[0001] The invention relates to an electrical connector assembly. The electrical connector
assembly is arranged for connecting together electrical power cables. The invention
also relates to a lighting unit and a lighting system that each include the electrical
connector assembly, and a method for manufacturing a first connector, which is part
of the electrical connector assembly.
[0002] Electrical connector assemblies for electrically connecting a lighting unit power
cable to a mains lighting ring are known. This type of electrical connector assembly
includes a first electrical connector that is connected to the supply side and a second
connector that is applied to the lighting unit power cable. However a significant
disadvantage of such known electrical connector assemblies is that they are difficult
to manufacture and assembly, for example it is necessary to manually insert each electrical
connector into a housing during an assembly process. Assembly is thus prone to error
and is relatively slow and costly.
[0003] A further problem is that the structure of at least one connector part is not particularly
optimised. For example, one known example includes a conventional screw operated terminal
block for receiving wires that is connected to electrical connectors via a PCB. This
requires additional components to manufacture and is relatively difficult for an electrician
to install.
[0004] Accordingly the invention seeks to provide apparatus and a method for manufacturing
a connector that mitigates at least one of the above-mentioned problems or at least
provides an alternative solution to known solutions.
[0005] According to one aspect, there is provided an electrical connector assembly arranged
for electrically connecting together at least one supply side electrical power cable
and a device electrical power cable according to claim 1.
[0006] The invention provides assembly advantages for the electrical connector since moulding
the set of first electrical connectors into the plastics support means that it is
not necessary to individually mount each electrical connector into a support member,
for example by hand. Hand mounting is a time consuming, costly and highly dexterous
process that is prone to error, for example dropping the electrical connectors. The
arrangement also enables a press terminal block to slide on to the electrical connectors,
as described in more detail below. In preferred arrangements the first connector is
attached to the supply side power cable and the second connector is attached to the
device power cable.
[0007] The second connector is typically attached to the device power cable during a device
assembly process and is sold in a configuration with the second connector attached
thereto. The first connector is typically attached to at least one supply side power
cable by an electrician, for example during a device installation process. Once the
first connector is installed, subsequent removal and replacement of the device can
be undertaken by a non-skilled person, such as a home owner, simply by separating
the second connector of the current device from the installed first connector and
then connecting the second connector of a new device to the installed first connector.
The processing is similar to removing and inserting a plug into a socket.
[0008] It will be appreciated that the electrical connector assembly can be sold separately
from a lighting unit, for example to enable it to be retrofitted to an existing device.
[0009] The electrical connector assembly enables the device, such as a lighting unit and
preferably a solid state lighting unit, to be electrically connected to electrical
power circuitry. For example, electrical power circuitry having an electrical supply
and at least one supply side electrical power cable connected directly or indirectly
to the electrical supply.
[0010] According to another aspect, there is provided an electrical connector assembly arranged
for electrically connecting together at least one supply side electrical power cable
and a device electrical power cable. The electrical connector assembly can include
a first connector arranged for electrical attachment to one of the supply side and
device power cables. The first connector can include a set of first electrical connectors.
The electrical connector assembly can include a second connector arranged for electrical
attachment to the other of the supply side and device power cables. The second connector
can include a set of second electrical connectors. The sets of first and second electrical
connectors can be arranged for mating engagement to form an electrical connection
between the supply side and device power cables and for disengagement to break the
electrical connection. The set of first of electrical connectors can be moulded into
a plastics support member, thereby embedding at least part of each first electrical
connector within the plastic support member.
[0011] The first connector can include a plurality of first electrical connectors, for example
two or three first electrical connectors. The assembly can include at least one of
live, switched live and neutral connectors. The assembly can include an earth connector.
The second connector can include a plurality of second electrical connectors, for
example two or three second electrical connectors. The assembly can include at least
one of live, switched live and neutral connectors. The assembly can include an earth
connector.
[0012] The support member can include a mounting wall. The mounting wall can comprise a
cuboid block.
[0013] The support member can include a plurality of tubular shrouds. The plurality of tubular
shrouds can protrude outwardly from a first side of the mounting wall. Each tubular
shroud can protrude perpendicularly outwards from the first side of the mounting wall.
[0014] Each first electrical connector can include a first part. Each first part can protrude
outwards from the support member, and preferably from a first side of the support
member. Each first part of each first electrical connector can be housed within a
respective one of the tubular shrouds. Typically the number of tubular shrouds matches
the number of first electrical connectors. Each tubular shroud is preferably arranged
co-axially with the first part of its respective first electrical connector.
[0015] The first part of each first electrical connector can be elongate. Each tubular shroud
can be moulded circumferentially around the first part of its respective first electrical
connector.
[0016] Each tubular shroud can be formed integrally with the mounting wall during the moulding
process.
[0017] The tubular shrouds can be arranged parallel with one another. Each tubular shroud
can have a longitudinal axis. The longitudinal axes can be arranged parallel to one
another. Typically the shrouds are offset from one another in a first direction, such
as lateral direction.
[0018] Each tubular shroud can extend beyond a distal end of the first part of its respective
first connector. This protects the electrical connector and provides creepage and
clearance compliance.
[0019] The first part of each first electrical connector can comprise a female connector.
For example, the first part can comprise a plurality of circumferentially distributed
prongs. The female connector can be arranged to receive a male connector. The female
part of the connector can be used to electrically test the connection to the supply
cables.
[0020] Each first electrical connector can comprise a second part. Each second part can
protrude outwards from the support member into a terminal block. This arrangement
allows for easy assembly of the electrical connector assembly. Each second part can
protrude outwards from the mounting wall. Each second part can protrude outwards from
a second side of the mounting wall directly into the terminal block, and preferably
a first side of the terminal block. The second side of the mounting wall can be opposite
to the first side of the mounting wall. The second part of each first electrical connector
can extend in a direction that is opposite to the direction of its respective first
part.
[0021] The second part of each first electrical connector can comprise a male connector,
such as a pin. The first and second parts of each first electrical connector can be
arranged co-axially. Preferably each first electrical connector is elongate. Preferably
each first electrical connector is rectilinear. The first part of each first electrical
connector can comprise a leading side and the second part of each first electrical
connector can comprise a trailing side with respect to the direction of insertion
of the first connector.
[0022] The terminal block can include a set of first apertures. Each first aperture can
be arranged to receive a respective one of the second parts of the first electrical
connectors. The terminal block can include a set of resilient electrical connectors.
The second part of each first electrical connector can form an electrical connection
with a first part of a respective resilient electrical connector, for example via
a respective first aperture. The engagement of the terminal block with the second
parts of each first electrical connector can provide sufficient retaining force to
fix the position of the terminal block within the first connector. That is, no further
fixing means, such as screws and/or adhesive, are required to fix the location of
the terminal block within the first con nector.
[0023] During assembly, the terminal block can be pushed on to the first electrical connectors.
This is a very quick and easy assembly method, and leads to low manufacturing cost.
[0024] The terminal block can include a set of second apertures each arranged to receive
a respective wire from the power cable, and typically the supply side power cable.
Each resilient electrical connector can include a second part that is arranged to
electrically connect with a respective wire from the power cable. The first and second
parts of each resilient electrical connector are electrically connected together thereby
enabling electricity to flow between the power cable and the set of first electrical
connectors.
[0025] The terminal block can be arranged to receive a plurality of supply side power cables,
for example in a "loop in" "loop out" arrangement. In this arrangement, one of the
supply side power cables carries electricity into the first connector and another
one of the supply side power cables "loops out" electricity to the next light fitting
and connector in the lighting circuit. In this arrangement, the terminal block can
include at least one of: a plurality of live terminals, a plurality of earth terminals
and a plurality of neutral terminals.
[0026] The terminal block can be a quick release terminal block. This terminal block is
convenient for installers as it doesn't require a tool to operate it, such as a screw
driver, and it speeds up installation.
[0027] The terminal block can include a set of manually operable actuators. Each actuator
can be arranged to actuate the second part of a respective resilient electrical connector,
thereby enabling the respective resilient electrical connector to be moved into and/or
out of electrical connection with the respective wire. When the respective actuator
is in a non-actuated condition, the second part of the respective resilient electrical
connector is arranged to bias against its respective wire, thereby fixing it in place.
Thus the second part of the respective resilient electrical connector is arranged
to mechanically load its respective wire in the non-actuated condition.
[0028] Each manually operable actuator can include a lever. Each lever can be pivotally
attached to a terminal block housing. For example, one end of each lever can be pivotally
attached to the terminal block housing. The lever can include an actuator member.
The actuator member can be located on one side of the lever, such as the underside
of the lever. The actuator member can be arranged to act on the second part of its
respective resilient electrical connector, or an intermediate component attached thereto,
to move the second part of the respective resilient electrical connector between wire
engaging and wire non-engaging positions.
[0029] The support member can include a base. The base can be arranged perpendicularly to
the mounting wall. The base can be formed integrally with the mounting wall and the
tubular shrouds during the moulding process.
[0030] The terminal block can be mounted on the base.
[0031] The first connector can include a cover. The cover can form a housing with the support
member. The housing can house the terminal block and an end portion of at least one
power cable. Preferably the housing is arranged to house end portions of a plurality
of supply side power cables. The cover can be arranged to snap-fit to the support
member, for example to snap-fit to at least one of the base and the mounting wall.
The support member base can provide a base for the housing. The support member mounting
wall can provide a leading wall of the housing.
[0032] One of the first and second connectors can include a latch and the other of the first
and second connectors can include a latch receiving formation. The latch and latch
receiving formation can be arranged to releasably connect the first and second connectors
together. The latching arrangement helps to prevent physical separation of the first
and second connectors when they are electrically connected together.
[0033] The first connector can include a cord grip adaptor that is arranged to adapt the
size of a cable receiving aperture from a first size to a second size. The first size
can be larger than the second size. The cord grip adaptor can be an integral part
of the support member, which is formed during the moulding process. The cord grip
adaptor can include a plurality of flexible straps. The cord grip adaptor includes
a plug located at distal ends of the flexible straps, which is adapted to adapt the
size of the aperture.
[0034] The second connector can include a plurality of tubular shrouds. A first part of
each second electrical connector can be housed within a respective one of the tubular
shrouds. The first part of each second electrical connector is preferably a male connector,
for example a pin. The first part of each second electrical connector is preferably
rectilinear. Typically the number of tubular shrouds matches the number of second
electrical connectors. Preferably each tubular shroud extends beyond a distal end
of the first part of its respective second connector. This protects the electrical
connector.
[0035] The tubular shrouds of one of the first and second connectors can be each sized and
shaped to receive at least part of a respective one of the tubular shrouds of the
other of the first and second connectors therein. Thus each tubular shroud of one
of the first and second connectors acts as a socket to receive a respective one of
the tubular shrouds of the other of the first and second connectors. The tubular shrouds
that are arranged to receive at least a part of a respective one of the other tubular
shrouds each have an internal diameter that is greater than or equal to the outside
diameter of the respective tubular shrouds that are received. The internal surface
of each receiving tubular shroud is spaced apart from its electrical connector housed
therein to create a space to receive the respective tubular shroud of the other connector.
[0036] In preferred embodiments each tubular shroud of the second connector is sized and
shaped to receive at least part of a respective one of the tubular shrouds of the
first connector. For example, the inside diameter of each tubular shroud of the second
connector can be greater than or equal to the outside diameter of its respective tubular
shroud of the first connector. The internal surface of each tubular shroud of the
second connector is spaced apart from the first part of its respective second electrical
connector housed therein to create a space to receive the respective tubular shroud
of the first connector.
[0037] One of the first and second connectors includes at least one key, and preferably
a plurality of keys. The other of the first and second connectors includes at least
one slot for receiving the key, and preferably a plurality of slots each arranged
to receive a respective one of the keys. The keys and slots are arranged for mating
engagement. The key-slot arrangement helps to prevent relative rotation between the
first and second connectors. At least one of the tubular shrouds can include the key.
At least one of the tubular shrouds can include the slot for receiving the key. Preferably
each tubular shroud of the first connector includes a respective one of the keys.
Preferably each tubular shroud of the second connector includes a respective one of
the slots that is arranged to receive a respective one of the keys.
[0038] According to another aspect there is provided a lighting unit including an electrical
power cable and an electrical connector assembly according to any configuration described
herein.
[0039] The lighting unit can include at least one solid state lighting device. The lighting
unit can include at least one LED light source. The lighting unit can include at least
one PCB.
[0040] The lighting unit can be a downlight that is arranged to be fitted into an aperture
formed in a partition such as a ceiling. The lighting unit is preferably an LED downlight.
[0041] The lighting unit can include a fire resistant housing. The fire resistant housing
can include material that melts at a temperature greater than or equal to 900C, preferably
greater than or equal to 950C and more preferably still greater than or equal to 1000C.
For example, the housing can include at least one of steel, brass, copper and ceramic.
The housing can be made from sheet material. In a particularly preferred arrangement
the fire resistant housing is made from steel. The housing can be made by pressing
sheet material, for example pressing sheet steel. The housing can include a plurality
of materials. For example, the housing can comprise a plurality of parts attached
together. The fire resistant housing can have a flange at an open side of the housing.
The flange prevents fire from passing through gaps between the lighting unit and a
ceiling.
[0042] The downlight can include a heatsink. The heatsink can be mounted on a rear side
of the fire resistant housing. The heatsink is entirely optional since many modern
LEDs no longer require a heatsink to function adequately. A heatsink may be required
for some high power applications.
[0043] The LED light source and PCB can be mounted within the fire resistant housing. For
example, the LED light source and PCB can be mounted on a front face of end wall of
the housing. Alternatively, the LED light source and PCB can be mounted on a rear
side of the fire resistant housing. The fire resistant housing can include at least
one hole formed through the housing to enable light emitted by the LED light source
to pass through the housing.
[0044] According to another aspect there is provided a lighting system, including: electrical
circuitry including an electrical supply and at least one supply side power cable
connected directly or indirectly to the electrical supply; a lighting unit having
a power cable; and an electrical connector assembly according to any configuration
described herein. The electrical connector assembly electrically connects the at least
one supply side power cable and the lighting unit power cable together. The lighting
unit can be arranged according to any configuration described herein.
[0045] The electrical supply is typically a mains supply. Additionally, or alternatively,
the electrical supply can include at least one electrical cell or a power generation
means such as a solar panel.
[0046] In use, the first connector is electrically attached to the at least one supply side
power cable. This is typically done by an electrician. The second connector is electrically
attached to the device power cable. This may be done when manufacturing and assembling
the lighting unit or can be done at some other time, such as during the installation
process. The first and second connectors are electrically connected together by moving
the set of first electrical connectors into mating engagement with the set of second
electrical connectors. The lighting unit can be disconnected from the electrical supply
circuit by uncoupling the first and second electrical connectors.
[0047] According to another aspect there is provided a method for manufacturing a first
connector. The first connector is part of the electrical connector assembly according
to any configuration described herein. The method includes: providing a set of first
electrical connectors; placing the set of first electrical connectors into a mould
for manufacturing a support member; inserting a flowable plastics material into the
mould; and allowing the plastics material to solidify to form the support member,
said support member having a mounting wall and a plurality of tubular shrouds protruding
outwardly from a first side of the mounting wall, wherein the set of first electrical
connectors is at least partly embedded within the mounting wall, a first part of each
first electrical connector is housed within a respective one of the tubular shrouds,
and a second part of each first electrical connector protrudes outwards from a second
side of the mounting wall.
[0048] The second side of the mounting wall can be opposite to the first side of the mounting
wall. The moulding step can make use of any suitable moulding method, for example
an injection moulding method.
[0049] The flowable plastics material can be a thermoplastic, such as at least one of Polycarbonate
(PC), Polypropylene (PP) and Polyamide (PA).
[0050] The method can include providing a terminal block having a set of first apertures
and a set of resilient electrical connectors. The method can include attaching the
terminal block to the set of first electrical connectors such that the second part
of each first electrical connector extends into a respective first aperture and forms
an electrical connection with a first part of a respective resilient electrical connector.
[0051] The terminal block can be a quick release terminal block.
[0052] The method can include sizing the outside diameter of each tubular shroud to fit
into a respective tubular shroud on a second connector.
[0053] Embodiments of the invention will now be described by way of example only with reference
to the drawings, wherein:
Figure 1 is an exploded isometric view of an electrical connector assembly according
to an embodiment, which includes a supply side connector and a device connector;
Figure 2 is an isometric view of an electrical terminal block mounted in the supply
side connector shown in Figure 1;
Figure 3 is a rearward end view of the electrical terminal block of Figure 2;
Figure 4 is a longitudinal cross-sectional view of the electrical terminal block of
Figure 2;
Figure 5 is an isometric view of the electrical connector assembly of Figure 1 in
an assembled state, wherein the supply side and device connectors are connected together;
Figure 6 is a longitudinal cross-sectional view of the electrical connector assembly
of Figure 1, with the supply side and device connectors connected together (N.B. the
electrical terminal block is shown in simplified form for clarity of the overall arrangement);
Figure 7 is an enlarged view of part of Figure 6;
Figure 8 is a diagrammatic view of a lighting system embodiment; and
Figure 9 is a diagrammatic view of a lighting unit, which is part of the lighting
system of Figure 8.
[0054] Figures 1 to 6 show an electrical connector assembly 1 in accordance with an embodiment.
The electrical connector assembly 1 is arranged to electrically connect supply side
and device electrical power cables 302,202 together. For example, a device 200, such
as a solid state lighting unit, having an electrical power cable 202 can be connected
to electrical power circuitry. The electrical circuitry can include an electrical
supply 300 and at least one supply side electrical power cable 302, which is electrically
connected to the electrical supply 300 either directly or indirectly.
[0055] Each electrical power cable 202,302 includes a live wire 203,303 and a neutral wire
205,305. Each cable 202,302 may also include an earth wire 207,307.
[0056] The electrical connector assembly 1 includes a first, supply side, connector 3 and
a second, device, connector 5. The supply side connector 3 is connectable to at least
one supply side power cable 302 and the device connector 5 is connectable to the device
power cable 202. The supply side and device connectors 3,5 can be coupled together,
in a releasable manner, in order to electrically connect the device 200 to the power
supply 300. The supply side and device connectors 3,5 can be uncoupled to electrically
disconnect the device 200 from the power supply 300.
[0057] In some arrangements the supply side connector 3 can be connected to a plurality,
for example two or three, first electrical cables 302 in order to loop electrical
current to other devices, such as other lighting units 200.
[0058] The supply side connector 3 includes a plurality of first electrical connectors 7,
which are arranged to engage with a plurality of complementary electrical connectors
on the device connector 5. Each electrical connector 7 includes a first part 9. The
first part 9 comprises a leading part of the electrical connector. The first part
9 preferably comprise a female electrical connector. Each electrical connector 7 includes
a second part 11. The second part 11 is a rearward part of the electrical connector.
Preferably the second part 11 comprises a male connector, such as a pin. The second
part 11 is typically rectilinear or includes a rectilinear engagement part. The terms
leading and rearward are with respect to the direction of connection of the supply
side connector 3 with the device connector 5. The supply side connector 3 typically
includes two or three electrical connectors 7. Typically, the supply side connector
3 includes, live, neutral and earth electrical connectors 7. In some arrangements
the supply side connector 3 may include live and neutral electrical connectors 7 only.
[0059] The electrical connectors 7 are moulded into a plastics support member 13 during
manufacture. That is, the support member 13 comprises a plastics moulded component,
and when the component is formed by a moulding process, such as injection moulding,
the electrical connectors 7 are located in the mould and the mould is then filled
with flowable plastics material. The flowable plastics material moulds over the electrical
connectors 7 according to the shape of the mould, and any spacers present, to produce
the support member 13, when the plastic material solidifies, with the electrical connectors
7 embedded therein. Typically, the plastics material comprises a thermoplastic material
such as at least one of Polycarbonate (PC), Polypropylene (PP) and Polyamide (PA).
This method of manufacture provides an arrangement that is easier to assemble than
a conventional arrangements, for example it is not necessary to fit individual electrical
connectors into cavities formed in a support member during the assembly process. This
leads to a decrease in assembly time and assembly cost, and with no additional components
allows the use a push-fit terminal block 31.
[0060] The support member 13 includes a mounting wall 14. The mounting wall 14 has a leading
side 16 and a rearward side 18. The terms leading and rearward are with respect to
the direction of connection of the supply side connector 3 with the device connector
5. Each electrical connector 7 is mounted in the mounting wall 14. The electrical
connectors 7 are arranged parallel to one another. Each electrical connector 7 extends
through the mounting wall 14. The first part 9 of each electrical connector protrudes
perpendicularly outwards from the front side 16 of the wall. The second part 11 of
each electrical connector protrudes perpendicularly outwards from the rearward side
18 of the wall. The support member 13 includes a plurality of shrouds 15, one for
each electrical connector 7. Each shroud 15 comprises a cylindrical tube that protrudes
outwardly from the front side 16 of the wall. Each shroud 15 houses the first part
9 of its respective electric connector. Each shroud 15 protrudes axially beyond a
distal end of the first part 9 of its respective electrical connector, thereby protecting
the connector. Each shroud 15 includes a key 17 running axially along the length of
the shroud 15. The keys 17 help to properly align the supply side and device connectors
3,5 and to prevent relative rotation of the supply side and device connectors 3,5
in use.
[0061] The supply side connector includes a cover 21 that is arranged to snap-fit to the
support member 13 to form a housing 19. The support member 13 includes snap-fit latches
22 that are arranged to engage snap-fit formations 24 formed in the cover 21. It will
be appreciated by the skilled person that the cover 21 can include at least one snap-fit
latch 22 and the support member can include at least one snap-fit formation 24. The
mounting wall 14 provides at least part of a leading end wall of the housing 19. The
support member 13 can include a base 23. The base 23 extends perpendicularly from
a lower end of the rearward side 18 of mounting wall 14. Thus the support member 13
has an L-shaped configuration when viewed side on (see Figure 1)
[0062] The housing 19 has an aperture 25 located towards a rearward end 27 for receiving
the supply side cable(s) 302. The support member 13 includes a cord grip adaptor 29
for fixing the cable(s) 302 to the housing 19. The cord grip adaptor 29 can be an
integral part of the support member, which is formed during the moulding process.
The cord grip adaptor includes a plurality of flexible straps 30. The cord grip adaptor
29 includes a plug 32 located at distal ends of the flexible straps 29. The cord grip
adaptor 29 an optional part the installer can choose to use depending on the thickness
of cable he is wiring to. The cord grip adaptor 29 is designed to accept two thicknesses
of cable. For the thinner of the two cables the installer can use the plug 32 to make
the aperture 25 slightly smaller and therefore grip the thinner cable.
[0063] A terminal block 31 is located in the housing 19. The terminal block 31 is electrically
connected to electrical connectors 7 at a first side 33 and is electrically connectable
to the supply side cable(s) 302 at a second side 35. The terminal block 31 includes
a first set of three apertures 37 at the first side. Each aperture 37 receives the
second part 11 of a respective electrical connector therein. Each aperture 37 is axially
aligned with the second part 11 of its respective electrical connector, which enables
the terminal block 31 to be pushed onto the electrical connectors 7 during the assembly
process. This provides for a fast assembly process. For example, the terminal block
31 can slide into position along the base 23, and is seated on the base 23 in its
resting position. The terminal block 31 includes resilient internal electrical connectors
39. Each resilient connector 39 includes a first part 41 that is arranged to resiliently
engage the second part 11 of its respective first electrical connector. In some arrangements,
no further fixing means, such as screws or adhesive are required to fix the terminal
block 31 within the housing 19. The frictional and/or resilient engagement between
the resilient connector 39 and the electrical connectors 7 is sufficient to firmly
locate the terminal block 31. However in some arrangements additional fixings can
be used. For example, there may be retaining clips in the base 23 that help lock terminal
block 31 in position.
[0064] The terminal block 31 includes a second set of three apertures 44 formed in the second
side 35. Each aperture 44 is arranged to receive a respective wire, live 303/ neutral
305 /earth 307, from the supply side cable 302. Each resilient connector 39 includes
a second part 43 that is arranged to resiliently engage its respective wire 303,305,307
to firmly hold the wire into engagement with the terminal block 31. Each resilient
connector 39 includes a third part 47 which electrically connects the first and second
parts 41,43 of the resilient connector together and enables an electrical current
to flow between the wire and the respective electrical connector 7, and hence the
device 200 and the electrical supply 300.
[0065] The terminal block 31 has a mechanism for providing quick wire attachment and quick
wire release. That is, it is not necessary to secure the wires 303,305,307 to their
resilient connectors 39 using screws. The terminal block 31 includes 3 levers 49 that
are pivotally attached to an upper side 51, preferably towards the first side 33.
Each lever 49 is associated with a respective resilient connector 39. Each lever 49
includes an actuating member 53 that is arranged to move the second part 43 of its
respective resilient connector. Typically the actuating member 53 is located on an
underside of the lever 49. In its non-actuated state, the second part 43 of the resilient
connector is biased into engagement with its respective wire 303,305,307. When the
lever 49 is depressed by the user, the actuating member 53 biases the second part
43 of the resilient connector away from the wire 303,305,307, which enables the wire
303,305,307 to be easily inserted into the aperture 44 to a position wherein the second
part 43 of the resilient connector will engage the wire when the user releases the
lever 49. When the lever is released, the resiliency of the second part 43 causes
the second part 43 to return to its non-actuated wire engaging position, and returns
the lever 49 to its non-depressed state. The mechanism can also be used to remove
the wire 303,305,307 from the terminal block 31. Depressing the lever 49 releases
the biasing force applied to the wire 303,305,307 by the second part 43 of the resilient
connector, thereby enabling the wire to be removed from the terminal block 31.
[0066] The terminal block 31 can include additional apertures 46 to receive additional cable
wires. For example, one or more additional supply side power cables 302 can be connected
to supply side connector 3, thereby looping in additional devices 200, such as additional
lighting units.
[0067] The device connector 5 includes a plurality of second electrical connectors 55, which
are arranged to engage with the first electrical connectors 7 on the supply side connector
3. Each second electrical connector 55 comprises a male connector part 57 that is
arranged to electrically connect with a respective one of the female first parts 9
of the electrical connectors 7, and a terminal 59 for receiving a respective wire
203,205,207 from the device cable 202. Each terminal 59 has an associated screw 61
that is used to fix the respective wire 203,205,207 to the terminal 59. The terminals
59 are mounted in a second terminal block 63. The male connector parts 57 protrude
out of the second terminal block 63 into tubular shrouds 65. The male connector parts
57 are elongate and are arranged co-axially with the tubular shrouds 65. Each electrical
connector 55 is inserted into the second terminal block 63 individually during assembly,
in a conventional fashion in some arrangements.
[0068] Each shroud 65 protrudes axially beyond a distal end of its respective male connector
part 57. Each tubular shroud 65 has an internal diameter that is sufficiently large
to receive a respective one of the shrouds 15 of the supply side connector 3. The
internal surface 66 of each shroud 65 is spaced apart from the external surface of
its respective male connector part 57 to enable the shroud 15 to be received within
the shroud 65. Each tubular shroud 65 has a longitudinal slot 67 that is arranged
to receive a respective one of the keys 17. When the supply side and device connectors
3 and 5 are connected together the shrouds 15 on the supply side connector 3 slide
axially into their respective shrouds 65 on the device connector 5, the keys 17 slide
into their respective slots 67, and the male connector parts 57 of the device connector
5 slide into, and electrically connect with, the female connector parts 9 of the supply
side connector 3.
[0069] The device connector 5 includes a base 69 and a cover 71. The cover 71 overlies the
base and the second terminal block 63. The cover 71 is attached to the base 69 by
screws 73.
[0070] The cover 71 includes a latch 75 that is arranged to engage a latch receiving formation
77 on the cover 21. The latch 75 is arranged to engage the latch receiving formation
77 when the supply side and device connectors 3,5 are connected together. The latch
75 and receiving formation 77 hold the connectors 3,5 together. The latch 75 includes
an actuator button 79. A user can separate the supply side and device connectors 3,5
by pressing the button 79 to release the latch and pulling the connectors 3,5 apart.
It will be appreciated that the latch 75 instead can be mounted on cover 21 and the
latch receiving formation 77 can be mounted on cover 71.
[0071] Typically, the device connector 5 is attached to the device cable 202 during the
device 200 assembly process. Thus it is envisaged that the device 200 will be sold
with the device connector 5 pre-attached. Of course, the electrical connector assembly
can be sold separately from the device, for example for retrofitting purposes.
[0072] The supply side connector 3 is attached to the supply side cable(s) 302 by an electrician
during an installation process. The device 200 is the connected to the circuitry by
connecting the device connector 5 to the supply side connector 3. When the device
comprises a lighting unit, such as a downlight, the downlight is then mounted into
an aperture formed in a ceiling and is secured in place. In the future, if it is necessary
to replace the lighting unit for example due to a lighting unit failure, or simply
for a change in style of the lighting unit, the user is able to disconnect the existing
lighting unit from the power supply and connect a new lighting unit to the power supply
without the need of an electrician. The user simply disconnects the supply side connector
3 from the existing device connector 5 and then connects the new device connector
5 to the already installed supply side connector 3. Thus fitting a new lighting unit
200 no longer requires a skilled electrician.
[0073] Figure 7 and 8 show a lighting system 100 in accordance with an embodiment. The lighting
system includes: at least one lighting unit 200 having an electrical cable 202; an
electrical connector assembly 1 similar to that described above; and further electrical
circuitry including an electrical supply 300, such as a mains supply and at least
one supply side cable 302 the is directly or indirectly connected to the electrical
supply 300.
[0074] The lighting unit 200 can be a downlight, and is preferably a solid state downlight.
For example, the downlight 200 can include at least one LED light source 204, such
as an LED chip, and a PCB 206. The downlight includes a power supply cable 202 that
is connected to the PCB 206. A device connector 5 attached is attached to cable 202.
[0075] The downlight 200 can include a fire resistant housing 208. The fire resistant housing
includes material that melts at a temperature greater than or equal to 900C, preferably
greater than or equal to 950C and more preferably still greater than or equal to 1000C.
For example, the housing 208 can include at least one of steel, brass, copper and
ceramic. The housing 208 can be made from sheet material. In a particularly preferred
arrangement the fire resistant housing is made from steel. Preferably the housing
208 is made by pressing sheet material, for example pressing sheet steel. The fire
resistant housing 208 can have a flange 210 at an open side. The flange 210 prevents
fire from passing through gaps between the lighting unit 200 and a ceiling. The downlight
200 can include a heatsink 212. Preferably the heatsink 212 is mounted on a rear side
of the fire resistant housing. The heatsink 212 is entirely optional since many modern
LEDs no longer require a heatsink to function adequately. A heatsink 212 however may
be required for some high power applications. The LED light source 204 and PCB 206
can be mounted within the fire resistant housing 208, for example on a front face
of end wall 214 thereof (see Figure 8). Alternatively, the LED light source 204 and
PCB 206 can be mounted on a rear side of the fire resistant housing 208, and the fire
resistant housing can include at least one hole formed through the housing 208 to
enable light emitted by the LED light source 204 to pass through the housing.
[0076] The lighting unit 200 can include at least one of: an optical device 216, such as
at least one lens; a front cover 218; and a trim element 220.
[0077] The lighting system 100 may be used in a domestic dwelling, such as a house or an
apartment or can be used in other facilities such as offices, shops, community buildings,
etc. The lighting system 100 typically includes several lighting units 200, which
are each individually connected to the further electrical circuitry by electrical
connector assemblies 1 described above. The electrical circuitry typically includes
at least one mains lighting circuit defined by electrical cables 302 which is connected
to a mains distribution board. The or each mains lighting circuit may include other
devices that are typically included in such circuits such as electrical switches,
dimmers, and other controllers.
[0078] It will be appreciated by the skilled person that modifications can be made to the
above embodiments that fall within the scope of the invention, for example the first
part of each electrical connector on the supply side can comprise a male connector
and the first part of each electrical connector on the lighting unit side can comprise
a female connector.
[0079] The moulded support member can sit within a housing rather than being part of the
housing.
[0080] In some arrangements the connector described as the supply side connector 3 above
can be attached to the device cable 202 instead of the supply side cable 302, and
the connector described as the device connector 5 above can be attached to the supply
side cable 302 instead of the device cable 202.
[0081] In some arrangements the electrical connectors 55 in the device connector 5 can be
moulded into a plastics support member, in a similar fashion to the electrical connectors
7 in the supply side connector 3.
[0082] In some arrangements the second terminal block 63 in the device connector 5 can be
replaced by a terminal block 31 similar to that used in the supply side connector
3, with the electrical connectors 55 being adapted for this purpose. For example,
instead of the electrical connectors 55 including terminals 59, the length of connectors
55 can be increased to enable a part of the connectors to protrude into apertures
37.
[0083] Not all of the shrouds need include a key or keyway.
[0084] The electrical power supply circuitry can include batteries or a power generation
device such as at least one photo voltaic unit.
1. An electrical connector assembly (1) arranged for electrically connecting together
at least one supply side electrical power cable (302) and a device electrical power
cable (202), wherein the electrical connector assembly (1) includes: a first connector
(3) arranged for electrical attachment to one of the first and device power cables
(302,202), said first connector (3) including a set of first electrical connectors
(7); and a second connector (5) arranged for electrical attachment to the other of
the first and device power cable s (302,202), said second connector (5) including
a set of second electrical connectors (55); the sets of first and second electrical
connectors (7,55) are arranged for mating engagement to form an electrical connection
between the first and device power cables (302,202) and for disengagement to break
the electrical connection; wherein the set of first electrical connectors (7) is moulded
into a plastics support member (13), thereby embedding at least part of each first
electrical connector (7) within the plastic support member (13), wherein each first
electrical connector comprises first and second parts (9,11), and each second part
(11) protrudes outwards from the support member (13) into a terminal block (31).
2. The assembly of claim 1, wherein the support member (13) includes a mounting wall
(14) and a plurality of tubular shrouds (15) protrude outwardly from a first side
(16) of the mounting wall, and the first part (9) of each first electrical connector
is housed within a respective tubular shroud (15).
3. The assembly of claim 2, wherein each tubular shroud (15) protrudes perpendicularly
outwards from the first side (16) of the mounting wall, and preferably the tubular
shrouds (15) are parallel to one another.
4. The assembly of any one of the preceding claims, wherein terminal block (31) includes
a set of first apertures (37) and a set of resilient electrical connectors (39), and
the second part (11) of each first electrical connector extends into a respective
first aperture (39) and forms an electrical connection with a first part (41) of a
respective resilient electrical connector.
5. The assembly of claim 4, wherein the terminal block (31) includes a set of second
apertures (44) each arranged to receive a respective wire (303, 305, 307) from the
power cable (302), each resilient electrical connector (39) includes a second part
(43) that is arranged to electrically connect with a respective wire (303, 305, 307)
from the power cable (302).
6. The assembly of claim 5, wherein the terminal block (31) includes a set of manually
operable actuators (49,53), each actuator (49,53) is arranged to actuate the second
part (43) of a respective resilient electrical connector (39), thereby enabling the
respective wire (303, 305, 307) to be moved into and/or out of electrical connection
with the respective resilient electrical connector (39).
7. The assembly of claim 6, wherein each actuator (49,53) includes a lever (49) that
is pivotally attached at one end to a terminal block housing.
8. The assembly of any one of the preceding claims, wherein support member includes a
base (23) and a cover (21), and the terminal block (31) is mounted on the base (23).
9. The assembly of any one of the preceding claims, wherein engagement of the terminal
block (31) with the second parts (11) of each first electrical connector provides
sufficient retaining force to fix the position of the terminal block (31) within the
first connector.
10. The assembly of any one of the preceding claims, wherein one of the first and second
connectors (3,5) includes a latch (75) and the other of the first and second connectors
includes a latch receiving formation (77), wherein the latch (75) and latch receiving
formation (77) are arranged to releasably connect the first and second connectors
(3,5) together.
11. The assembly of any one of the preceding claims, wherein the first connector includes
a cord grip adaptor (29).
12. The assembly of any one of the preceding claims, wherein the second connector (5)
includes a plurality of tubular shrouds (65) and a first part (57) of each second
electrical connector is housed within a respective one of the tubular shrouds (65),
and wherein the tubular shrouds (15,65) of one of the first and second connectors
(3,5) are each sized and shaped to receive at least part of a respective one of the
tubular shrouds (15,65) of the other of the first and second connectors (3,5) therein.
13. The assembly of claim 12, wherein each tubular shroud (15,65) of one of the first
and second connectors (3,5) includes a key (17) and each tubular shroud (15,65) of
the other of the first and second connectors (3,5) includes a slot (67) for receiving
a respective one of the keys (17), and preferably each tubular shroud (15) of the
first connector (3) includes a key (17) and each tubular shroud (65) of the second
connector (5) includes a slot (67) for receiving a respective one of the keys (17).
14. A lighting unit (200) including an electrical power cable (202) and an electrical
connector assembly according to any one of the preceding claims.
15. The lighting unit of claim 14, wherein the lighting unit (200) includes at least one
solid state lighting device (204).
16. The lighting unit of claim 14 or 15, wherein the lighting unit (200) is a downlight
that is arranged to be fitted into an aperture formed in a partition such as a ceiling,
and preferably the lighting unit (200) includes a fire resistant housing (208).
17. A lighting system, including: electrical circuitry including an electrical supply
and at least one supply side power cable (302) connected directly or indirectly to
the electrical supply (300); a lighting unit (200) having an electrical power cable
(202); and an electrical connector assembly according to any one of claims 1 to 13;
wherein the electrical connector assembly is arranged to electrically connect the
at least one supply side power cable (302) and the lighting unit power cable (202)
together.
18. A method for manufacturing a first connector that is part of the electrical connector
assembly according to any one of claims 1 to 13, including providing a set of first
electrical connectors (7); placing the set of first electrical connectors (7) into
a mould for manufacturing a support member (13); inserting flowable plastics material
into the mould; allowing the flowable plastics material to solidify to form the support
member (13), said support member (13) having a mounting wall and a plurality of tubular
shrouds (15) protruding outwardly from a first side (16) of the mounting wall, wherein
the set of first electrical connectors (7) is at least partly embedded within the
mounting wall, a first part (9) of each first electrical connector is housed within
a respective one of the tubular shrouds (15), and a second part (11) of each first
electrical connector protrudes outwards from a second side of the mounting wall into
a terminal block (31).
19. A method according to claim 18, including providing a terminal block (31) having a
set of first apertures (37) and a set of resilient electrical connectors (39); attaching
the terminal block (31) to the set of first electrical connectors (7) such that the
second part (11) of each first electrical connector (7) extends into a respective
first aperture (37) and forms an electrical connection with a first part (41) of a
respective resilient electrical connector (39).