High current electrical outlet and mating plug

Abstract

High Current Electrical Outlet and Mating Plug A high current electrical outlet (50) and mating plug (60) are disclosed The electrical outlet (50) comprises a nonconductive housing (50A), a peripheral shroud (50A1), a central projecting core (50A2) comprising of a pair of projections (50A3) and three pockets (50A4) and a set of conductive contacts (50B). The conductive contacts (50B) form a unique arrangement for the conductive pins (60B) and (60C) of the mating plug (60) to physically touch at two faces (50B6) and (50B9) thereby adding higher surface area of contact and hence high current carrying capacity. The plug (60) comprises slots (60A1) inside either side of the shroud wall of the non- conductive housing (60A) which fit into the projections (50A3) of the outlet (50). The high current electrical outlet (100) has a lockable fitment (100A6) to lock the mating plug (80).

Description

[0001] TITLE: High Current Electrical Outlet and Mating Plug

[0002] FIELD OF INVENTION:

[0003] The present application is based on, and claims priority from an Indian Application Number 202421072773 filed on 26thSeptember, 2024, the disclosure of which is hereby incorporated by reference herein.

[0004] The invention relates to a high current electrical outlet and mating plug assembly similar in size and shape to IEC-60320 standard. The said outlet and plug offer a compact, space saving solution for high current connectivity comparable to the prevalent standard IEC-60320 products and at the same time prevention against use of incorrect IEC mating plug so as to ensure safety of the equipment and the user where high current electrical outlet is being used.

[0005] BACKGROUND AND PRIOR ART:

[0006] Electrical appliance outlets and plugs are available under IEC-60320 C-13, C19 & C-21 versions Conventionally these connectors are compact but rated for up to 16 Amp max current capacity. For applications demanding high current connectivity, suitable outlets and plugs are not available in the said standard in similar form factors and sizes. The design of electrically conductive contact terminals used in such connectors imposes a limitation for high current connectivity because of the limited area of contact surface with the contact pin of mating power cord plug. An abnormal heating is experienced in such outlets with eventual burning when a high current of say 30 Amps is passed on a continuous basis.

[0007] Referring to Figure 1, the prior art CN211428413 comprises of a power outlet with non-conductive housing of a shape and size as per IEC-60320 standard with conductive metallic contacts, the middle portion of which is provided with a parallel land and on one end of the land profiled with twin locking arms which lock inside the pockets of housing. At the other end of land, a V-shaped fork arms diverge inside to form a mating edge configured to receive the conductive contact pin of mating plug which assists to establish electrical connectivity. The V-shaped fork arms are further bent to create a converging V-shaped fork opening which guides the conductive contact pin of mating plug and assist for easy entry. In this embodiment the connectivity between the conductive contact of outlet and the pin of plug is only possible at the interface of converging and diverging shapes of fork arms. However, such contact surface is not adequate for conducting a high current of over 16A or so for a continuous longer interval. In case of continuous exposure to high current, high heat is generated over the metallic contact eventually leading to melting of non-conductive housing. In short, the current carrying capacity with such contact profile cannot be more than 16 A or so due to lesser surface area contact with the mating plug pin

[0008] Referring to Figure 2, the prior art US 2016149331 Al use conductive metallic contacts with pair of parallel fork arms generated by U-bending. In the absence of proper locking arrangement on the contacts it is required to create the non- conductive housing in 3 parts instead of being a monolithically formed. In such a case the housing assembly becomes complex.

[0009] Referring to Figure 3, as per the prior art EP2321879B1 of Burland Technology a set of conductive metallic contacts having land as well as fork arms at plug pin receiving end but without locking fork arms on the other end are provided. The locking edges are generated by way of stepped cutting profiles at the bottom of the terminal end. Here again the contact surface area with the conductive pin of plug is inadequate for high power connectivity.

[0010] Referring to Figure 4, the prior art US 2023 / 0011560 of Bizlink uses a set of 3- conductive metallic contacts each of which comprise of an elastic sheet (flat spring) and a terminal connected to each other. The elastic sheet creates a contact pressure on the conductive terminal of mating plug for connectivity. In other words, the contact of outlet is a two-part design wherein the elastic sheet creates holding pressure between the terminals of outlet and the plug. The said connector uses thickened partition walls for high creepage distances. This embodiment offers a pair of male and female connectors with high creepage distance for high density servers.

[0011] The male connector comprises of non-conductive front block (2) of proprietary shape with set of 3 pocket openings (21, 22, 23) which assist for fitment of conductive terminals (212, 213, 214). Anon-conductive inner insert (24) fits inside the non-conductive front block (1). The female connector comprises of non- conductive ring-shaped outer wall (1) with hollow section and terminal seats (11, 12, 13) which facilitates seating of set of 3 -conductive terminals (2142) each one of which backed by elastic plate (2141) which creates a contact pressure between conductive terminals (2142) of female connector and the conductive terminals (11, 12, 13) of male connector to establish the electrical connectivity. The thickened middle partition walls on the ring-shaped outer wall (1) and the non-conductive front block (2) offer high creepage distance for use in high density servers. The overall assembly of this prior art is complex.

[0012] Thus, each of the above-mentioned prior art has a limitation in its capability to offer high current electrical connectivity on a continuous basis.

[0013] The solution to all the above difficulties lies in the disclosure of present invention which is designed to facilitate a pair of high current electrical outlet and mating plug which facilitates the high current connectivity by way of a simplified and space saving compact solution providing.

[0014] OBJECT OF THE INVENTION:

[0015] The object of the present invention is to overcome the disadvantages / shortcomings of the devices known in the prior art by providing a device which is simple and practical.

[0016] Another object of the present invention is to provide a device which is capable of having a high current carrying capacity.

[0017] Yet another object of the present invention is to provide locking for mating plug. SUMMARY OF THE INVENTION:

[0018] A high current electrical outlet (50) comprising a non-conductive housing (50A), a pair of projections (50A3), pockets (50A4), cantilever snaps (50A5) and conductive pins (50B) such that the middle portion (50B2) of each conductive pin (50B) has a converging and diverging bulge (50B7) and (50B8) inside and the bottom portion (50B3) of each conductive pin (50B) has a pair of fork arms each having a converging profile (50B4) and a diverging profile (50B5).

[0019] An assembly of the high current electrical outlet (50) and a high current mating plug (60) such that the high current outlet (50) has a pair of projections (50A3) mating with the corresponding clots (60A1) of the high current mating plug (60).

[0020] Typically, the high current electrical outlet (70) as recited in claim 1, wherein the pockets (70A4) are vertically oriented.

[0021] Typically, the high current mating plug (80) as recited in claim 2, wherein the conductive pins (80B), (80C) are vertically oriented.

[0022] Typically, the high current electrical outlet (100) as recited in claim 3, wherein the high current electrical outlet (100) has a lockable fitment (100A6) comprising of a cantilever locking arm (100A7), a projection (100A8) and a locking tip (100A9).

[0023] BRIEF DESCRIPTION OF DRAWINGS:

[0024] In order to provide a full understanding of the manner, in which these and other objectives are attained in accordance with the invention, particularly advantageous embodiments thereof will be described with reference to the accompanying drawings, which form a part of this specification and wherein:

[0025] Figure 1 is a perspective view of the metallic contact profile of prior art CN211428413U having a fish shaped profile. Figure 2 is an exploded perspective view of alternate type of conventional outlet as per prior art US2016149331A1 which uses a set of U-shaped metallic contact of different type, and it does not have a provision for contact locking. That is why a non-conductive cover is added to retain the metallic contact in place at inside of the non-conducting housing.

[0026] Figure 3 is a perspective view of alternate type of conductive metallic contact used in the outlets as per prior art EP2321879B1.

[0027] Figure 4 is an exploded perspective view of the male-female connector pair of the prior art disclosed in US2023 / 0011560 with high creepage distance configuration. It depicts the profile of housings, set of conductive contacts and the elastic plate which creates a pressure on the terminals.

[0028] Figure 5 is a perspective view of the assembly of high current outlet and mating plug designed for use up to 30 Amps.

[0029] Figure 6 is an exploded perspective view of the outlet and plug of Figure 5.

[0030] Figure 7 is a perspective view of the high current electrical outlet.

[0031] Figure 8 is an exploded perspective view of the high current electrical outlet and mating plug of Figure 5.

[0032] Figure 9 is a front view of the high current electrical outlet of Figure 7 as per the invention which shows the arrangement of projecting ribs for arresting the use of incorrect power plug. Figure 10 is a front view of the conductive contact as per Figure 8 showing the position of electrical connectivity of the conductive pin of the plug at two locations for greater current conductivity.

[0033] Figure 11 is the front view of high current plug of invention as per Figure 6 showing the outline profile of the mating area of the plug.

[0034] Figure 12 is the perspective view of the alternative embodiment of the disclosure of the outlet with vertically oriented pin entry pockets.

[0035] Figure 13 is the exploded perspective view of alternative embodiment of Figure 8 showing the conductive contacts as per original embodiment and the nonconductive housing as per alternate embodiment.

[0036] Figure 14 is the perspective view of the mating plug with vertically oriented pins suitable for outlet as per alternative embodiment of Figure 12.

[0037] Figure 15 is the exploded assembly view of alternate embodiment of invention showing the plug having the contact pins with vertical orientation.

[0038] Figs 16, 17 and 18 indicate the alternate embodiment of high current outlet with lockable fitment of plugs.

[0039] DETAILED DESCRIPTION OF THE INVENTION:

[0040] The present disclosure will now be described with reference to the accompanying drawings wherein the same numerals are used to denote the same part. However, the drawings only illustrate the disclosure and in no way limit the disclosure.

[0041] The terms and words used in the following description and claims are not limited to the bibliographical meanings but are merely used by the inventor to enable a clear and consistent understanding of the disclosure. The description given herein is only representative of the illustrative embodiments and examples. Only for the sake of convenience, the description has focused on a limited number of representative examples of the drawings. However, the drawings and / or illustrations in no way limit the scope of the disclosure. It is understood that modifications and / or alterations of the drawings / illustrations of this disclosure other than those specifically set forth herein may be achieved by those skilled in the art and that such modifications and alterations are to be considered as falling within the overall scope of this disclosure.

[0042] Terms used herein are used only in order to describe an exemplary embodiment rather than limiting the present disclosure. In this case, singular forms include plural forms unless interpreted otherwise in context.

[0043] A high current electrical outlet and mating plug disclosed herein facilitates the high current connectivity by way of a simplified and space saving compact solution by providing adequate creepage distances between the conductive contacts. The high current connectivity is possible by using a set of conductive contacts of unique profile by which the physical contact area between the forks of conductive contacts of outlet and the conductive pins of mating plug is greater. The shape and size of the high current outlet of the present disclosure is similar to 16 Amp rated IEC- 60320 C-21; however, the non-conductive housing of the outlet is modified to prevent use of standard C-20 electrical plug. Referring to Figure 5, 6 and 7, the high current electrical outlet (50) comprises a nonconductive housing (50A) similar to IEC-60320 C-21 and a set of conductive contacts (50B). As detailed in Figure 8, the non-conductive housing (50A) of the high current electrical outlet (50) is profiled with a central projecting core (50 A2) which accommodates the conductive contacts (50B). A set of three pockets (50A4) is disposed on the central projecting core (50A2) for the entry of conductive contact pins (60B), (60C) of the mating plug (60) to establish the connection. The peripheral shroud (50 Al) surrounds the central projecting core (50A2) where cantilever snaps (50A5) are disposed on at least two sides of the housing (50A). A pair of projections (50A3) are profiled out of the central projecting core (50A2) to prevent the entry of any conventional electrical plugs.

[0044] The conductive contacts (50B) are profiled with a top portion (50B1) formed like inverted V-shape which deflect elastically towards outward directions and revert to nearly original shape while the contacts (50B) are inserted and pressed inside the pockets (50A4) of the non-conductive housing (50A). The middle portion (50B2) of the conductive contact (50B) is flat on either arm which assists for stability of contact inside the pocket (50A4) of non-conductive housing (50A). The bottom portion (50B3) is a combination of V and inverted V shape generated by a converging profile (50B4) and a diverging profile (50B5) on the fork arms which creates a connecting face (5 OB 6) at the interface of the V and inverted V. The connecting face (50B6) is the connecting face between the conductive parts of the outlet (50) and the plug (60) and this is the portion of the fork arm which generates a retention force between the two when coupled. Further, an additional connecting face (50B9) is formed in the middle portion (50B2) with a combination of V and inverted V shape generated by a converging profile (50B7) and a diverging profile (50B8). This unique arrangement ensures high current conductivity since the conductive pins (60B) and (60C) of the mating plug (60) physically touch at two faces (5 OB 6) and (5 OB 9) thereby adding higher surface area of contact. The higher surface area supports better electrical conductivity which is necessary for higher current connectivity.

[0045] The mating plug (60) is profiled with a non-conductive housing (60A) and a set of conductive contact pins (60B) and (60C) therein. Slots (60A1) are disposed inside either side of the shroud wall of the non-conductive housing (60A). The projections (50A3) of the non-conductive housing (50A) of the high current outlet (50) fit into the slots (60A1) of the mating plug (60) to ensure that the high current electrical outlet (50) can mate only with the corresponding plug (60) of the present disclosure. Therefore, other conventional low current plugs cannot be coupled with it. Figure 9 shows the top view of the high current electrical outlet (50) showing the non-conductive housing (50 A), the shroud (50 Al), the central projecting core (50A2), the projections (50A3) and the pockets (50A4).

[0046] Figure 10 shows the conductive pin (60B) of the mating plug (60) inserted into the contact (50B) such that conductive pins (60B) and (60C) of the mating plug (60) physically touch at two faces (50B6) and (50B9).

[0047] Figure 11 shows the top view of the mating plug (60) showing the shroud wall of the non-conductive housing (60A), the slots (60A1) and the conductive pins (60B) and (60C).

[0048] In an alternate embodiment of the present disclosure as shown in Figure 12, 13 and 14, a high current outlet (70) has pin entry pockets (70A4) oriented vertically.

[0049] Figure 13 shows the conductive contacts (50B) as per original embodiment detailed above and the nonconductive housing as per alternate embodiment (70).

[0050] A mating plug (80) as disclosed in Figure 14 can be coupled with the outlet (70) as the conductive pins (80B and 80C) of plug (80) are located vertically to suit the entry pockets (70A4) of the electrical outlet (70).

[0051] Further, various child parts of mating plug (80) namely a non-conductive housing (80A), a holding strip (80C), a cable grommet (80D) and screw fitments (80E), (80G) are shown in the exploded view as per Figure 15. A set of conductive pins (80B and 80C) are placed inside the nonconductive housing (80A). The cable holding strip (80C) and cable grommet (80D) act as a strain relief to the cable.

[0052] In another embodiment a high current outlet (100) having pin entry pockets (100A4) oriented vertically is disclosed as shown in Figure 16, 17 and 18 which offers a lockable fitment (100A6) to lock the mating plug (80). The cantilever locking arm (100A7) is integrally formed with the non-conductive housing (100A) of the outlet (100). The said arm has a projection (100A8) and locking tip (100A9). The locking tip (100A9) latches with the peripheral step on the outer face of the surrounding shroud of the non-conductive housing (80A). It offers protection against unwanted extraction of the plug from outlet. The projection (100A8) acts as a handle for actuation of the arm for locking and unlocking purposes.

Claims

Claims:We claim:

1. A high current electrical outlet (50) comprising a non-conductive housing (50 A), a pair of projections (50A3), pockets (50A4), cantilever snaps (50A5) and conductive pins (50B) characterized by the fact that the middle portion (50B2) of each conductive pin (50B) has a converging and diverging bulge (50B7) and (50B8) inside and the bottom portion (50B3) of each conductive pin (50B) has a pair of fork arms each having a converging profile (50B4) and a diverging profile (50B5).

2. An assembly of the high current electrical outlet (50) and a high current mating plug (60) characterized by the fact that the high current outlet (50) has a pair of projections (50A3) mating with the corresponding clots (60A1) of the high current mating plug (60).

3. The high current electrical outlet (70) as recited in claim 1, wherein the pockets (70A4) are vertically oriented.

4. The high current mating plug (80) as recited in claim 2, wherein the conductive pins (80B), (80C) are vertically oriented.

5. The high current electrical outlet (100) as recited in claim 3, wherein the high current electrical outlet (100) has a lockable fitment (100A6) comprising of a cantilever locking arm (100A7), a projection (100A8) and a locking tip (100A9).Dated this 24thday of September, 2025Himanshu W Kane Applicant’s Patent Agent IN / PA-29

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