AU2020200096A1 - Improvements in wall mounted electrical outlets and switch plates - Google Patents

Abstract

Disclosed is an arrangement on a first electrical plate comprising a fastener receiver for receiving a fastener for fastening the first electrical plate to a surface; and a cover for covering the fastener receiver. When the cover is not covering the fastener receiver, the cover provides an obstructing portion that, in use, prevents a second electrical plate from fully engaging with the first electrical plate. This reduces the chance of an installer connecting the second electrical plate while the cover is open, which may lead to electrically-exposed elements and an increased safety risk. 6/9 9090 Figure 12A Figure 12B 2001g 11 90 101 100 83 82 81 80 Figure 13

Description

6/9

9090

Figure 12A Figure 12B

2001g 90 11 101

100 83 82 81 80

Figure 13

IMPROVEMENTS IN WALL MOUNTED ELECTRICAL OUTLETS AND SWITCH PLATES PRIORITY

[0001] The present application claims priority from Australian Patent Application No 2018904909 filed on 21 December 2018.

[0002] The entire content of this priority application is hereby incorporated by reference.

TECHNICAL FIELD

[0003] The present application relates to electrical outlet or switch plates that are mounted to a surface.

INCORPORATION BY REFERENCE

[0004] This application refers to the following Australian Patent Applications:

- Australian Patent Application No. 2015275225 entitled "Electrical System, Apparatus and Method";

- Australian Patent Application No 2015275227 entitled "Switch Assembly, System and Method"

- Australian Patent Application No 2015275234 entitled "Push Button Switch Assembly, and Operational Part";

- Australian Patent Application No 2015275233 entitled "Switch Assembly with Rotatable Operational Part";

- Australian Patent Application No 2015221512 entitled "Electrical Outlet and Support For Electrical Device";

- Australian Patent Application No. 2016235020 entitled "Connectors For Electrical System";

- Australian Patent Application No 2017236025 entitled "Electrical Outlet Faceplate and System".

[0005] The entire content of each of these applications is hereby incorporated by reference.

BACKGROUND

[0006] Electrical outlets such as power outlets and data outlets, or switch plates providing one or more switches for a user to actuate, are often mounted to a surface such as a wall. The fasteners used, such as screws, are often electrically conductive and can be a potential electrocution hazard if they are not properly covered. A fastener cover is usually provided to cover these fasteners, however, sometimes, the covers are not always used, or are inadvertently left off, and the fastener may be inadvertently left exposed.

SUMMARY

[0007] According to a first aspect, there is provided an arrangement on a first electrical plate comprising: a fastener receiver for receiving a fastener for fastening the first electrical plate to a surface; and a cover for covering the fastener receiver; wherein when the cover is not covering the fastener receiver, the cover provides an obstructing portion that, in use, prevents a second electrical plate from fully engaging with the first electrical plate.

[0008] According to a second aspect, there is provided a grid plate comprising the arrangement of the first aspect.

[0009] According to a third aspect, there is provided a grid plate comprising: a fastener receiver for receiving a fastener; and a fastener cover for covering the fastener; wherein the fastener cover is pivotable about a hinge between a closed position covering the fastener and an open position, not covering the fastener.

BRIEF DESCRIPTION OF DRAWINGS

[0010] Embodiments of the various aspects described herein will be detailed with reference to the accompanying drawings in which:

[0011] Figure IA - shows a front perspective view of a general embodiment of a base unit according to one aspect described herein;

[0012] Figure lB - shows a rear view of the base unit of Figure 1A;

[0013] Figure 2- shows aside view of an electrical system according to an aspect described herein;

[0014] Figure 3 - shows an embodiment of a base unit or grid plate and a cover unit or face plate according to an aspect described herein;

[0015] Figure 4- shows an example of the base unit or grid plate for Figure 3 and exchangeable cover units or face plates according to an aspect described herein;

[0016] Figure 5- shows an embodiment of a system in which the arrangement of the present application may be used, in this example, a power outlet;

[0017] Figure 6 - shows a grid plate of the system of Figure 5;

[0018] Figure 7 - shows the grid plate of Figure 6 with a cover covering a fastener;

[0019] Figure 8 - shows a close up view of the arrangemet of Figure 7;

[0020] Figure 9 - shows a side view of the grid plate of Figure 6;

[0021] Figure 10 -shows a side cross section along the line A-A' of Figure 7;

[0022] Figure 11 - shows the view of Figure 10 with a face plate engaged therewith;

[0023] Figure 12A - shows a top plan view of a cover according to some embodiments;

[0024] Figure 12B - shows an underside perspective view of the cover of Figure 12A;

[0025] Figure 13 - shows the view of Figure 11 with the cover open and preventing the face plate from engaging with the grid plate;

[0026] Figure 14 - shows an arrangement according to another aspect, with the cover in a closed position;

[0027] Figure 15A - shows the arrangement of Figure 14 with a face plate fully engaged with the grid plate;

[0028] Figure 15B - shows the view of Figure 15A with the cover in an open position preventing the face plate from fully engaging with the grid plate;

[0029] Figure 16A - shows an arrangement according to another aspect, with the cover in a closed position;

[0030] Figure 16B - shows the arrangement of Figure 16A, with the cover in the open position preventing the face plate from fully engaging with the grid plate;

[0031] Figure 17A - shows an arrangement according to another aspect, with the cover in a closed position;

[0032] Figure 17B - shows the arrangement of Figure 17A, with the cover in the open position preventing the face plate from fully engaging with the grid plate;

DESCRIPTION OF EMBODIMENTS

[0033] In one aspect described herein, there is provided a base unit 100 for mounting to a surface and for electrical connection to a mains or supply power. Figure IA shows a front perspective view of a general embodiment of base unit 1A and Figure lB shows a rear perspective view of the base unit 100 of Figure IA. In one aspect, the base unit 100 comprises a mounting region 110 for mounting the base unit 100 to the surface. In some embodiments, the surface is a wall. In some other embodiments, the surface is a floor. In some other embodiments, the surface is a wall of a box or other enclosure. In other embodiments, the surface is frame for supporting the base unit.

[0034] In some embodiments, the mounting region 110 is itself a surface which will come into contact with the surface to which the base unit 100 is to be mounted. In other embodiments, the mounting region 110 is a pin, tab or other connector.

[0035] As shown in Figure 1A, base unit 100 also comprises a base connector 120 for connecting the base unit to a cover unit 200 as will be described in more detail below. The base connector is shown generically in Figure 1A but can take on any form that allows connection of the cover unit to the base unit 100. Such forms include a recess for receiving a protrusion from the cover unit, a protrusion for being received in a corresponding recess in the cover unit, a clipping arrangement, or a magnet for attracting and retaining a region of the cover unit. In other embodiments, the base connector is an adhesive, or a loop-hook connector such as a product sold under the trade mark Velcro@ by Velcro Industries B.V. In this embodiment, base connector 120 can be either the loop component of the connector or the hook component.

[0036] Base unit 100 also comprises a base supply power input 130 for electrically connecting the base unit 100 to a supply or mains power supply (see Figure 1A). In some countries, the mains, or supply power is provided as an alternating current (AC) electrical signal of about 240V (for example between about 220V and 260V) and about 50Hz frequency. In other countries, mains or supply power is provided as an AC signal of between about 1OV and 130V. Some systems use a frequency of about 50Hz while others use a frequency of about 60Hz. Some supply power systems are single phase and others may be three-phase. It will be understood that any electrical power that would be considered to be supply or mains power can be used.

[0037] In some embodiments, base unit 100 will also comprise a base power output 150 (see Figure 1A) for providing output power to the cover unit 200 when cover unit 200 is connected to base unit 100.

[0038] Base power output 150 can be provided by any suitable means including a direct plug/socket arrangement with a recess provided in base unit 100 leading to conductive elements which make electrical connection with a corresponding electrically conductive element of a cover unit power input 210 (see below), or can be provided by a radiating element that transfers power from base unit 100 to cover unit 200 by induction or other means. An example of this embodiment is described in more detail below. Any other form of power transfer can also be used.

[0039] In some embodiments, base power output 150 and base connector 120 can be provided by the same element. In one such embodiment, the connection of cover power input to the base power output 150 will also provide sufficient support to retain cover unit 200 to base unit 100 without a further additional base connector 120 or other connection arrangement.

[0040] In some embodiments, base unit 100 will also comprise a power converter 140 which converts the supply input power received at the base supply power 130 input to the output power provided by the base power output 150 to provide useable power to the cover unit 200 when in use.

[0041] In some embodiments, the base power output will be shielded or otherwise protected so that no electrically-live element is easily accessible by a user when the base unit 100 is installed. In some embodiments, the default state of the base power output is to an OFF state and is electrically isolated from the mains or supply power, and/or from the output of the power converter 140. In such an embodiment, only when the cover unit 200 is in place will the base power outlet be electrically connected to the mains or supply power and/or the output of the power converter 140.

[0042] Figure 2 shows an embodiment of base unit 300 and cover unit 200 connected together, with base unit 300 mounted to a surface 40 (e.g. a wall), and mains or source power 50 connected to the base supply power 130 input.

[0043] In other embodiments, base unit 100 also comprises a base switch interface 160 for interfacing with a switch element of the cover unit 200, to allow actuation of a switch on the cover unit 200 to be effected on the base unit 100. Figure 3 shows a base unit 100 with base switch interface 160. In some embodiments, base switch interface 160 is an electrical interface such as a radio frequency (RF) receiver for receiving RF signals from a switch on the cover unit 200 when actuated. In some embodiments, base switch interface 160 is an infrared (IR) receiver for receiving IR signals from a switch of cover unit 200. In other embodiments, base switch interface 160 is a component of a touch switch which actuates upon a user touching or near-touching a corresponding switch element on the cover unit 200. An example of such a touch switch arrangement is described in PCT patent application no. PCT/AU12011/001675 (published as WO 12012/083380) entitled "Touch Switch" incorporated by reference in its entirety.

[0044] In other embodiments, base switch interface 160 is a mechanical interface for engaging with a switch element or a cover switch interface of cover unit 200 as is described in more detail in Australian Patent Application No. 2015275225 previously incorporated by reference in its entirety.

[0045] Figure 3 shows a general representation of the components of an embodiment of a switch assembly, connected to base unit 100 according to one aspect. Broadly, in this aspect, switch assembly 500 comprises two sub-assemblies, being base unit switch part 510 and operational part 1200. As shown in Figure 3, base unit switch part 510 comprises a functional part 1000 and a base switch interface 160.Operational part 1200 is for actuation by a user and for controlling the functional part 1000, via the base switch interface 160, for interfacing the functional part 1000 and the operational part 1200.

[0046] It will be noted that the operational part 1200 is not fixed to the base switch interface 160 or the functional part 1000 and is able to move freely with respect thereto as discussed in more detail in Australian Patent Application No. 2015275225 previously referred to, as well as Australian Patent Application No 2015275227 entitled "Switch Assembly, System and Method", Australian Patent Application No 2015275234 entitled "Push Button Switch Assembly, and Operational Part"; and Australian Patent Application No 2015275233 entitled "Switch Assembly with Rotatable Operational Part", all previously incorporated by reference in their entirety.

[0047] It will be understood that there can be any combination of different operational parts 1200 and plates or cover units 200. For example, a switch assembly 500 with a small dolly 1201B might be converted to a switch assembly with a big dolly 1201B by replacing the operational part 1200 with a small dolly as described above. In another example, a switch assembly with a round push-button switch might be converted to a switch assembly with a square push-button/rocker switch by changing the operational part and the plate. In another combination, as shown in Figure 4, the appearance of system 300 may be changed completely by changing the existing plate or cover unit 200 with a plate or cover unit 200' of a different type. In one embodiment, the user interface 1201 can be used, or a different user interface 1201 can be used. In the example of Figure 4, the switch interface 1201 is changed from a round dolly 1201B to a square dolly 1201B'.

[0048] Figure 5 shows a perspective view of an electrical system 300 according to some embodiments, and in this example, a general power outlet (GPO). Shown there is cover unit 200 (in this case a face plate), with power sockets 111, and switch user interfaces 1201, 1201', in this example being switch rockers.

[0049] Face plate 200 covers base unit 100 (in this case, a grid plate), as will be understood by the person skilled in the art.

[0050] Figure 6 shows the grid plate 100 of Figure 5 without the face plate 200. Shown in this view are power sockets 111, 111', switch rockers 1201, 1201', and fastener receiving region 80 containing fastener receiver 81. In some embodiments, the fastener 87 (not shown in this view) is a screw. In some embodiments, fastener 87 is a bolt. In some embodiments, fastener 87 is a nail. Any other fastener that will be able fasten the grid plate to a surface can be used as will be understood by the person skilled in the art. Since these fasteners are usually of metal and electrically conductive, there is a risk that they may come into contact with an electrically-live element of the outlet 300, and thus present a hazard of potential electrocution to anybody working on the outlet 300 who may inadvertently come into contact with the fastener.

[0051] Accordingly, a cover 90 is provided to cover one or more of these fasteners once the outlet 300 is installed, as shown in Figure 7. Shown there is fastener receiving region 80, with fastener receiver 81, receiving a fastener 87 (in this case a screw). Fastener cover 90 is shown covering the fastener receiver 81. Fastener cover 90 is made from any suitable non-conductive material such as a plastic, thereby protecting a technician from electrocution via the fastener 87.

[0052] When installing or uninstalling the outlet 300, the technician removes the fastener cover 90 to access the fastener. This may be done in any suitable manner including lifting, sliding or pivoting the cover 90 away from the fastener receiver 81. After installing the outlet 300, the cover 90 must be replaced to cover the fastener.

[0053] Figure 8 shows an arrangement according to an aspect described herein. Shown in Figure 8 are a fastener receiving region 80, within which lies fastener receiver 81, hinge 82 hingedly connecting cover 90 to the fastener receiving region 80, and a fastener receiving region slope 83, the purpose of which will be described further below.

[0054] Figure 9 shows a side view of the grid plate 100 of Figure 7. Shown there are switch interfaces or rockers 1201, 120 1' and fastener receiving region 80. Also shown in this view is first electrical plate or grid plate face 101 which defines a plane.

[0055] Figure 10 shows a side view of a cross section of grid plate 100 along the line A-A' of Figure 7, showing cover 90 in the closed position covering fastener receiver 81. From this view, it can be seen that the cover is substantially in line with, or within, the plane 101. This allows a second electrical plate or face plate 200, to cover and fully engage with first electrical plate or grid plate 100, as shown in Figure 11.

[0056] Figures 12A and 12B show a top plan and a bottom perspective view respectively of cover 90.

[0057] In some embodiments as shown in Figures 7 to 11, to move the cover 90 from a closed position covering fastener receiver 81 (and thus fastener 87 when in use), cover 90 is rotated about hinge 82. As the cover 90 is rotated away about hinge 82 from the closed position, the rear of cover 90 abuts against fastener receiving region slope 83 to thereby restrict the range of rotation that cover 90 can undergo. As shown in Figure 13, which shows the same side view of the cross -section of the outlet 300 shown in Figure 11, this restricted rotation results in a portion of the cover 90 extending beyond the plane 101, by a distance X. This portion creates an obstructing portion that prevents second electrical plate (or face plate) 200 from fully engaging with the first electrical plate or grid plate 100. This leaves the face plate 200 being unable to be connected to the grid plate 100, which provides the technician with the indication that the cover 90 is not covering the fastener 87. For the technician to be able to complete the installation and connect the face plate 200 to the grid plate 100, the technician must close the cover over the fastener receiver 81. Upon doing this, the face plate can be connected or fully engaged, as shown again in Figure 11.

[0058] This feature reduces the risk of inadvertently leaving the fastener 87 exposed.

[0059] In another aspect, as shown in Figures 14 to 15B, fastener receiving region 80 does not have a fastener receiving region slope 83, but instead, has an open cover receiver 84 for receiving the fully opened cover 90 which can be fully rotated to lie within plane 101. In this aspect, there is also provided a recess 85 for receiving a projection from the second electrical plate or face plate 200.

[0060] Figure 15A shows the arrangement of Figure 14 with the cover 90 in the closed position over fastener receiver 81, and face plate 200 fully engaged with grid plate 100. In this aspect, face plate 200 is able to fully engage with, or connect to, grid plate 100 because recess 85 is open to receive a projection 201 of face plate 200, allowing the face plate 200 to lie directly against the plane 101.

[0061] In the situation shown in Figure 15B, in which the cover 90 is in the open position, and received in the open cover receiver 84, it can be seen that recess 85 is closed by the cover 90 in the open position, and thus the projection 201 of the face plate 200 is not able to be received by the recess, 85, preventing the face plate 200 from fully engaging with the grid plate 100. In this aspect, the portion of the cover 90 that is covering the recess 85 provides the obstructing portion that prevents the second electrical plate from fully engaging with the first electrical plate.

[0062] In another aspect as shown in Figures 16A and 16B, the cover 90 itself has a cover protrusion 91, which is accommodated in a cover protrusion recess 86 in the fastener receiving region 80 when the cover 90 is closed over the fastener receiver 81. However, when cover 90 is rotated about hinge 82 to lie flat in the open cover receiver 84 as shown in Figure 16B, cover protrusion 91 extends beyond the plane 101 by an amount "X" to thereby provide the obstructing portion to prevent the second electrical plate (face plate) 200 from fully engaging with the first electrical plate (grid plate) 100 as previously described.

[0063] In another aspect as shown in Figures 17A and 17B, the cover 90 is slidable within fastener receiving region 80, from a closed position to an open position. Figure 17A shows the situation in which the cover 90 is in the closed position covering the fastener receiver 81 (and thus the fastener 87 when in use). In this position, recess 85 is open to receive the projection 201 of the face plate and thus allow the face plate to be fully engaged or connected with the grid plate.

[0064] In the situation shown in Figure 17B, where the cover 90 has been slid across to the open position to expose the fastener receiver 81 and thus the fastener 87, the cover 90 covers the recess 85, thus preventing the projection from being received within recess 85, and thus preventing the face plate from fully engaging with the grid plate, as in the situation described with reference to Figure 15B.

[0065] It will also be appreciated that in other embodiments, recess 85 need not be provided, and the open cover receiver 84 acts as the space to accommodate the cover unit projection 201. When the cover is in that space, this is sufficient to prevent the cover unit/second electrical plate/face plate 200 from fully engaging with the base unit/first electrical plate/grid plate 100.

[0066] In a broad aspect, there is provided an arrangement on a first electrical plate 100 (e.g. a grid plate) comprising a fastener receiver 81 for receiving a fastener 87 for fastening the first electrical plate 100 to a surface; and a cover 90 for covering the fastener receiver 81; wherein when the cover 90 is not covering the fastener receiver, the cover provides an obstructing portion that, in use, prevents a second electrical plate 200 from fully engaging with the first electrical plate 100.

[0067] Also provided is a grid plate 100 having the arrangement described above in its various aspects and embodiments.

[0068] In another broad aspect, there is also provided a grid plate comprising: a fastener receiver for receiving a fastener; and a fastener cover for covering the fastener; wherein the fastener cover is pivotable about a hinge between a closed position covering the fastener and an open position, not covering the fastener.

[0069] It will be appreciated that while the various aspects have been described with reference to a system 300 as described with reference to Figure 1 to 4, the various aspects are equally applicable to standard systems such as for example, in which the switch and switch interface/rocker is provided as a switch mechanism which is connected to the grid plate.

[0070] Throughout the specification and the claims that follow, unless the context requires otherwise, the words "comprise" and "include" and variations such as "comprising" and "including" will be understood to imply the inclusion of a stated integer or group of integers, but not the exclusion of any other integer or group of integers.

[0071] The reference to any prior art in this specification is not, and should not be taken as, an acknowledgement of any form of suggestion that such prior art forms part of the common general knowledge.

[0072] It will be appreciated by those skilled in the art that the invention is not restricted in its use to the particular application described. Neither is the present invention restricted in its preferred embodiment with regard to the particular elements and/or features described or depicted herein. It will be appreciated that the invention is not limited to the embodiment or embodiments disclosed, but is capable of numerous rearrangements, modifications and substitutions without departing from the scope of the invention as set forth and defined by the following claims.

Claims (14)

1. An arrangement on a first electrical plate comprising: a fastener receiver for receiving a fastener for fastening the first electrical plate to a surface; and a cover for covering the fastener receiver; wherein when the cover is not covering the fastener receiver, the cover provides an obstructing portion that, in use, prevents a second electrical plate from fully engaging with the first electrical plate.

2. An arrangement as claimed in claim 1 wherein when the cover covers the fastener receiver, the obstructing portion is positioned so as not to prevent the second electrical plate from fully engaging with the first electrical plate.

3. An arrangement as claimed in any one of claims 1 or 2 wherein the fastener is a screw.

4. An arrangement as claimed in any one of claims 1 to3 wherein the first electrical plate is a grid plate and the second electrical plate is a face plate.

5. An arrangement as claimed in any one of claims 1 to 4 wherein the fastener receiver is provided in a fastener receiving region.

6. An arrangement as claimed in claim 5 wherein the fastener receiving region comprises a hinge for hingedly connecting the cover to the fastener receiving region to allow the cover to rotate from a fastener covering state to a fastener uncovering state.

7. An arrangement as claimed in claim 6 wherein the fastener receiving region comprises a fastener receiving region slope adjacent the hinge to limit the range of rotation of the cover when rotating from the fastener covering state to the fastener uncovering state.

8. An arrangement as claimed in claim 7 wherein the limited range of rotation of the cover results in a portion of the cover extending beyond a plane of the first electrical plate to thereby provide the obstructing portion to prevent the second electrical pate from fully engaging with the first electrical plate.

9. An arrangement as claimed in any one of claims 1 to 5 wherein the fastener receiving region comprises a recess for receiving a second electrical plate projection.

10. An arrangement as claimed in claim 9 wherein the fastening region comprises a hinge for hingedly connecting the cover to the fastener receiving region to allow the cover to rotate from a fastener covering position to a fastener uncovering position.

11. An arrangement as claimed in claim 10 wherein the cover covers the recess when the cover is in the fastener uncovering position, to thereby provide the obstructing portion, preventing the second electrical projection from being received in the recess thereby preventing the second electrical plate from fully engaging with the first electrical plate.

12. An arrangement as claimed in claim 9 wherein the fastener cover is slidable between the covering position and the non-covering position.

13. A grid plate comprising the arrangement of any one of claims I to 12.

14. A grid plate comprising: a fastener receiver for receiving a fastener; and a fastener cover for covering the fastener; wherein the fastener cover is pivotable about a hinge between a closed position covering the fastener and an open position, not covering the fastener.