Electrical plug with replaceable surge protector

Abstract

This invention relates to an electrical plug with a replaceable surge protector that provides protection against electrical surges using a replaceable surge protector housing that can be easily removed and replaced along the outside of the plug. The surge protector circuitry within the housing absorbs electrical surges received from the mains power supply at the plug, and the plug maintains electrical continuity from the plug pins to the wires both before and after the surge protector has absorbed the surge.

Description

[0001] This application is a divisional application of the invention patent application entitled "Electric Plug with Replaceable Surge Protector", filed on May 11, 2022, with application number 202210510937.8.

[0002] Cross-reference to related applications

[0003] This application claims priority to U.S. Provisional Application No. 63 / 248,174, filed September 24, 2021, and to U.S. Provisional Application No. 63 / 187,072, filed May 11, 2021, the entire contents of which are incorporated herein by reference. Technical Field

[0004] This invention relates to a power plug for inserting into an electrical socket and supplying power to electrical equipment. Background Technology

[0005] Electrical plugs are typically used at the power receiving end of wires used to supply power to various devices and appliances. Plugs designed to receive high-voltage AC power (typically 110V AC or 220V AC) from the mains power supply are sometimes susceptible to surges caused by lightning strikes, surges from generators or other sources, or electrical accidents during service activities or other events. Unless surge protectors are provided, such surges can permanently damage electrical equipment receiving power from the plug. Surge protectors are typically integrated into power boards that have a conventional plug, a section of flexible wire, and multiple sockets for receiving the plug of an electrical device or appliance. If a surge is received by the wires of a surge-protected power board, the surge protector absorbs the surge and may result in a loss of power at its sockets; however, the replacement cost of a power board is generally lower than the replacement cost of the equipment or appliance it is designed to protect. Summary of the Invention

[0006] This invention provides an electrical plug with a surge protector box that is easily replaceable in case of damage due to absorbing an electrical surge. After a surge damages the surge protector, the electrical plug can continue to deliver power to its connected electrical installations or equipment, but without further surge absorption capacity or with reduced surge absorption capacity. In this case, the electrical plug should be repaired by replacing the damaged surge protector box with a new or repairable one so that the plug can once again provide surge protection. Optionally, lights or other indicators provide status information for the plug and the surge protector.

[0007] These and other objects, advantages, intentions and features of the present invention will become apparent from reading the following description in conjunction with the accompanying drawings. Attached Figure Description

[0008] Figure 1 This is a perspective view of an electrical plug with a replaceable surge protector according to the present invention;

[0009] Figure 2 yes Figure 1 A front view of an electrical plug with a replaceable surge protector, wherein the surge protector is shown to be separate from the plug housing;

[0010] Figure 3 It is a partially transparent bottom perspective view of the plug housing to reveal the internal components;

[0011] Figure 4 yes Figure 3 Top perspective view of the plug housing;

[0012] Figure 5 yes Figure 3 A front view of the plug housing;

[0013] Figure 6 It is a top perspective view that shows the surge protector with partial transparency to reveal the internal components;

[0014] Figure 7 yes Figure 6 Bottom perspective view of the surge protector;

[0015] Figure 8 yes Figure 6 A top view of a surge protector;

[0016] Figure 9 This is a side sectional view of a surge protector;

[0017] Figure 10-13 yes Figure 1 A perspective view of an electrical plug with a replaceable surge protector;

[0018] Figure 14-19 It is a plan view and a front view of an electrical plug with a replaceable surge protector;

[0019] Figure 20-22 This is an exploded perspective view of an electrical plug with a replaceable surge protector;

[0020] Figure 23 This is a bottom plan view of an electrical plug with a replaceable surge protector;

[0021] Figure 24 This is a rear view of an electrical plug with a replaceable surge protector;

[0022] Figure 25 It is along Figure 24 Side sectional view of section line XXV-XXV in the middle;

[0023] Figure 26 It is along Figure 24 Bottom sectional view of section lines XXVI-XXVI in the diagram;

[0024] Figure 27 It is along Figure 23 Front sectional view of section lines XXVII-XXVII in the middle;

[0025] Figure 28 This is a front perspective view of an electrical plug and wire section with an in-line surge protector according to the present invention;

[0026] Figure 29 This is a front perspective view of an electrical plug with a pass-through socket and a replaceable surge protector according to the present invention.

[0027] Figure 30 This is a front perspective view of another electrical plug with a replaceable surge protector for output to a modular electrical system according to the present invention.

[0028] Figure 31 This is a front perspective view of another electrical plug according to the invention, which has a low-voltage USB power socket and a replaceable surge protector; and

[0029] Figure 32 yes Figure 31 A simplified circuit diagram of electrical plugs, sockets, and surge protectors. Detailed Implementation

[0030] Referring now to the accompanying drawings and the illustrative embodiments described therein, the electrical plug assembly 10 includes a main plug housing 12 and a replaceable surge protector box 14, as shown below. Figure 1 and 2 As shown. The main plug housing 12 has at least two electrical pins 16 extending outwardly from it. Figure 4 ), used with such Figure 1 and 2 The electrical socket 18 shown is engaged. A wire 20 extends outward from the plug housing 12 and is electrically connected to the electrical pins 16. The wire 20 can terminate at its opposite end in virtually any desired socket, such as a NEMA 5-15 socket, IEC C5, C7, or C13 connector commonly used in desktop computers, computer monitors, and electrical appliances. The wire 20 can also terminate at a bare conductor 21. Figure 20 The electrical plug assembly 10 provides recoverable surge protection for any device or electrical appliance that receives power through the wire 20, or a separate terminal for subsequent connection to the terminal of an appliance or device. Because the surge protector box 14 is replaceable, the electrical plug assembly 10 is suitable for permanent installation on electrical appliances without requiring a separate surge protector board or circuit with its own plug and socket.

[0031] Surge protector box 14 includes a two-piece surge protector housing 31 ( Figure 1 , 2 (and 6-9), surge protector circuit 22 installed in surge protector housing 31 ( Figure 6-9 ) and multiple surge protector contacts 24 electrically connected to surge protector circuit 22. Figure 6 and 8 When the surge protector housing 14 is inserted into the recess 28 defined by the main plug housing 12, the surge protector contact 24 engages with the corresponding electrical contact 26 within the recess 28. The surge protector circuit 22 absorbs the electrical surge at the electrical pin 16 and transmitted via the electrical contact 26 and the surge protector contact 24. Electrical continuity from the electrical pin 16 to the power line 20 is maintained before and after the surge protector circuit 22 absorbs the electrical surge. Optionally, the circuitry within the main plug housing 12 is configured such that electrical continuity from the electrical pin 16 to the power output line 20 is maintained even after the surge protector housing 14 is removed from the cavity 28.

[0032] When fully inserted into the recess 28, the surge protector housing 14 remains accessible along the outside of the plug housing 12 and can be easily replaced in case of a surge that causes the surge protector circuit 22 to no longer provide surge protection. See also Figure 20-22 The plug housing 12 comprises a main housing portion 12a, which mates with a rear housing or cover portion 12b and a bottom housing or cover portion 12c to enclose a main circuit board 29a and a pair of sub-circuit boards 29b, 29c, which will be described in more detail below. The mating surfaces of the housing portions 12a-c include mating channels and ridges that are positioned together during assembly to ensure proper alignment and optionally provide surface areas for ultrasonic welding, adhesives, etc. The housing portions can optionally be secured together using screw fasteners. The main housing portion 12a and the rear cover portion 12b mate to define a strain relief portion 27 that makes close contact with the outer sheath of the wire 20 during assembly. The wire 20 may include a collar or strap 25 to help ensure that the wire 20 cannot be pulled out of the main housing 12. The two-piece housing 31 of the surge protector box 14 comprises a main surge protector housing portion 31a and a cover portion 31b, which cooperate to enclose the surge protector circuit 22. Similar to housing portions 12a-c, the mating surfaces of surge protector housing portions 31a-b include cooperating channels and ridges that are positioned together during assembly.

[0033] Optionally, the circuit breaker 30 is disposed along the plug housing 12 and is operable to selectively disconnect or open the electrical continuity between the electrical pin 16 and the wire 20 in response to a current overload condition present at the wire 20, such as due to an electrical short circuit at the downstream end of the wire, or due to a device or apparatus that requires or otherwise draws more current than is designed for the electrical plug assembly 10. (Refer to...) Figure 20-22 The circuit breaker 30 has a pair of blade contacts 33, which are received in corresponding recessed terminals 35 mounted on a sub-plate 29b. Another sub-plate 29c supports recessed terminals or contacts 26 engaged by surge protector contacts 24 of the housing 14.

[0034] When inserted into, such as Figure 1 and 2 When the power outlet 18 is shown, an indicator in the form of a color-changing light 32 provides the user with an indication of the plug assembly status. The light 32 illuminates in one color (e.g., green) when the wire 20 is energized and surge protection is available from the surge protector box 14, and illuminates in a different color (e.g., red) when surge protection is not available from the surge protector box 14. Other forms of marking are also conceivable, such as solid or flashing lights of one or more colors, tonal markings, and similar markings.

[0035] Optional arrangements of the electrical plug assembly include, for example, along the flexible electrical input line 120a and the flexible electrical output line 120b. Figure 28 ) Installed and mounted in series between them, surge protector assembly 110, with AC adapter socket 250 ( Figure 29 The electrical plug assembly 210 and the electrical plug assembly 310 configured to supply power to the modular electrical system. Figure 30 ) and has a low-voltage DC socket 450 ( Figure 31 The surge protection and circuit breaker functions of each of the components 110, 210, 310, and 410 are substantially the same as those of the surge protection and circuit breaker functions of the surge protection and circuit breaker functions of the surge protection and circuit breaker assembly 10 described above, and therefore will not be repeated here. Furthermore, it should be understood that... Figure 28-31 The components of the additional components are assigned reference numerals corresponding to those of similar components of the plug assembly 10, with the addition of 100, 200, 300 or 400, so that they can be easily understood with reference to the preceding description.

[0036] Series surge protector assembly 110 ( Figure 28Power is received from a flexible electrical input line 120a having a conventional plug assembly 140 with a set of pins 116 at one end. An electrical output line 120b extends from the opposite side of the surge protector assembly 110 and supplies power to a power-consuming device (not shown). The power supplied to the user via the output line 120b is overload protected by a circuit breaker 130 and surge protected by a surge protector box 114, both located at the surge protector assembly 110. Functionally, it is the same as or substantially the same as the surge protector assembly 10 described above, except for the physical separation between the plug assembly 140 with pins 116 and the surge protector assembly 110. It should also be understood that virtually any type of power receiving connector can be used in place of the plug assembly 140, including any country-specific plug or proprietary modular electrical connector. The plug assembly 140 may also be omitted, and the individual wires at the input ends remain exposed for hard-wiring applications, or fitted with individual electrical terminals.

[0037] Electrical plug assembly 210 ( Figure 29 The adapter assembly 210 is substantially the same as surge protector assembly 10, but includes a through-hole AC socket 250, allowing another electrical device with a compatible plug to be inserted into the AC socket 250 in the front surface of the assembly housing 212. The adapter AC socket 250 may be surge and circuit breaker protected, like the conductor of wire 220, or may be directly connected to the plug pins (not shown) of the plug assembly 210 to bypass surge and overload protection provided to wire 220 and the electrical devices connected thereto.

[0038] Modular electrical plug assembly 310 ( Figure 30 It is essentially the same as surge protector assembly 10, but instead of having a wire 20 extending from its housing 312, it is equipped with a dedicated modular electrical connector 360 to supply power only to compatible modular electrical connectors and associated wires or other conductors (not shown). An optional surge box protection indicator 362 is located directly at the surge box 314 and can provide, for example, a visual indication of the incremental level of available surge protection.

[0039] Electrical plug assembly 410 ( Figure 31 It is essentially the same as surge protector assembly 10, but includes a low-voltage DC socket 450 (e.g., a USB-type socket), which has Figure 32 The relevant circuitry is shown. The DC socket 450 provides power to charging cables and other devices, typically small portable electronic devices. Now refer to... Figure 32The simplified circuit diagram shows that the surge protector box 414 includes multiple variable resistors 462 connected in parallel, which are capable of absorbing spikes in the power supply. For example, four variable resistors 462 can absorb a total of approximately 1000 joules of energy. The output of the variable resistors 462 is to the surge indicator conductor 464 and the fuse conductor 466. A Zener diode 468 selectively allows power to pass through to the fuse LED indicator 470, while the adjacent LED indicator 472 (similar to or equivalent to the indicator 32 described above) provides an indication of the surge protection status. The standard diode 474 and the fuse 476 provide reverse polarity protection, and the AC-to-DC power converter 478 receives high-voltage AC power from the live and neutral wires 480A, 480b and supplies lower-voltage (e.g., 5V to 12V) DC power to the low-voltage DC socket 450.

[0040] Other features that can be incorporated into electrical components include power quality monitoring and recording capabilities, providing notification when a surge occurs, monitoring the percentage of surge absorption capacity remaining in the box, recording the number of surges experienced, time-based box replacement scheduling (where boxes are replaced according to a set schedule rather than individually as needed), and wireless communication for on / off control and / or tracking data via Bluetooth, WiFi, or WiFi switching capabilities. These can be used for replaceable plugs and / or sockets or terminals at the output of surge protection lines or conductors in different countries, and for circuits used with different voltage power supplies. Other envisioned options include providing surge protection without a circuit breaker, removable wires that can be disconnected and plugged into other sockets, rather than being permanently installed in the surge protector plug assembly. The various features of the electrical plug assembly disclosed herein can be applied to multi-circuit applications, can have a surge protector box spaced apart from the plug head, and can utilize IEC plugs for computer server racks, etc.

[0041] Therefore, replaceable surge protector boxes can provide continuous power to one or more electrical devices, circuits, etc., and can do so using surge protection circuits that are easily replaceable by the user, ensuring continuous and uninterrupted surge protection without the need for replacement wiring or surge protection power boards. Users can notify the need for a replacement box via an indicator on the device itself or via electronic data signals sent by the device to a receiving computer, which generates a message or flag. By maintaining the supply of existing compact surge protector boxes, surge protection devices in workplaces, residences, etc., can quickly restore their surge protection capabilities after a surge event. Alternatively, replacement surge protector boxes can be distributed to users on an order basis and replaced according to a predetermined schedule regardless of conditions, helping to ensure maximum surge protection is available substantially at all times.

[0042] Changes and modifications may be made to the specific embodiments described without departing from the principles of the invention, which are defined only by the scope of the appended claims, as interpreted in accordance with the principles of patent law including the doctrine of equivalents.

Claims

1. A surge protection system, comprising: Electrical input conductor; A housing defining a cavity for receiving circuitry that receives power from the electrical input conductor, the circuitry comprising: A power output section for guiding power from the power input conductor to power-consuming equipment; Multiple electrical contacts, recessed in the cavity and electrically connected to the electrical input conductor; and Surge protector box, comprising: A surge protector housing that can be inserted into the cavity; Surge protector circuitry, which is disposed within the surge protector housing; and A plurality of surge protector contacts, electrically connected to the surge protector circuit, and configured to engage the plurality of electrical contacts at the housing; and An indicator configured to generate a marker that indicates the power output unit to be energized when it can receive surge protection from the surge protector box, and also indicates the power output unit to be energized when it cannot receive surge protection from the surge protector box; The circuit is configured to (i) maintain electrical continuity from the electrical input conductor to the power output section after the surge protector circuit has absorbed an electrical surge at the electrical input conductor, or (ii) after the surge protector box has been removed from the cavity; and The surge protector housing includes an insertion portion that supports the plurality of surge protector contacts and can be inserted into the cavity, and a gripping portion that remains outside the cavity to facilitate replacement of the surge protector housing.

2. The surge protection system according to claim 1, wherein, The power output section includes power output lines extending outward from the housing.

3. The surge protection system according to claim 2, wherein, The electrical input conductor includes input wires that extend into the housing and into the circuit.

4. The surge protection system according to claim 3, wherein, The electrical input conductor also includes an electrical plug configured to receive power from a corresponding power outlet, the electrical plug being connected to the input wire.

5. The surge protector system of claim 2, wherein the electrical output line has an opposing end opposite to the housing, and wherein the opposing end terminates at least one selected from (i) a bare wire, (ii) an electrical terminal of an electrical device, (iii) a NEMA 5-15 socket, (iv) an IEC C5 connector, (v) an IEC C7 connector, and (vi) an IEC C13 connector.

6. The surge protection system of claim 2 further includes a circuit breaker at the housing, wherein the circuit breaker is configured to selectively disconnect the electrical continuity between the electrical input conductor and the electrical output line in response to a current overload condition present at the electrical output line.

7. An electrical plug and surge protector, comprising: The plug housing that defines the cavity; A pair of electrical prongs extending outward from the plug housing for receiving power from the socket; A power output section for directing power from the pair of electrical pins to power-consuming devices; Multiple electrical contacts are recessed in the cavity and electrically connected to the pair of electrical pins; Surge protector box, comprising: A surge protector housing that can be inserted into the cavity; Surge protector circuitry, which is disposed within the surge protector housing; and A plurality of surge protector contacts, electrically connected to the surge protector circuit, and configured to engage the plurality of electrical contacts at the plug housing; and An indicator configured to generate a marker that indicates the power output unit to be energized when it can receive surge protection from the surge protector box, and also indicates the power output unit to be energized when it cannot receive surge protection from the surge protector box; The electrical plug is configured to maintain electrical continuity from the pair of electrical pins to the power output section after (i) the surge protector circuit has absorbed an electrical surge at the pair of electrical pins, or (ii) after the surge protector housing has been removed from the cavity; and The surge protector housing includes an insertion portion that supports the plurality of surge protector contacts and can be inserted into the cavity, and a gripping portion that remains outside the cavity to facilitate replacement of the surge protector housing.

8. The electrical plug and surge protector according to claim 7, wherein, The power output section includes a wire extending outward from the plug housing.

9. The electrical plug and surge protector according to claim 8, wherein, The wire has a counterpart end opposite to the plug housing, and the counterpart end terminates at least one selected from (i) a bare wire, (ii) an electrical terminal of an electrical device, (iii) a NEMA 5-15 socket, (iv) an IEC C5 connector, (v) an IEC C7 connector, and (vi) an IEC C13 connector.

10. The electrical plug and surge protector according to claim 9, wherein, It also includes a circuit breaker located at the plug housing, wherein the circuit breaker is configured to selectively disconnect the electrical continuity between the pair of electrical pins and the wire in response to a current overload condition present at the wire.

11. An electrical plug and surge protector, comprising: Plug housing; At least two electrical pins extending outward from the plug housing; An electrical wire extends outward from the plug housing and is electrically connected to the at least two electrical pins; Multiple electrical contacts are located at the plug housing and are electrically connected to the at least two electrical pins; A surge protector box having a surge protector housing, a surge protector circuit disposed in the surge protector housing, and a plurality of surge protector contacts electrically connected to the surge protector circuit and configured to engage the plurality of electrical contacts at the plug housing; as well as An indicator configured to generate a marker that indicates whether the wire is energized when it receives surge protection from the surge protector box, and also indicates whether the wire is energized when it does not receive surge protection from the surge protector box. The surge protector circuit is configured to absorb electrical surges at the at least two electrical pins, and the electrical plug is configured to maintain electrical continuity from the at least two electrical pins to the wires both before and after the surge protector circuit has absorbed the electrical surge. and The surge protector housing includes a gripping portion and an insertion portion. The gripping portion is held outside the cavity and can be accessed along the outside of the plug housing, and the insertion portion supports the plurality of surge protector contacts and can be inserted into the cavity, so that the surge protector housing can be replaced at the plug housing.

12. The electrical plug and surge protector according to claim 11, wherein, The plug housing defines a recess for receiving a portion of the surge protector housing, and the plurality of electrical contacts of the plug housing are recessed within the recess, wherein the plurality of surge protector contacts are received by the plurality of electrical contacts of the plug housing when the portion of the surge protector housing is inserted into the recess.

13. The electrical plug and surge protector of claim 11, further comprising a circuit breaker located at the plug housing, wherein the circuit breaker is configured to selectively disconnect the electrical continuity between the at least two electrical pins and the wire in response to a current overload condition present at the wire.

14. The electrical plug and surge protector according to claim 11, wherein, The markers include lights capable of displaying different colors.

15. The electrical plug and surge protector according to claim 11, wherein, The wire has a counterpart end opposite to the plug housing, and the counterpart end terminates at least one selected from (i) a bare wire, (ii) an electrical terminal of an electrical device, (iii) a NEMA 5-15 socket, (iv) an IEC C5 connector, (v) an IEC C7 connector, and (vi) an IEC C13 connector.

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