a first conductor internal to the housing, the first conductor comprising a first innermost surface forming a continuous first ring within the housing;

providing a second conductor internal to the housing, the second conductor comprising a second innermost surface forming a continuous second ring within the housing;

providing a third conductor internal to the housing, the third conductor comprising a third innermost surface forming a continuous third ring within the housing;

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 prong arm extending past the rotatable section; and

a first prong flange unitary with the first arm and in contact with the first innermost surface of the first conductor within the housing;

providing a second electrical prong coupled to the rotatable section and comprising;

a second prong arm extending past the rotatable section; and

a second prong flange unitary with the second arm and in contact with the second innermost surface of the second conductor within the housing;

and

providing a third electrical prong coupled to the rotatable section and comprising;

a third prong arm extending past the rotatable section; and

a third prong flange unitary with the third arm and in contact with the third innermost surface of the third conductor within the housing;

wherein providing the first, second, and third conductors comprises;

providing the first, second, and third conductors to be parallel to each other and non-coplanar with each other.

19. The method of claim 18, wherein:

providing the rotatable section comprises;

providing first, second, and third apertures at a plug face of the rotatable section; and

providing first, second, and third slot mechanisms within the rotatable section;

providing the first electrical prong comprises;

providing the first prong flange substantially perpendicular to the first prong arm;

routing a distal portion of the first prong arm through the first aperture to an exterior of the housing; and

securing the first prong flange with one or more walls of the first slot mechanism at a first distance from the plug face to contact the first conductor at the first distance;

providing the second electrical prong comprises;

providing the second prong flange substantially perpendicular to the second prong arm;

routing a distal portion of the second prong arm through the second aperture to the exterior of the housing; and

securing the second prong flange with one or more walls of the second slot mechanism at a second distance from the plug face to contact the second conductor at the second distance;

providing the third electrical prong comprises;

providing the third prong flange substantially perpendicular to the third prong arm;

routing a distal portion of the third prong arm through the third aperture to the exterior of the housing; and

securing the third prong flange with one or more walls of the third slot mechanism at a third distance from the plug face to contact the third conductor at the third distance;

and

the first, second and third distances are different from each other.

20. The method of claim 19, wherein:

providing the first electrical prong comprises;

providing the first prong arm to comprise a first length;

providing the second electrical prong comprises;

providing the second prong arm to comprise a second length different than the first length;

providing the third electrical prong comprises;

providing the third prong arm to comprise a third length different than the first and second lengths;

providing the rotatable section comprises;

providing a first projection extending from an end of the rotatable portion;

abutting the first projection against the first prong flange to maintain the first prong flange in the first slot mechanism at the first distance from the plug face and in contact with the first innermost surface of the first conductor;

providing a second projection extending from the end of the rotatable portion;

and

abutting the second projection against the second prong flange to maintain the second prong flange in the second slot mechanism at the second distance from the plug face and in contact with the second innermost surface of the second conductor.