AU2003271282B1 - Moisture proof plug blade - Google Patents

Description

22-DEC-2003 15:04 A J PAfRK 64 4 4723358 P. 07/54 Regulation 3.2

AUSTRALIA

PATENTS ACT, 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT

ORIGINAL

Name of Applicant: Actual Inventor: Address for service GEM TERMINAL IND. CO., LTD.

Tun-Li SU in Australia: A J PARK, Level 11, 60 Marcus Clarke Street, Canberra ACT 2601 Invention Title: MOISTURE PROOF PLUG BLADE The following statement is a full description of this invention, including the best method of pcrforming it known to mae -1- (followed by page la) COMS ID No: SMBI-00546580 Received by IP Australia: Time 14:14 Date 2003-12-22 e 1I:04 A J PRK 64 4 4723352 P.8/54 Moisture Proof Plut BMe BpjclIowd af the I4vention .Field of he Inventio The present invention relates to a plug blade. In particular, the present invention relates to a moisture proof plug blade for preventing moisture from entering an interior of a plug.

2. Description ofte Related Art A plug is a necessary element to all industries and other fields. The plug is engaged with a socket to supply electricity to an electric appliance or other electric equipments that may be used in many places including a humid environment. Thus. there is a risk of short circuit, as ihoisture may enter a gap between an outer periphery of a respective plug blade and a peripheral wall delimiting a respective slot of a socket into which the plug blade is inserted.

Figs. I and 2 illustrate a conventional plug blade 1 having a protective sleeve 2 mounted thereon. The protective sleeve 2 includes a through-hole 21 that is rectangular in section and through which the plug blade 1 extends. However, additional cost is incurred for a mold for producing the protective sleeve 2.

Further the protective sleeve 2 and the plug blade I are separae members such that entrance of moisture via the gap between the protective sleeve 2 and the plug blade I is still possible. Further, the bonding force between the protective sleeve 2 and the plug blade 1 is insufficient such that the protective sleeve 2 may disengage from the plug blade I during a subsequent procedure of coupling a wire to the plug blade 1.

Ia COMS ID No: SMBI-00546580 Received by IP Australia: Time 14:14 Date 2003-12-22 0 Summary of the Invention An object of the present invention is to provide a moisture proof plug blade for preventing moisture from entering an interior of a plug, avoiding IN potential short circuit and damage.

Another object of the present invention is to provide a moisture proof plug blade including an insulating layer firmly bonded thereto.

0A plug blade comprising a front section and a rear section, the rear section having an embossed section formed in two opposing faces thereof and a through-hole formed in the embossed section and extending from a first face of the two opposing faces to the second opposing face thereof, an insulating layer being formed on the rear section by injection molding and filling the through-hole of the rear section of the plug blade, the insulating layer including a flange formed at a rear end thereof, and circumscribing the rear section and having four corners, each of the corners of the flange having an arcuate contour, the flange being adapted to abut against an inner face of an inner frame during a procedure for forming a housing of a plug, thereby preventing moisture from entering an interior of the housing of the plug.

Other objects, advantages, and novel features of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.

Brief Description of the Drawinqs FIG. 1 is an exploded perspective view of a conventional plug blade.

FIG. 2 is a sectional view of the conventional plug blade.

FIG. 3 is a perspective view of a row of plug blades in accordance with a first embodiment of the present invention, wherein an insulating layer on the respective plug blade is removed to show structure of the respective plug blade.

FIG. 4 is an elevational view of the row of plug blades in FIG. 3.

FIG. 5 is a perspective view of the row of plug blades in accordance with the first embodiment of the present invention.

&c H0 J P-RK 64 4 4723358 P. 10/54 Fig. 6 is an exploded perspective view of a semi-product of a two-blade type plug made from the plug blades in accordance with the first embodiment of the present invention.

Fig. 7 is a perspective view of the semi-product in Fig. 6.

Fig. 8 is a perspective view of a final plug product made from the semi-product in Fig. 7.

Fig. 9 is exploded perspective view of a semi-product of another two-blade type plug made from the plug blades in accordance with the first embodiment of the present invention.

Fig. 10 is a perspective view of the semi-product in Fig. 9.

Fig. 11 is a perspective view of a final plug product made from the semi-product in Fig. Fig. 12 is an exploded perspective view of a semi-product of a three-blade type plug made from the plug blades in accordance with the first embodiment of the present invention.

Fig. 13 is a perspective view of the semi-product in Fig 12.

Fig. 14 is a perspective view of a final plug product made from the semi-product in Fig. 13.

Fig. 15 is a perspective view of a row of plug blades in accordanc with a second embodiment of the present invention, wherein an insulating layer on the respective plug blade is removed to show structure of the respective plug blade.

Fig. 16 is an elevational view of the row of plug blades in Fig. Fig. 17 is a perspective view of a row of plug blades in accordance with the second embodiment of the present invention.

3 COMS ID No: SMBI-00546580 Received by IP Australia: Time 14:14 Date 2003-12-22 *SD-rd -'Dl 4 rac.

I i H L J r-FHK 64 4 4723358 P. 11/54 Fig, 18 is an exploded perspective view of a semi-product of a two-blade type plug made from the plug blades in accordance with the second embodiment of the present invention.

Fig. 19 is a perspective view of the semi-product in Fig. 18.

Fig. 20 is a perspective view of a final plug product made from the semi-product in Fig. 19.

Fig. 21 is exploded perspective view of a semi-product of another two-blade type plug made from the plug blades in accordance with the second embodiment of the present invention.

Fig. 22 is a perspective view of the semi-product in Fig. 21.

Fig. 23 is a perspective view of a final plug product made from the semi-product in Fig. 22.

Fig. 24 is an exploded perspective view of a semi-product of a three-blade type plug made from the plug blades in accordance with the second embodiment of the present invention.

Fig. 25 is a perspective view of the semi-product in Fig 24, Fig. 26 is a perspective view of a final plug product made from the semi-product in Fig. Fig. 27 a perspective view of a row of plug blades in accordance with a third embodiment of the present invention wherein an insulating layer on the respective plug blade is removed to show structure of the respective plug blade.

Fig. 28 is an elevational view of the row of plug blades in Fig. 27.

Fig. 29 is a perspective view of a row of plug blades in accordance with the third embodiment of the present invention.

4 COMS ID No: SMBI-00546580 Received by IP Australia: Time 14:14 Date 2003-12-22 22_Dc"_ra- *2rac n- C1i n- 2- i4.o H J I- RK 64 4 4723358 P. 12/54 Fig. 30 is an exploded perspective view of a semi-product of a two-blade type plug made from the plug blades in accordance with the third embodiment of the present invention.

Fig. 31 is a perspective view ofthe semi-product in Fig. Fig. 32 is a perspective view of a final plug product made from the semi-product in Fig. 31.

Fig 33 is exploded perspective view of a semi-product of another two-blade type plug made from the plug blades in accordance with the third embodiment of the present invention.

Fig. 34 is a perspective view of the semi-product in Fig. 33.

Fig. 35 is a perspective view of a final plug product made from the semi-product in Fig. 34.

Fig. 36 is an exploded perspective view of a semi-product of a three-blade type plug made from the plug blades in accordance with the third embodiment of the present invention.

Fig. 37 is a perspective view of the semi-product in Fig. 36.

Fig. 38 is a perspective view of a final plug product made from the semi-product in Fig. 37.

Fig. 39 is an elevational view illustrating a modified embodiment of the present invention.

Fig. 40 is a perspective view of a plug blade in accordance with the second embodiment of the present invention.

Fig. 41 is a sectional view taken along plane A-A in Fig. Fig. 42 is a perspective view of a modified embodiment of the plug blade in Fig. Fig. 43 is a sectional view taken along plane B-B in Fig. 42.

COMS ID No: SMBI-00546580 Received by IP Australia: Time 14:14 Date 2003-12-22 DO-rcr-omm"T 4 M-- DDr.....oa o -H J n-ri 64 4 4723352 P.13/54 Fig. 44 is a side view, partly sectioned, of the plug blade in accordance with the second embodiment of the present invention.

Fig 44A is an enlarged view of a circled portion in Fig. 44.

Fig, 45 is a sectional view of the semi-product of Fig, 19.

Fig 46 is a perspective view of another two-blade plug made from the plug blades in acordance with the present invention, Fig. 47 is a perspeotive view of another three-blade plug made from the plug blades in accordance with the present invention, Fig. 48 is a perspective view of a further two-blade plug made from the plug blades in accordance with the present invention.

Fig. 49 is a perspective view of still another two-blade plug made from the plug blades in accordance with the present invention.

Detailed mtioon of the Preferred Ebdmucettst Referring to Figs. 3, through 5, a plug blade 3A in accordance with the present invention is cut from a row of plug blades 3A in Fig. 5 and includes an enclosed rear section 31A enclosed by an insulating layer 34A and an exposed front section 32A- The enclosed rear section 3 1A includes a through-hole 33A extending from a first face of the rear section 3 IA through a second face of the rear section 31A opposite to the first face. The plug blade 3A is made of metal for conducting electricity.

The insulating layer 34A is made of plastics and formed on the rear section 31A by injection molding, as shown in Fig. 5. The insulating layer 34A may include a flange 341A on a rear end thereof. Molten plastic material is poured into a mold (not shown) in which the respective plug blade 3A is placed.

The molten plastic material also fills the through-hole 33A of the respective plug blade 3A. Thus, after hardening of the molten plastic material, the insulating layer 6 COMS ID No: SMBI-00546580 Received by IP Australia: Time 14:14 Date 2003-12-22 ee -ULL-.eaWI' 1i-0b H J PRK 64 4 4723358 P. 14/54 34A is firmly bonded with the rear section 31A of the respective plug blade 3A, best shown in Fig. 5. Four faces 34A of the rear section 31A are lower than those of the front section 32A. After formation, four faces of the insulating layer 34A (except the flange 341A) ar respectively flush with those of the front section 32A.

Referring to Figs. 6 through 8, an insulating layer 34A is firstly formed on the respective plug blade 3A. After coupling an end of a wire (not shown) to the respective plug blade 3A, the respective plug blade 3A is mounted on and thus positioned by a rectangular inner frame 4A fir subsequent formation of a homing SA by means of injection molding. Thus, a plug with two plug blades 3A is provided.

Referring to Figs. 9 through 11, two plug blades 3A are mounted on and thus positioned by a cirular inner frame 6A for subsequent formation of a housing 7A by means of injection molding. Thus, a plug with two plug blades 3A is provided.

Refring to Figs. 12 through 14, two plug blades 3A and a grounding prong or blade 3 are mounted on and thus positioned by a circular inner frme SA for subsequent formation of a housing 9A by means of injection molding. Thus, a plug with three plug blades 3A and 3 is provided.

Figs. 15 through 17 illustrate a row of plug blades 3B of another type. In this embodiment the plug blade 3B includes a front section 328 and a rear section 31B having a through-hole 33B extending from a first face of the rear section 31B through a second face of the rear section 31B opposite to the first face. An insulating layer 34B having a flange 341B encloses the rear section 31B and fills the through-hole 33B, as mentioned above.

COMS ID No: SMBI-00546580 Received by IP Australia: Time 14:14 Date 2003-12-22 e-e, -a r O* H J hI-NK 64 4 4723358 P.15/54 Refering to Figs. 18 through 20, two plug blades 3B are mounted on and thus positioned by a rectangular inner frame 4B having two slots 41B for subsequent formation of a housing SB by means of injection molding. Thus, a plug with two plug blades 3B is provided.

Referring to Figs. 21 through 23. two plug blades 3B are mounted on and thus positioned by a circular inner frame 6B for subsequent formation of a housing 7B by means of injection molding. Thus, a plug with two plug blades 3B is provided.

Referrting to Figs. 24 through 26, two plug blades 3B and a grounding prong or blade 3 are mounted on and thus positioned by a circular inner fiame s8B for subsequent formation of a housing 9A by means of injection molding. Thus, a plug with three plug blade 3B and 3 is provided.

Figs. 27 through 29 illustrate a row of plug blades 3C of another type. In this embodiment, the plug blade 3C includes a front section 32C and a rear section 31C having a through-hole 33C extending from a first face of the rear section 31 C through a second face of the rear section 31C opposite to the first face. An insulating layer 34C having a flange 341C encloses the rear section 31C and fills the through-hole 33C, as mentioned above. Two lateral faces (not labeled) of the rear section 31C are lower than those of the front section 32C. After formation, two lateral faces of the insulating layer 34C (except the flange 341C) are respectively flush with those of the front section 32C.

Refrringto Figs. 3 0 through 32, two plug blades 3C are mounted on and thus positioned by a rectangular inner frame 4C for subsequent formation of a housing 5C by means of injection molding. Thus, a plug with two plug blades 3C is provided.

8 COMS ID No: SMBI-00546580 Received by IP Australia: Time 14:14 Date 2003-12-22 ru"t f f r a-7 4 4" 'i' H J PI-fKK 64 4 4723359 P. -16/54 Referring to Figs. 33 through 35, two plug blades 3B are mounted on and thus positioned by a circular inner frame 6C for subsequent formation of. a housing 7C by means of injection molding. Thus, a plug with two plug blades 3C is provided.

Referring to Figs. 36 through 38, two plug blades 3C and a grounding prong or blade 3 are mounted on and thus positioned by a circular inner frame 8C for subsequent formation of a housing 9C by means of injection molding. Thus, a plug with three plug blades 3C and 3 is provided.

As illustrated in Fig. 39, an embossed section 35B may be formed on at least one of the two faces of the rear section 31B of the respective plug blade plug blade 3B). The embossed section 35B improves the bonding strength between the respective face of the respective plug blade 3B and the insulating layer on the respective plug blade 3B, further avoiding entrance of moisture into an interior of the housing of the final plug.

Fig. 40 is an exploded perspective view of a plug blade in accordance with the second embodiment of the present invention. Fig. 41 is a sectional view taken along plane A-A in Fig. 40. The flange 341B of the insulating layer 34B may include rounded corners 342, and the remaining portion of the insulating layer 34B may include rounded corners 343.

Fig. 42 is a perspective view illustrating a modified embodiment of the insulating layer 34B. Fig. 43 is a sectional view taken along plane B-B in Fig. 42, In this embodiment, the flange 341B of the insulating layer 34B includes rounded corners 344, and the remaining portion of the insulating layer 34B includes rounded comers 345.

Fig. 44 is a sectional view of the respective plug blade in accordance with the present invention. Fig. 44A is an enlarged view of a circled portion in Fig. 44.

9 COMS ID No: SMBI-00546580 Received by IP Australia: Time 14:14 Date 2003-12-22 I c *M"

L

J r -f 64 4 4723358 P. 17/54 As illustrated in Figs. 44 and 44A4, the insulating layer 34B may include an inclined end face 346 on an end thereof that is adjacent to the exposed front section 32B of the respective plug blade 3B. The inclined end face 346 allows the plug blade 3B to be smoothly inserted into a slot (not shown) of a socket (not shown) with less friction.

Fig. 45 is a sectional view of the semi-product of Fig. 19. As illustrated in Fig. 45, the flange 34 IB of the insulating layer 34B abuts against an inner face of the inner frame 4B and thus avoids entrance of moisture into an interior of the housing of the plug product.

Fig, 46 is a perspective view of another two-blade plug D made from the plug blades in accordance with the present invention, wherein the plug D is generally used in the United States, Canada, Japan, etc. Fig. 47 is a perspective view of another three-blade plug E made from the plug blades in accordance with the present invention, wherein the plug E is generally used in the United States, Canada, Japan, etc. Fig. 48 is a perspective view of a further two-blade plug F made from the plug blades in accordance with the present invention, wherein the plug F is generally used in the United States, Canada, etc. Fig. 49 is a perspective view of still another two-blade plug G made from the plug blades in accordance with the present invention, wherein the plug G is generally used in Australia, Argentina, etc.

According to the above description, it is appreciated that the insulating layer 34A, 34B, 34C is firmly bonded with the plug blade 3A, 3B, 3C as the insulating layer 34A, 34B, 34C fills the through-hole 33A, 33B, 33C of the plug 3A, 3B, 3C. The insulating layer 34A, 34H, 34C made of plastic material provides a strong bonding effect with the through-hole 33A, 33B, 33C of the plug 3A, 3B, 3C. The flange 341A, 341B, 341C that abuts against the inner face of the inner COMS ID No: SMBI-00546580 Received by IP Australia: Time 14:14 Date 2003-12-22 nn r ~n, L_.-?MUI 1o H J 64 4 4723358 P. 1i/S4 frame 4A, 6A, 8A, 4B, 6B, 8B, 4C, 6C, 8C avoids entrance of moisture into an interior of the housing 5A, 7A, 9A, 5B, 7B, 9B, 5C. 7C, 9C. The insulating layer 34A, 34B, 34C on the rear section 31A, 31B, 31C of the plug blade 3A. 3B, 3C reduces the risk of shock resulting from inadvertent touch of the rear section 31 A, 31B, 31C of the plug blade 3A, 3B, 3C by the use.

Although the invention has been explained in relation to its preferred embodiments, it is to be understood that many other possible modifications and variations can be made without departing from the scope of the invention as hereinafter claimed.

11 COMS ID No: SMBI-00546580 Received by IP Australia: Time 14:14 Date 2003-12-22

Claims (3)

1. A plug blade comprising a front section and a rear section, the rear section having an embossed section formed in two opposing faces 0thereof and a through-hole formed in the embossed section and N 5 extending from a first face of the two opposing faces to the second 00 opposing face thereof, an insulating layer being formed on the rear i section by injection molding and filling the through-hole of the rear o section of the plug blade, the insulating layer including a flange formed at a rear end thereof, and circumscribing the rear section and having four corners, each of the corners of the flange having an arcuate contour, the flange being adapted to abut against an inner face of an inner frame during a procedure for forming a housing of a plug, thereby preventing moisture from entering an interior of the housing of the plug.

2. The plug blade as claimed in claim 1, wherein a remaining portion of the insulating layer includes four rounded corners. t. 13 0 o

3. The plug blade as claimed in claim 1 or claim 2, wherein the insulating Slayer includes an inclined end face on an end thereof that is adjacent to the front section of the respective plug blade, allowing smooth NO insertion of the plug blade into a slot of a socket. 00 (c ci