Electrical wiring device with high current USB charging capabilities

• US 8,758,031 B2
• Filed: 07/23/2012
• Issued: 06/24/2014
• Est. Priority Date: 04/19/2012
• Status: Active Grant

• Current Assignee: Pass & Seymour Incorporated (Legrand SA)
• Original Assignee: Pass & Seymour Incorporated (Legrand SA)
• Inventors: Cheng, Wai Chun, Lam, Chung Fai, Trolese, Lorenzo
• Primary Examiner(s): LE, THANH TAM T
• Application Number:
  US13/555,749
• Publication Number:
  US 20130280956A1
• Time in Patent Office: 701 Days
• Field of Search: 439/107, 439/535, 439/536, 439/538, 439/620.01, 439/620.15, 439650-652, 307/11, 307/12
• US Class Current: 439/107
• CPC Class Codes: H01H 13/023 Light-emitting indicators for multi-layer switches H01H13/83
• CPC Class Codes: H01H 13/20 Driving mechanisms
• CPC Class Codes: H01H 13/22 acting with snap action depending upon deformation of elastic members H01H13/26
• CPC Class Codes: H01H 13/30 one end of spring transmitting movement to the contact member when the other end is moved by the operating part
• CPC Class Codes: H01H 2219/036 Light emitting elements
• CPC Class Codes: H01H 2219/06 Reflector
• CPC Class Codes: H01H 2219/066 Lens
• CPC Class Codes: H01H 50/08 Indicators; Distinguishing marks
• CPC Class Codes: H01H 71/123 using a solid-state trip unit circuits H02H
• CPC Class Codes: H01H 71/128 Manual release or trip mechanisms, e.g. for test purposes two similar push buttons for closing or resetting and opening or tripping H01H71/58; test switches for earth fault circuit breakers H01H83/04
• CPC Class Codes: H01H 71/24 Electromagnetic mechanisms
• CPC Class Codes: H01H 71/50 Manual reset mechanisms which may be also used for manual release
• CPC Class Codes: H01R 13/506 assembled by snap action of the parts
• CPC Class Codes: H01R 13/514 composed as a modular blocks or assembly, i.e. composed of co-operating parts provided with contact members or holding contact members between them
• CPC Class Codes: H01R 13/518 for holding or embracing several coupling parts, e.g. frames
• CPC Class Codes: H01R 13/6658 on printed circuit board H01R13/6666 - H01R13/6691 take precedence
• CPC Class Codes: H01R 13/713 the switch being a safety switch
• CPC Class Codes: H01R 13/7135 with ground fault protector H01R13/7132 takes precedence
• CPC Class Codes: H01R 13/7175 Light emitting diodes (LEDs)
• CPC Class Codes: H01R 25/006 the coupling part being secured to apparatus or structure, e.g. duplex wall receptacle
• CPC Class Codes: H01R 43/20 : for assembling or disassembling contact members with insulating base, case or sleeve
• CPC Class Codes: H02G 3/081 : Bases, casings or covers
• CPC Class Codes: H02G 3/086 : Assembled boxes
• CPC Class Codes: H02G 3/10 : for surface mounting on a wall
• CPC Class Codes: H02G 3/12 : for flush mounting
• CPC Class Codes: H02G 3/14 : Fastening of cover or lid to box
• CPC Class Codes: H02G 3/18 : providing line outlets
• CPC Class Codes: H02H 3/162 : for ac systems
• CPC Class Codes: H02H 3/33 : using summation current transformers H02H3/347 takes precedence
• CPC Class Codes: H05K 5/02 : Details
• CPC Class Codes: H05K 5/0221 : Locks; Latches
• CPC Class Codes: H05K 7/026 : Multiple connections subassemblies

Abstract

The present invention is directed to an electrical wiring device that includes an AC power supply control circuit, an isolation interface circuit and a low voltage printed circuit board (PCB) assembly. The low voltage PCB assembly includes a universal serial bus (USB) charging interface circuit configured to convert the modulated power signal into a low voltage direct current (DC) charging signal. The at least one low voltage PCB assembly includes at least one USB socket coupled to the USB charging interface circuit and accessible via the at least one USB aperture formed in the front cover member. The USB charging interface circuit is configured to provide the low voltage DC charging signal to at least one device-under-charge at a maximum predetermined charging current.

Claims

1. An electrical wiring device comprising:

a housing assembly including a plurality of terminals configured to connect the device to an AC power source, the housing assembly further including a back body member coupled to a front cover member, the back body member further comprising at least one compartment, the at least one compartment including a separator member configured to divide the at least one compartment into at least one lower compartment and at least one upper compartment;

at least one AC printed circuit board (PCB) assembly disposed under the separator member within the at least one lower compartment and including an AC power supply control circuit coupled to the plurality of terminals, the AC power supply control circuit being configured to conduct a power control signal based on at least one feedback parameter, the at least one AC PCB assembly further including an isolation interface circuit coupled to the AC power supply control circuit, the isolation interface circuit being configured to provide a modulated power signal based on the power control signal and provide a feedback signal corresponding to the at least one feedback parameter to the AC power supply control circuit; and

at least one low voltage printed circuit board (PCB) assembly disposed over the separator member within the at least one upper compartment spaced apart from the at least one AC PCB assembly, the at least one low voltage PCB assembly including a universal serial bus (USB) charging interface circuit configured to convert the modulated power signal into a low voltage direct current (DC) charging signal, the at least one low voltage PCB assembly including at least one USB socket coupled to the USB charging interface circuit and accessible via the at least one USB aperture formed in the front cover member, the USB charging interface circuit being configured to provide the low voltage DC charging signal to at least one device-under-charge at a maximum predetermined charging current.

2. The device of claim 1, further comprising a mounting strap configured to affix the device to a device box, the device being configured to accommodate a cover plate to complete the enclosure.

3. The device of claim 1, further comprising a frame assembly configured to affix the device to a device box, the housing assembly being configured as modular housing insertable into the frame assembly to thereby complete the enclosure.

4. The device of claim 3, wherein the device box is a single gang device box and the frame assembly accommodates up to three modules selected from a group of modules including a USB module, an electrical switch module, or an outlet receptacle module.

5. The device of claim 3, further comprising an aesthetic cover plate that is configured to be connected to the frame assembly, the aesthetic cover plate not completing the enclosure.

6. The device of claim 1, wherein the plurality of terminals include a plurality of line terminals, a plurality of feed-through load terminals or a plurality of receptacle load terminals.

7. The device of claim 1, wherein the isolation interface circuit provides DC isolation between the at least one AC PCB assembly and the at least one low voltage PCB assembly.

8. The device of claim 1, wherein the modulated power signal includes a pulse width modulated signal.

9. The device of claim 1, wherein the maximum predetermined charging current is greater than two amperes (2 A).

10. The device of claim 1, wherein the at least one compartment includes a first compartment and a second compartment side-by-side adjacent thereto.

11. The device of claim 10, further comprising an electrical switch assembly including at least one user actuatable switch disposed in the second compartment, the electrical switch assembly being coupled to the AC power source via the plurality of terminals.

12. The device of claim 10, wherein the USB charging interface circuit includes a first single port USB socket spaced apart from a second single port USB socket, the first single port USB socket and the second single port USB socket being accessible via a first USB aperture and a second USB aperture, respectively, formed in a first portion of the front cover member corresponding to the first compartment.

13. The device of claim 12, further comprising an electrical receptacle disposed in the second compartment, the electrical outlet receptacle being coupled to the AC power source via the plurality of terminals.

14. The device of claim 12, further comprising an electrical switch assembly that includes at least one user actuatable switch disposed in the second compartment, the electrical switch assembly being coupled to the AC power source via the plurality of terminals.

15. The device of claim 14, wherein the electrical switch assembly includes at least one switch actuator disposed adjacent a modular element that substantially spans a width of the second compartment.

16. The device of claim 15, wherein the modular element is a lighting element.

17. The device of claim 16, wherein the lighting element is configured to be illuminated when the at least one switch actuator is turned OFF.

18. The device of claim 14, wherein the electrical switch assembly is a mechanical ON/OFF switch.

19. The device of claim 18, wherein the electrical switch assembly includes a paddle switch actuator.

20. The device of claim 12, wherein the first single port USB socket and the second single port USB socket combined are configured to provide the maximum predetermined charging current.

21. The device of claim 20, wherein the maximum predetermined charging current is greater than two amperes (2 A).

22. The device of claim 10, wherein the at least one AC PCB assembly includes a first AC PCB assembly disposed in the first compartment and a second AC PCB assembly disposed in the second compartment, and the at least one low voltage PCB assembly includes a first low voltage PCB assembly disposed in the first compartment and a second low voltage PCB assembly disposed in the second compartment.

23. The device of claim 22, wherein a first USB charging interface circuit of the first low voltage PCB assembly includes a first single port USB socket spaced apart from a second single port USB socket, the first single port USB socket and the second single port USB socket being accessible via a first USB aperture and a second USB aperture, respectively, formed in a first portion of the front cover member corresponding to the first compartment, and wherein a second USB charging interface circuit of the second low voltage PCB assembly includes a third single port USB socket spaced apart from a fourth single port USB socket, the third single port USB socket and the fourth single port USB socket being accessible via a third USB aperture and a fourth USB aperture, respectively, formed in a second portion of the front cover member corresponding to the second compartment.

24. The device of claim 23, wherein the first single port USB socket and the second single port USB socket combined are configured to provide the maximum predetermined charging current, and wherein the third single port USB socket and the fourth single port USB socket combined are configured to provide the maximum predetermined charging current.

25. The device of claim 24, wherein the maximum predetermined charging current is greater than two amperes (2 A).

26. The device of claim 22, wherein a first USB charging interface circuit of the first low voltage PCB assembly includes a first single port USB socket accessible via a first USB aperture formed in a first portion of the front cover member corresponding to the first compartment, and wherein a second USB charging interface circuit of the second low voltage PCB assembly includes a second single port USB socket accessible via a second USB aperture formed in a second portion of the front cover member corresponding to the second compartment.

27. The device of claim 26, wherein the first single port USB socket is configured to provide the maximum predetermined charging current, and wherein the second single port USB socket is configured to provide the maximum predetermined charging current.

28. The device of claim 1, wherein the at least one feedback parameter includes an amount of DC current being drawn by at least one device-under-charge.

29. The device of claim 1, wherein the at least one feedback parameter includes an ambient temperature proximate the at least one AC PCB assembly.

30. The device of claim 1, wherein the isolation interface circuit is configured to provide the AC power supply control circuit with a feedback signal corresponding to the amount of DC current being drawn by at least one device-under-charge.

31. The device of claim 1, wherein the isolation interface circuit includes a transformer circuit.

32. The device of claim 31, wherein the modulated power signal is provided to the at least one low voltage PCB assembly via the transformer circuit.

33. The device of claim 1, wherein the USB charging interface circuit includes a rectifier circuit to convert the modulated power signal into a low voltage direct current (DC) charging signal.

34. The device of claim 33, wherein the low voltage direct current (DC) charging signal is approximately +5 VDC.

35. The device of claim 1, wherein the at least one AC PCB assembly includes a first printed circuit board and the at least one low voltage PCB assembly includes a second printed circuit board that is substantially normal to the first printed circuit board.

36. The device of claim 1, wherein the back body member includes vent holes adjacent to the lower compartment.