Tamper resistant receptacle using rocker and flaps

Abstract

A tamper-resistant receptacle having a pair of blocking flaps biased in the closed position by leaf spring members attached to a rocker mechanism. The rocker rotates under pressure to either flap in isolation to contact a stop preventing further rotation. Under pressure to both flaps, the rocker does not rotate and the bias of the leaf springs is overcome to move the flaps downwardly. A secondary flap for a 20-Amp opening hingedly attached in a position that allows pressure on the secondar flap to cam against one of the two blocking flaps to cause downward force acting on the rocker.

Description

TAMPER RESISTANT RECEPTACLE USING ROCKER AND FLAPSCORSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of U.S. Provisional Application No. 63 / 670,410, filed July 12, 2024, the entire contents of which is incorporated by reference herein in its entirety.FIELD

[0002] The present disclosure relates to tamper resistant electrical receptacles. More particularly, the present disclosure relates to tamper resistant electrical receptacles using spring-loaded flaps.BACKGROUND

[0003] Tamper resistant receptacles are known in the art. “Tamper Resistant” or “TR” receptacles refers to a type of electrical wiring device, such as a household duplex electrical receptacle, equipped with means for physically blocking access to the electrical contacts which lie below the hot and neutral plug blade openings in the faceplate of the receptacle unless simultaneous force is exerted upon both the hot and neutral plug blade openings at the same time. Currently, NEC Code 406.11 et seq. and other regulatory requirements provide that not only must the outlet openings remain blocked unless force is applied to both openings at the same time, but also that any foreign object 1 / 32 inch or larger, must be prevented from bypassing the blocking member of a plug opening. All new construction and major renovations are mandated to by code to use TR receptacles.

[0004] As will be appreciated, these code requirements were enacted in response to the all-to-often tragic phenomena of a curious child inserting a conductive material, such as a paper clip or small toy, into either the hot or neutral plug blade opening of a receptacle faceplate and contacting the live hot or neutral electrical contact resulting in electrical shock, burns, or even death.

[0005] In meeting the code standard and providing the level of protection sought from these devices, the art has gravitated towards a configuration of receptacles utilizing cooperating shutter members to block access beyond the faceplate openings of the outlet. Specifically, to ensure that force directed into only one of the two blade openings is prevented from reaching the electrical contact that lies beneath, a sliding shutter mechanism is spring-biased into a position blocking (or “shuttering”) the blade opening from underneath the faceplate. The shutter physically prevents an object entering the blade opening from reaching the electrical contact below that shutter. In order to allow the shutter of a respective blade opening to be uncovered, the spring-bias must be overcome by a camming action caused by the other plug blade during insertion in the other blade opening.

[0006] To this end, the most common prior art configuration of a TR receptacle includes a shutter assembly comprising a pair of cooperating shutters. Each of the shutters includes a blocking portion positioned below a respective one of the blade openings blocking access to the contacts. Each of the shutters also includes a cam portion that extends to the opposite blade opening that receives contact from a plug blade and translates the vertical force of a plug blade and camming action into a lateral sliding displacement of the blocking portion. Thus, force by vertical insertion of a plug-blade on the neutral blade opening will move the shutter from obstructing access to the electrical contact below the hot blade opening, and vice versa.

[0007] Specifically, for example, during insertion of a plug, the neutral blade tine will cam against and past the shutter cam surface forcing the shutter cam arm to move laterally, thereby overcoming the spring bias of the shutter and causing the hot blade shutter blocking portion to slide into a position away from and revealing the electrical contact beneath the hot blade opening. Likewise, force on the hot blade opening will contact the cam surface and allow the blade to cam past and move the arm and compress the spring to move the shutter blocking portion that covers the neutral blade opening out of the way.

[0008] As will be appreciated, with this configuration, when a child tries to insert a toy into either opening of the outlet, the blocking portion of the shutter remains immobile from the spring bias of the opposite shutter and prevents the child from reaching the electricalcontact. However, when both blades of an electrical plug contact the shutters simultaneously, the simultaneous force and camming action allows both blades to continue their downward insertion by simultaneously sliding respective shutter blocking portions laterally out of the way of the electrical contacts of the opposite shutter until the blades cam past the shutters and are able to properly “plug in” to the outlet's internal face contacts.

[0009] Existing prior art TR receptacle designs and their operational details are available in U.S. Pat. No. 4,379,607 to Bowden, Jr.; U.S. Pat. No. 7,645,148 to Carbone et aL; and U.S. Publ. No. 2013 / 0295788 to Baldwin, et al. and the references cited therein.

[0010] The proliferation of these important safety devices has led to an appreciation of the issues affecting their effective life span and cost. A presently appreciated issue recognized by the present inventor stems from the need to use a shutter housing component with mounted pairs of shutter members arranged therein to effectuate the safety features of the sliding shutters. Having to deploy an entire sub-housing comprising numerous pieces beneath the faceplate of an outlet may be a significant cost increase, difficult to assembly, and have multiple points of failure thereby hindering the life span.

[0011] The foregoing underscores some of the problems associated with conventional TR receptacles. Furthermore, the foregoing highlights the long-felt, yet unresolved need in the art for a TR receptacle that may extend the useful life of the device. Moreover, the forgoing highlights the long-felt, yet unresolved need in the art for a TR receptacle that has an extended service life at a reasonable cost by using fewer and uncomplicated constituent parts.SUMMARY

[0012] Various examples of the present disclosure can overcome various of the aforementioned and other disadvantages associated with known TR receptacles and offer new advantages as well.

[0013] According to various examples of the present disclosure there is provided a tamper-resistant receptacle sub-assembly comprising a sub-assembly platform that includes a face surface and a concave section, a rocker that includes a first rocker arm with a first distal end and a second rocker arm with a second distal end, a rocker axelconfigured as part of the rocker to fit against the concave section, a spring component, a first main flap biased against the first rocker arm by the spring component and a second main flap biased against the second rocker arm.

[0014] In some forms, the first main flap being in a closed position prevents a foreign object from being fully inserted in the tamper-resistant receptacle, and the second main flap being in the closed position prevents the foreign object from being fully inserted in the tamper-resistant receptacle.

[0015] In some forms, the spring component is a first spring component, the tamperresistant receptacle sub-assembly also includes a second spring component configured to bias the second main flap against the second rocker arm. In some forms, with nothing inserted into the tamper-resistant receptacle, the spring component keeps the rocker in a neutral position.

[0016] In some forms, the tamper-resistant receptacle sub-assembly also includes a hot prong opening, wherein with the rocker in the neutral position the hot prong opening is aligned with the first main flap and aligned outside the first distal end of the first rocker arm. The tamper-resistant receptacle may also include a neutral prong opening, wherein with the rocker in the neutral position the neutral prong opening is aligned with the second main flap and aligned outside the second distal end of the second rocker arm.

[0017] In some forms the first main flap includes a first main flap distal end and the second main flap includes a second main flap distal end, the tamper-resistant receptacle sub-assembly may also include a first stop tab positioned beneath the first main flap with the rocker in the neutral position, and a second stop tab positioned beneath the second main flap with the rocker in the neutral position.

[0018] In some forms a foreign object inserted in the hot prong opening pushes the first rocker arm downward via the first main flap, causing the first main flap distal end to contact the first stop tab putting the first main flap in the closed position. In some forms a foreign object inserted in the neutral prong opening pushes the second rocker arm downward via the second main flap, causing the second main flap distal end to contact the second stop tab putting the second main flap in the closed position.

[0019] In some forms the tamper-resistant receptacle sub-assembly is configured to receive an electrical plug with a hot prong and a neutral prong. In response to inserting the electrical plug, the hot prong pushes downward on the first main flap simultaneous to the neutral plug pushing downward on the second main flap, keeping the rocker in the neutral position and allowing the hot prong and the neutral prong to be fully inserted.

[0020] According to various examples of the present disclosure there is provided a 20-Amp (20-A) tamper-resistant receptacle sub-assembly including a sub-assembly platform with a face surface and a concave section, a rocker including a first rocker arm with a first distal end, a second rocker arm with a second distal end and a rocker axel configured to fit against the concave section, a spring component, a first main flap biased against the first rocker arm by the spring component, a second main flap biased against the second rocker arm, and a 20-A flap positioned above the second main flap.

[0021] In some forms the first main flap in a closed position prevents a foreign object from being fully inserted in the 20-A tamper-resistant receptacle. The second main flap in the closed position prevents the foreign object from being fully inserted in the 20-A tamper-resistant receptacle. The 20-A flap in the closed position prevents the foreign object from being fully inserted in the 20-A tamper-resistant receptacle.

[0022] In some forms the spring component is a first spring component, and the 20-A tamper-resistant receptacle sub-assembly further includes a second spring component configured to bias the second main flap against the second rocker arm. In some forms with nothing inserted into the 20-A tamper-resistant receptacle, the spring component keeps the rocker in a neutral position.

[0023] In some forms the 20-A tamper-resistant receptacle sub-assembly further includes a hot prong opening, wherein with the rocker in the neutral position the hot prong opening is aligned with the first main flap and aligned outside the first distal end of the first rocker arm, and a neutral prong opening. In some forms, with the rocker in the neutral position the neutral prong opening is aligned with the second main flap and aligned outside the second distal end of the second rocker arm.

[0024] In some forms the 20-A tamper-resistant receptacle sub-assembly further includes a neutral tee opening, wherein with the rocker in the neutral position the neutraltee opening is aligned with the 20-A flap and aligned outside the second distal end of the second rocker arm.

[0025] In some forms the first main flap includes a first main flap distal end and the second main flap includes a second main flap distal end. In some forms the 20-A tamper-resistant receptacle sub-assembly may further include a first stop tab positioned beneath the first main flap with the rocker in the neutral position, and a second stop tab positioned beneath the second main flap with the rocker in the neutral position.

[0026] In some forms a foreign object inserted in the hot prong opening pushes the first rocker arm downward via the first main flap, causing the first main flap distal end to contact the first stop tab putting the first main flap in the closed position. In some forms a foreign object inserted in the neutral prong opening pushes the second rocker arm downward via the second main flap, causing the second main flap distal end to contact the second stop tab putting the second main flap and the 20-A flap in the closed position.

[0027] In some forms the second main flap in the closed position causes the 20-A flap to remain in the closed position. In some forms a foreign object inserted in the neutral tee opening pushes the second rocker arm downward via the 20-A flap and the second main flap, causing the second main flap distal end to contact the second stop tab putting the second main flap and the 20-A flap in the closed position.

[0028] In some forms the 20-Amp tamper-resistant receptacle sub-assembly is configured to receive an electrical plug with a hot prong and a tee shaped neutral prong, and in response to inserting the electrical plug, the hot prong pushes downward on the first main flap simultaneous to the neutral plug pushing downward on the second main flap and the 20-A flap, keeping the rocker in the neutral position and allowing the hot prong and the tee shaped neutral prong to be fully inserted.

[0029] According to one aspect of various examples of the present disclosure there is provided a tamper-resistant receptacle sub-assembly comprising a body having a bottom surface, a pair of lateral opposing side walls, and an open top; said sidewalls defining a respective pin notch on opposite sides of the body; a rocker member seated in said notches; said rocker being a generally bent or V-shaped solid piece with support arms terminating in respective knob bodies; a pair of leaf springs anchored on said rockercentral hub and terminating to spring bias a respective outlet opening flap blocker. Said rocker having a generally circular hub section that sits in said notches in a manner that allows at least partial rotation in a cradle defined by said notches or defined in a raised platform in said bottom surface. A pair of raised blocking stops disposed operatively under a respective flap member; wherein a respective spring member biases said flaps in a closed position and the insertion of an object into a single plug blade opening of the TR device causes the rocker to rock said flap into a blocking stop thereby preventing access into the interior of the housing. And whereby, simultaneous insertion of plug blades in each outlet opening engages the flaps to overcome the spring bias of the flap members without the rocker rocking closed and allowing the plug blades to flex the flaps out of the way and engage the electrical contacts of the device.

[0030] In a preferred example, the tamper-resistant receptacle sub-assembly is configured such that simultaneous insertion of a hot plug blade and a neutral plug blade causes simultaneous flexing of said spring members to cause vertical movement of the blocking flaps without rotation of the rocker member.

[0031] In some forms, there is a rocker assembly for a tamper-resistant receptacle sub-assembly. The rocker assembly includes a rocker body with a rocker axel that can permit pivotal movement of the rocker assembly. The rocker assembly also includes a first rocker arm and a second rocker arm. The first rocker arm that extends from the rocker body, wherein the first rocker arm has a first distal end having a first pin seat. The second rocker arm that extends from the rocker body, wherein the second rocker arm has a second distal end having a second pin seat. The rocker assembly further includes a first flap and a second flap. The first flap has a first receiving surface and a first pin pivotably received within the first pin seat. The second flap having a second receiving surface and a second pin pivotably received within the second pin seat. Finally, the rocker assembly includes a first spring coupled to the first flap and a second spring coupled to the second flap.

[0032] The disclosure herein should become evident to a person of ordinary skill in the art given the following enabling description and drawings. The drawings are for illustration purposes only and are not drawn to scale unless otherwise indicated. The drawings are not intended to limit the scope of the disclosure. The following enabling disclosure isdirected to one of ordinary skill in the art and presupposes that those aspects within the ability of the ordinarily skilled artisan are understood and appreciated.BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Various aspects and advantageous features of the present disclosure will become more apparent to those of ordinary skill when described in the detailed description of preferred examples and reference to the accompany drawing wherein:

[0034] Various aspects and advantageous features of the present disclosure will become more apparent to those of ordinary skill when described in the detailed description of preferred examples and reference to the accompany drawing wherein:

[0035] FIG. 1 is an exploded view of the constituent parts of a tamper resistant receptacle sub-assembly according to various examples disclosed herein.

[0036] FIG. 2 is perspective view of the assembled constituent parts of the tamper resistant receptacle sub-assembly of FIG. 1 .

[0037] FIG. 3 is a is an elevated perspective view of the assembled constituent parts of the tamper resistant receptacle sub-assembly of FIG. 1 .

[0038] FIG. 4 is a view of the elevated perspective view of FIG. 3.

[0039] FIG. 5 is perspective view of a housing member of a tamper resistant receptacle sub-assembly according to various examples disclosed herein.

[0040] FIG. 6 is perspective view of a housing member of a tamper resistant receptacle sub-assembly according to various examples disclosed herein.

[0041] FIG. 7 is a top perspective view of a rocker member of a tamper resistant receptacle sub-assembly according to various examples disclosed herein.

[0042] FIG. 8 is an isolated perspective view of a pair of leaf spring members of a tamper resistant receptacle sub-assembly according to various examples disclosed herein.

[0043] FIG. 9 is a perspective view of the underside of a first blocking flap member of a tamper resistant receptacle sub-assembly according to various examples disclosed herein.

[0044] FIG. 10 is a perspective view of the underside of a second blocking flap member of a tamper resistant receptacle sub-assembly according to various examples disclosed herein.

[0045] FIG. 11 is a top perspective view of a 20-A blocking flap of a tamper resistant receptacle sub-assembly according to various examples disclosed herein.

[0046] FIG. 12 is a side cross-sectional view of a tamper resistant receptacle subassembly in the home position blocking access to the electrical contacts according to various examples disclosed herein.

[0047] FIG. 13 is a side cross-section view of a tamper resistant receptacle subassembly with a 20-A electrical plug fully deployed and plugged into the electrical contacts.

[0048] FIG. 14 is a side cross-sectional view of a tamper resistant receptacle subassembly blocking access to the electrical contacts when an object is inserted into the neutral blade opening according to various examples disclosed herein.

[0049] FIG. 15 is a side cross-sectional view of a tamper resistant receptacle subassembly blocking access to the electrical contacts when an object is inserted into the hot blade opening according to various examples disclosed herein.DETAILED DESCRIPTIONS

[0050] The Figures depict a presently preferred example of a tamper-resistant receptacle sub-assembly for use in a TR receptacle. As depicted, the example in the Figures, the tamper-resistatnt sub-assembly can be configured for use with a 15-Amp and / or 20-Amp receptacle adapted for receipt of a two-prong or three-prong plug member. However, one of ordinary skill in the art armed with the present specification will readily appreciate that the teachings of the present disclosure may be adapted for any specific type of TR device through routine experimentation, including duplex receptacles, electrical cords, receptacles with USB ports, receptacles with circular or other geometries for the face or prongs, etc.

[0051] Turning back to the Figures, a TR receptacle (not shown) has a tamperresistant receptacle sub-assembly 10 having a housing 20, a rocker member 40, a pairof leaf springs 50A, 50B, and a pair of prong-opening blocking flaps 60A, 60B. In some examples, such as the exploded view of FIG. 1 , a 20-A (20-Amp) blocking flap 70 is included.

[0052] As best shown in FIGs. 2-4, disposed in the housing are the rocker 40, leaf spring(s) 50A, 50B and flaps 60A, 60B, and 70. The housing 20 includes a plastic body 21 having a generally planar bottom surface 22, an open top 23, and a pair of upwardly extending sides 24A, 24B. In some forms, as best shown in FIGs. 5 and 6, the bottom surface 22 is generally rectangular and includes a first rectangular opening 25 for allowing passage of an electrical plug hot prong or blade 101 to pass through the bottom 22 of body 21 to engage with the hot electrical contact of a receptacle. The bottom surface 22 also includes a neutral blade opening 26 that is either lateral (15-A) or a T-shaped (20-A) configured for allowing passage of an electrical plug neutral prong or blade 102 to pass through the bottom 22 of the body 21 to engage with the neutral contact of the given receptacle. The T-shape includes a parallel opening 27 for 15-Amp plugs and a perpendicular opening 28 for 20-Amp plugs.

[0053] Upwardly extending sides 24A, 24B in some forms each define a pair of corresponding cutouts 29A, 29B that define a cradle 35. In its simplest form, the cutouts and cradle are integral with the sides as part of a singular molded body. The cradle 35 is preferably seated in, or used with, a raised central platform 30 for receiving the rocket member 40.

[0054] The bottom 22 of housing preferably defines the central raised platform 30 as well as first and second stops 31 , 32 disposed on opposite ends of sub-assembly 10 in the area of a respective plug opening 25, 26. In some forms, the stops 31 , 32 sit at an elevation that prevents anything more than minimal rotation of the rocker 40. As elaborated on below, the elevation of the platform 30 and whether or not it defines a cradle 35 depends on the amount of rocking or vertical movement that needs to be hindered to prevent a single plug blade or object to be inserted into the device and reach the electrical contact for a given or intended configuration and form factor of the device and housing.

[0055] A rocker 40 is located generally centrally of the device. In the depicted example as best shown in FIG. 7, the rocker 40 is a bent, or generally V-shaped body. In some forms, the V-shaped body 40 includes a central hub or axle 41 and first and second arms42, 43 each terminating in a pair of C-shaped pin seats or knobs 47A, 47B and 48A, 48B. The central hub 41 of the rocker 40 is sized to sit in the cradle 35 of the raised platform 30 and / or cutouts 29A, 29B with its axle ends 49A, 49B rotatably seated. The exact configuration and method of configuring the rocker and its association with the housing may be altered as long as it carries out the essential functions of properly blocking and allowing access to the electrical contacts based on object insertion in one or both plug blade openings of the TR-receptacle.

[0056] A pair of leaf springs 50A, 50B are used in operation of the depicted example. In some forms, such as depicted in FIG. 8, the leaf springs 50A, 50B are each anchored to the central axel 41 of the rocker 40 on opposite sides of the axle 41 by wrapping them around the axle on the springs’ proximal ends 51 A, 51 B. A first leaf spring 50A is bent around the central hub 41 via its proximal end 51 A and extends generally laterally toward a first end of the device, such as the hot contact side. The second leaf spring 50B is bent in the opposite direction around the hub 41 via its proximal end 51 B and extends laterally towards a second end of the device, such as the neutral contact side. With this configuration, the first spring 50A is position and biased upwardly in an area towards of the hot blade opening 101 and the second spring 50B is positioned and biased upwardly in an area towards the neutral blade opening 102.

[0057] A respective blocking flap 60A, 60B is attached to the flexed or distal end 52A, 52B of a respective leaf spring member 50A, 50B. In the depicted example of FIGs. 9- 10, the flaps 60A, 60B include a lateral slot 61 A, 61 B for receiving the ends 52A, 52B of the leaf springs 50A, 50B. With this configuration, the flaps are biased upwardly by the leaf springs. The blocking flaps are thus flexed to block the lateral portions of the hot and neutral prong openings on a 15-Amp or 20-Amp TR device. In 20-Amp devices, a 20-A (20-Amp) blocking flange 70 is also preferably used. The 20-A blocking flange is position adjacent and serves to block the perpendicular portion of a 20-A neutral blade plug opening in a TR device.

[0058] The blocking flaps 60A, 60B have a curved proximal end 62A, 62B and a generally planar distal end 63A, 63B defining a plug blade receiving surface 64A, 64B. The underside of the blocking flaps 60A. 60B in the curved end 62A, 62B each have an axle member 65A, 65B sized to frictionally fit in a respective pair of C-shaped pin holdersof the rocker 40. With this configuration, the flaps 60A, 60B may only rotate in the seat of its respective C-shaped pin holders when a downward force is sufficient to overcome the spring bias of its respective leaf spring 50A, 50B.

[0059] The bottom surface 22 of the body 21 of the housing 20 also preferably defines or includes a pair of raised stop members 31 , 32. In some forms, the stop members 31 , 32 are integrally molded protuberances on opposite ends of the bottom surface 22 and sized to operatively cooperate with the raised platform 30 and rocker 40. Specifically, as discerned from the depicted example, the stops 31 , 32 serve as mechanical stops to prevent lateral tilting, or “rocking”, of the rocker 40 when only one of the plug openings of a TR receptacle receives force from a foreign object. The rocking and mechanical stops are configured to ensure that the rocker 40, when receiving force on only one of the plug receiving surfaces 64A, 64B of the blocking flaps 60A, 60B, cannot rotate or tilt in that direction enough to allow an object to enter the sub-assembly regardless of which of the openings is tried in isolation. To access the hot and neutral contacts of the device, the plug blades must be simultaneously inserted into both the hot and neutral openings of the device as described below.

[0060] In some forms of a 20-Amp example, a separate 20-A blocking flap 70 is needed to block the perpendicular slot of the neutral blade opening. A presently preferred example of a 20-A flap is depicted in FIG.1 1. With this configuration, the 20-A flap is sized and arranged to fit over the blocking flap 60B under the neutral plug blade opening. The 20-A flap 70 is a generally planar member with a large central portion 71 defining a 20-A neutral blade receiving surface. The 20-A flap also defines a generally round and integral pivot pin 72 and a finger extension 73. In some forms, the pivot pin 72 is designed to fit is a C-shaped hinge seat 36 and pin seat 37 defined in the sidewall of the housing (preferably on the side opposite the leaf spring on the neutral side). As depicted, the 20- A flap 70 is mounted on a back corner area away from the spring side slot of the neutral flap 60B and the raised stop 32 is positioned in the bottom of housing on the other side of the housing. Thus, the 20-A flap does not contact the flap and can pivot fully open during proper operation to ensure there is sufficient clearance for the neutral prong to pass.

[0061] Once in place, the finger extension 73 extends over, and is in contact with, the neutral flap 60B. The hinge 72 and finger 73 are intentionally configured to allow the perpendicular portion of a 20-A plug to pivot both flaps 60B, 70 downwardly until the blade passes which separates the flaps 60B, 70. In order to ensure that upon retraction of the plug the 20-A flap remains on top of the neutral flap 60B, the finger extension 73 remains in contact with the top surface of the neutral flap 60B and is pivoted back into its blocking position by the bias of neutral flap 60B as discussed in more detail below.

[0062] Once fully assembled, as best understood in connection with the Figures, the TR sub-assembly 10 is sized and configured to sit below the hot and neutral plug openings in the face of a TR receptacle. Once assembled and included as part of a TR receptacle, the rocker 40 sits in the cradle 35 of the raised platform 30 in the central area of the bottom surface 22 of the body 21 . The cradle 35, defined by a pair of slots, or cutouts, 29A, 29B (and preferably a curved surface in the central area of the raised platform). With this configuration, the cradle 35 accept the ends of the rocker 40 central axle 41 . The rocker 40 rests in the cradle 35 with a rounded central axle 41 which allows force on either C-shaped knob 46, 47 to rotate or rock the rocker 40 in the cradle 35.

[0063] As best shown in FIG. 12, the leaf springs 50A, 50B are preferably attached on opposite sides near the ends of the cradle central axle 41 and bias oppositely disposed blocking flaps 60A, 60B to block the hot and lateral neutral openings of the TR receptacle as described above. The separate 20-A blocking flap 70 is positioned under the perpendicular slot of the 20-A neutral opening of the TR receptacle faceplate.

[0064] As depicted in FIG. 14, when a child or other user attempts to insert an object, such as a paper clip into the hot blade opening of the TR receptacle it contacts the contact surface of the hot blocking flap 60A. As pressure is applied to the surface of the hot blocking flap 60A, the downward force is translated to the leaf spring and knob 46 of the arm 42 on the rocker 40 and cause the central axle 41 to frictionally rotate in the direction of the of hot opening. The raised stop 31 beneath the hot blocking flap 60A contacts the bottom of the flap and prevents downward rotation of the flap while also preventing any biasing of spring member, thereby preventing the object from entering the sub-assembly and reaching the hot electrical contact.

[0065] Similarly, as best shown in FIG. 13, when a child or other user attempts to insert paper clip or other object into the lateral portion of a neutral blade opening a TR receptacle faceplate, the object contacts the surface of the blocking flap 60B. The downward force is again translated to the leaf spring, C-shaped knob, and arm of the rocker to cause the central hub 41 to rotate in the cradle 35 towards the neutral opening. The raised stop 31 beneath the neutral blocking flap 60B contacts the underside of the flap and blocks downward rotation of the flap or any flexing of the spring member to thereby keep the lateral portion of the neutral opening from being accessible to allow the object to pass into the sub-assembly and reach the neutral contact

[0066] For a 20-Amp plug with a perpendicular neutral blade member, the attempted insertion of an object into the perpendicular potion of the neutral blade opening results in the object contacting the blade receiving surface of the 20-A neutral blocking flap. Upon contact, the 20-A flap 70 will attempt to pivot downwardly in the hinge seat 36 of the housing 20. The finger 75 and / or distal end of the flap 70 will contact the neutral flap 60B to force it to rotate into its associated raised stop 32. Thus, the 20-A neutral flap 70 will remain in place and deny the object entry into the sub-assembly.

[0067] In operation, as best shown in FIG. 12, when a user desires to plug in an electrical cord, the hot and neutral blades of the plug are simultaneously inserted into the plug opening in the TR receptacle faceplate. The blades simultaneously hit the blade receiving surface of their respective blocking flaps. Continued force, if unequal, may result in the rocker attempting to rock only to be blocked by its respective stop. Ultimately, the downward force will be equalized and the rocker will be held upright in the cradle. At this point, continued downward force will not result in contact with the either stop beneath their respective flaps. Rather, as will be appreciated, the leaf spring members will now be under force until the force overcomes the springs bias and they flex downwardly. The flexing of the leaf springs pivots their respective flaps via their axles seated in the seats of the C-shaped knobs of the rocker. The rotation downward continues until the flaps are forced out of the way by the plug blades which continue downwardly, passing by the ends of the flaps, and reaching the electrical contacts and plugging in the plug.

[0068] With a 20-Amp TR receptacle, the perpendicular blade will contact the 20-A flap. If the hot blade is inserted simultaneously, the flap finger 75 or distal end of the flapwill cam against the lateral opening blocking flap 65. As the flap 70 attempts to rotate downwardly from its pivot point 72, the downward pressure from the flap finger 75 or distal end will be sufficient to put a pressure equal to that being applied to the hot flap 60A by the hot blade to cause the rocker 40 to equilibrate and the leaf springs to bend as described above. Continued downward movement (and pressure) by the plug will flex the flap 60A out of the way on the hot side and allow the 20-A flap 70 to rotate at its hinge pin as the flap 60B is moved out of the way until both flaps 60B, 70 on the neutral side provide clearance for the neutral blade to pass and reach the neutral contact. The finger 75 provides the downward force and posting of the neutral flap 60B once the flap ends have rotated out of contact. The finger 75 remains in contact with the top surface of the neutral flap 60B.

[0069] Upon full insertion of the plug, the flaps have been vertically displaced by overcoming the bias of the springs. Upon retraction of the plug, the springs operate to return the TR sub-assembly to the original position blocking access to the hot and neutral blade opening of the TR receptacle. Specifically, as the plug is removed, the leaf springs bias the flaps back in the upwards direction to their original position forcing the flaps 60A, 60B, 70 back up into their position of blocking the hot and neutral openings of the TR receptacles faceplate.

[0070] The above examples and similar examples use few parts and are thus easy and cost effective to build. Fewer parts also increase the useful life of the products as there are fewer points of failure. Fewer parts and simple mechanical interaction also increase the lifespan of the products. All of these benefits help to encourage and increase the use, availability, and reliability of these important safety products.

[0071] The above-described example utilized a pair of lateral spring members. A pair of spring members disposed on opposite sides provides the advantage of redundancy and prevents binding non-uniform movement of the shutter. However, one of ordinary skill in the art will readily appreciate that a single lateral spring, or a single centrally disposed angled spring could easily be used in various examples according to the present disclosure. Similarly, while leaf springs are used in the depicted example, other types of biasing springs and components could equally be used according to various examples of the present disclosure.

[0072] One of ordinary skill will appreciate that the exact dimensions and materials are not critical to the disclosure and all suitable variations should be deemed to be within the scope of the disclosure if deemed suitable for carrying out the objects of the disclosure.

[0073] One of ordinary skill in the art will also readily appreciate that it is well within the ability of the ordinarily skilled artisan to modify one or more of the constituent parts for carrying out the various examples of the disclosure. Once armed with the present specification, routine experimentation is all that is needed to determine adjustments and modifications that will carry out the present disclosure.

[0074] The above examples are for illustrative purposes and are not intended to limit the scope of the disclosure or the adaptation of the features described herein. Those skilled in the art will also appreciate that various adaptations and modifications of the above-described preferred examples can be configured without departing from the scope and spirit of the disclosure. Therefore, it is to be understood that, within the scope of the appended claims, the disclosure may be practiced other than as specifically described.

Claims

CLAIMSWhat is claimed is:1 . A tamper-resistant receptacle sub-assembly comprising: a sub-assembly platform including a face surface and a concave section; a rocker including a first rocker arm with a first distal end, a second rocker arm with a second distal end and a rocker axel configured to fit against the concave section; a spring component; a first main flap biased against the first rocker arm by the spring component; and a second main flap biased against the second rocker arm; wherein the first main flap in a closed position prevents a foreign object from being fully inserted in the tamper-resistant receptacle sub-assembly; and wherein the second main flap in the closed position prevents the foreign object from being fully inserted in the tamper-resistant receptacle sub-assembly.

2. The tamper-resistant receptacle sub-assembly of claim 1 , wherein the spring component is a first spring component, the tamper-resistant receptacle sub-assembly further comprising: a second spring component configured to bias the second main flap against the second rocker arm.

3. The tamper-resistant receptacle sub-assembly of claim 2, wherein, with nothing inserted into the tamper-resistant receptacle sub-assembly, the spring component keeps the rocker in a neutral position.

4. The tamper-resistant receptacle sub-assembly of any one of claims 1 to 3, further comprising:a hot prong opening, wherein with the rocker in a or the neutral position the hot prong opening is aligned with the first main flap and aligned outside the first distal end of the first rocker arm.

5. The tamper-resistant receptacle sub-assembly of claim 4, further comprising: a neutral prong opening, wherein with the rocker in the neutral position the neutral prong opening is aligned with the second main flap and aligned outside the second distal end of the second rocker arm.

6. The tamper-resistant receptacle sub-assembly of claim 5, wherein the first main flap includes a first main flap distal end and the second main flap includes a second main flap distal end, the tamper-resistant receptacle sub-assembly further comprising: a first stop tab positioned beneath the first main flap with the rocker in the neutral position; and a second stop tab positioned beneath the second main flap with the rocker in the neutral position.

7. The tamper-resistant receptacle sub-assembly of claim 6, wherein the foreign object inserted in the hot prong opening pushes the first rocker arm downward via the first main flap, causing the first main flap distal end to contact the first stop tab putting the first main flap in the closed position.

8. The tamper-resistant receptacle sub-assembly of claim 7, wherein the foreign object inserted in the neutral prong opening pushes the second rocker arm downward via the second main flap, causing the second main flap distal end to contact the second stop tab putting the second main flap in the closed position.

9. The tamper-resistant receptacle sub-assembly of claim 8, wherein the tamper-resistant receptacle sub-assembly is configured to receive an electrical plug with a hot prong and a neutral prong.

10. The tamper-resistant receptacle sub-assembly of claim 9, wherein, in response to inserting the electrical plug, the hot prong pushes downward on the first main flap simultaneous to the neutral prong pushing downward on the second main flap, keeping the rocker in the neutral position and allowing the hot prong and the neutral prong to be fully inserted.1 1. A 20-Amp tamper-resistant receptacle sub-assembly comprising: a sub-assembly platform including a face surface and a concave section; a rocker including a first rocker arm with a first distal end, a second rocker arm with a second distal end and a rocker axel configured to fit against the concave section; a spring component; a first main flap biased against the first rocker arm by the spring component; a second main flap biased against the second rocker arm; and a 20-Amp flap positioned above the second main flap; wherein the first main flap in a closed position prevents a foreign object from being fully inserted in the 20-Amp tamper-resistant receptacle; wherein the second main flap in the closed position prevents the foreign object from being fully inserted in the 20-Amp tamper-resistant receptacle; and wherein the 20-Amp flap in the closed position prevents the foreign object from being fully inserted in the 20-Amp tamper-resistant receptacle.

12. The 20-Amp tamper-resistant receptacle sub-assembly of claim 1 1 , wherein the spring component is a first spring component, the 20-Amp tamper-resistant receptacle sub-assembly further comprising: a second spring component configured to bias the second main flap against the second rocker arm.

13. The 20-Amp tamper-resistant receptacle sub-assembly of claim 12, wherein, with nothing inserted into the 20-Amp tamper-resistant receptacle, the spring component keeps the rocker in a neutral position.

14. The 20-Amp tamper-resistant receptacle sub-assembly of any one of claims 1 1 to 13, further comprising: a hot prong opening, wherein with the rocker in the neutral position the hot prong opening is aligned with the first main flap and aligned outside the first distal end of the first rocker arm; and a neutral prong opening, wherein with the rocker in the neutral position the neutral prong opening is aligned with the second main flap and aligned outside the second distal end of the second rocker arm.

15. The 20-Amp tamper-resistant receptacle sub-assembly of claim 14, further comprising: a neutral tee opening, wherein with the rocker in the neutral position the neutral tee opening is aligned with the 20-Amp flap and aligned outside the second distal end of the second rocker arm.

16. The 20-Amp tamper-resistant receptacle sub-assembly of claim 15, wherein the first main flap includes a first main flap distal end and the second main flap includes a second main flap distal end, the 20-Amp tamper-resistant receptacle sub-assembly further comprising: a first stop tab positioned beneath the first main flap with the rocker in the neutral position; and a second stop tab positioned beneath the second main flap with the rocker in the neutral position.

17. The 20-amp tamper-resistant receptacle sub-assembly of claim 16, wherein the foreign object inserted in the hot prong opening pushes the first rocker armdownward via the first main flap, causing the first main flap distal end to contact the first stop tab putting the first main flap in the closed position.

18. The 20-amp tamper-resistant receptacle sub-assembly of claim 17, wherein the foreign object inserted in the neutral prong opening pushes the second rocker arm downward via the second main flap, causing the second main flap distal end to contact the second stop tab putting the second main flap and the 20-Amp flap in the closed position; and wherein the second main flap in the closed position causes the 20-Amp flap to remain in the closed position.

19. The 20-Amp tamper-resistant receptacle sub-assembly of claim 17 or claim 18, wherein the foreign object inserted in the neutral tee opening pushes the second rocker arm downward via the 20-Amp flap and the second main flap, causing the second main flap distal end to contact the second stop tab putting the second main flap and the 20-Amp flap in the closed position.

20. The 20-Amp tamper-resistant receptacle sub-assembly of any one of claims 17 to 19, wherein the 20 amp tamper-resistant receptacle sub-assembly is configured to receive an electrical plug with a hot prong and a tee shaped neutral prong; wherein, in response to inserting the electrical plug, the hot prong pushes downward on the first main flap simultaneous to the neutral prong pushing downward on the second main flap and the 20-Amp flap, keeping the rocker in the neutral position and allowing the hot prong and the tee shaped neutral prong to be fully inserted.21 . A rocker assembly for a tamper-resistant receptacle sub-assembly, the rocker assembly comprising: a rocker body including a rocker axel configured to permit pivotal movement of the rocker assembly; a first rocker arm that extends from the rocker body, wherein the first rocker arm has a first distal end having a first pin seat;a second rocker arm that extends from the rocker body, wherein the second rocker arm has a second distal end having a second pin seat; a first flap having a first receiving surface and a first pin pivotably received within the first pin seat; a second flap having a second receiving surface and a second pin pivotably received within the second pin seat; a first spring coupled to the first flap; and a second spring coupled to the second flap.

22. The rocker assembly of claim 21 , wherein the first spring and the second spring are leaf springs.

23. The rocker assembly of claim 21 or claim 22, wherein the rocker body includes a concave section, and wherein the rocker axel extends through the rocker section.

24. The rocker assembly of any one of claims 21 to 23, wherein a rocker axis extends through the rocker axel, and wherein the first rocker arm and the second rocker arm are disposed on the same side of the rocker axis.

25. The rocker assembly of any one of claims 21 to 23, wherein a rocker axis extends through the rocker axel, and wherein the first rocker arm and the second rocker arm are disposed on the opposite sides of the rocker axis.

26. The rocker assembly of any one of claims 21 to 25, further comprising, a third rocker arm that extends from the rocker body, wherein the third rocker arm has a third distal end having a third pin seat; and a fourth rocker arm that extends from the rocker body, wherein the fourth rocker arm has a second distal end having a second pin seat; wherein the first pin is received within the third pin seat; and wherein the second pin is received within the fourth pin seat.

27. The rocker assembly of any one of claims 21 to 26, wherein the first spring is coupled to a first end of the rocker axel and the second spring is coupled to a second end of the rocker axel.

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