Electrical receptacle assembly with housing

• US 9,368,924 B2
• Filed: 05/08/2015
• Issued: 06/14/2016
• Est. Priority Date: 05/09/2014
• Status: Active Grant

• Current Assignee: Byrne Electrical Specialists Incorporated
• Original Assignee: Norman R. Byrne
• Inventors: Byrne, Norman R., Young, Patrick E., Petersen, Thomas A., Pate, Randell E.
• Primary Examiner(s): Riyami, Abdullah
• Assistant Examiner(s): Alhawamdeh, Nader J
• Application Number:
  US14/707,579
• Publication Number:
  US 20150325962A1
• Time in Patent Office: 403 Days
• Field of Search: 439/106, 439/536, 439/535, 439/529, 174/66, 174/53
• US Class Current: 1/1
• CPC Class Codes: H01R 13/5205 Sealing means between cable and housing, e.g. grommet H01R13/5221 takes precedence
• CPC Class Codes: H01R 13/73 Means for mounting coupling parts to apparatus or structures, e.g. to a wall
• CPC Class Codes: H01R 13/743 integral with the housing
• CPC Class Codes: H01R 2103/00 Two poles
• CPC Class Codes: H01R 24/22 with additional earth or shield contacts
• CPC Class Codes: H01R 24/30 with additional earth or shield contacts
• CPC Class Codes: H01R 31/06 Intermediate parts for linking two coupling parts, e.g. adapter with a holder adapted for supporting apparatus to which its counterpart is attached H01R33/94
• CPC Class Codes: H02G 3/12 for flush mounting

Abstract

An electrical receptacle assembly with protective housing is adapted for installation in unconventional areas or surfaces, including areas that are more susceptible to spills or other contaminants than traditional mounting locations. The electrical receptacle assembly includes a receptacle subassembly with a main receptacle body and a front surface portion in which a plurality of electrical contacts are housed and made accessible to corresponding contacts of an electrical or electronic device. A housing defines a cavity for receiving the receptacle body, and a face plate is coupled to the housing and defines a receptacle opening for engaging and supporting the electrical receptacle subassembly. The face plate may take on many different sizes and shapes for a desired application, while the other components of the electrical receptacle assembly can remain the same.

Claims

1. An electrical receptacle assembly comprising:

a face plate defining a receptacle opening;

an electrical receptacle subassembly having a main receptacle body, a front surface portion defining at least one contact opening, electrical wiring, and a plurality of electrical contacts disposed in said main receptacle body behind said front surface portion and electrically coupled to said electrical wiring, said electrical contacts being accessible through said at least one contact opening;

wherein said electrical receptacle subassembly is configured for insertion of said main receptacle body through said receptacle opening with said front surface portion engaging said face plate at said receptacle opening, whereby said electrical receptacle subassembly is supported by said face plate;

a housing defining a cavity for receiving said main receptacle body, said housing having a front opening through which said main receptacle body is received, and a rear opening through which passes said electrical wiring; and

wherein said face plate is coupled directly to said housing at said front opening.

2. The electrical receptacle assembly of claim 1, wherein:

said face plate comprises at least one hollow projection configured to extend into said housing when said face plate is coupled thereto;

said housing defines at least one fastener opening that is substantially aligned with said hollow projection; and

a fastener that extends through said fastener opening and engages said hollow projection;

wherein said fastener and said at least one hollow projection cooperate to secure said face plate at said housing.

3. The electrical receptacle assembly of claim 2, comprising at least two of said hollow projections, at least two of said fastener openings, and at least two of said fasteners.

4. The electrical receptacle assembly of claim 2, wherein said hollow projection comprises a tubular cylinder and said housing defines an elongate channel configured for receiving said tubular cylinder, wherein said elongate channel terminates at said fastener opening, and wherein said fastener comprises a threaded shaft configured to engage an inner surface of said tubular cylinder.

5. The electrical receptacle assembly of claim 4, wherein said face plate is substantially planar.

6. The electrical receptacle assembly of claim 5, wherein said face plate is polygonal or circular in shape.

7. The electrical receptacle assembly of claim 1, wherein said face plate comprises a concave rear surface and said housing comprises a convex forward surface defining at least a portion of said front opening, wherein said concave rear surface sealingly engages said convex forward surface at said front opening.

8. The electrical receptacle assembly of claim 1, wherein said face plate sealingly engages said housing at said front opening.

9. The electrical receptacle assembly of claim 8, further comprising a wire grommet disposed in said rear opening of said housing, said wire grommet configured for receiving the electrical wiring.

10. The electrical receptacle assembly of claim 1, wherein said face plate comprises a formed channel member defining a recessed region in which said front surface portion of said electrical receptacle subassembly is positioned and accessible.

11. The electrical receptacle assembly of claim 1, wherein said face plate defines at least one fastener opening configured to receive a fastener for attaching said electrical receptacle assembly to a surface.

12. The electrical receptacle assembly of claim 1, wherein said face plate comprises a resilient latch tab for releasably securing said face plate to an opening formed in a surface.

13. The electrical receptacle assembly of claim 1, further comprising:

an electrical plug having a insulative body and a plurality of male prongs in electrical communication with said electrical wiring of said electrical receptacle subassembly; and

a contiguous molded rubber or rubber-like insulative coating forming (i) said main receptacle body, (ii) said front surface portion, (iii) said insulative body of said electrical plug, and (iv) an insulative jacket around said electrical wiring between said main receptacle body and said electrical plug, and filling spaces disposed between said electrical contacts of said electrical receptacle subassembly.

14. An electrical receptacle assembly comprising:

a face plate defining a receptacle opening and having at least one tubular projection configured to extend into a housing when said face plate is coupled thereto;

an electrical receptacle subassembly having a main receptacle body, a front surface portion defining at least one contact opening, electrical wiring, and a plurality of electrical contacts disposed in said main receptacle body behind said front surface portion and electrically coupled to said electrical wiring, said electrical contacts being accessible through said at least one contact opening;

wherein said electrical receptacle subassembly is configured for insertion of said main receptacle body through said receptacle opening with said front surface portion engaging said face plate at said receptacle opening, whereby said electrical receptacle subassembly is supported by said face plate;

said housing defining a cavity for receiving said main receptacle body, an elongate channel for receiving said tubular projection of said face plate, and a fastener opening at an end of said elongate channel, said housing having a front opening through which said main receptacle body is received, and a rear opening through which passes said electrical wiring; and

a fastener extending through said fastener opening an into said elongate channel for engagement with said tubular projection.

15. The electrical receptacle assembly of claim 14, wherein said face plate is coupled directly to said housing at said front opening, and wherein said fastener threadedly engages said tubular projection.

16. The electrical receptacle assembly of claim 15, wherein said elongate channel is open to said cavity.

17. The electrical receptacle assembly of claim 14, further comprising:

an electrical plug having a insulative body and a plurality of male prongs in electrical communication with said electrical wiring of said electrical receptacle subassembly; and

a contiguous molded rubber or rubber-like insulative coating forming (i) said main receptacle body, (ii) said front surface portion, (iii) said insulative body of said electrical plug, and (iv) an insulative jacket around said electrical wiring between said main receptacle body and said electrical plug, wherein said insulative coating is further disposed between said electrical contacts of said electrical receptacle subassembly.

18. The electrical receptacle assembly of claim 14, wherein said face plate comprises a curved rear surface and said housing comprises a curved forward surface defining at least a portion of said front opening and having a curvature that generally corresponds to said curved rear surface of said face plate.

19. The electrical receptacle assembly of claim 18, wherein said curved rear surface of said face plate sealingly engages said curved forward surface of said housing at said front opening.

20. The electrical receptacle assembly of claim 14, wherein said face plate comprises at least one chosen from (i) a fastener opening configured to receive a fastener for attaching said electrical receptacle assembly to a surface, and (ii) a resilient latch tab for releasably securing said face plate to an opening formed in a surface.