Note: Descriptions are shown in the official language in which they were submitted.
81786856
MODIFIED ELECTRICAL DEVICES
[00011
BACKGROUND
[00021 Outlets and switches are electrical devices that are a part of
modem homes.
Outlets are wall mounted devices with receptacles that supply power when
prongs of a
cord are inserted into the receptacles. Switches are wall mounted devices that
control
the flow of electrical power to various lights, appliances, etc. For example,
a switch
may control the flow of electrical power to a ceiling mounted light or fan.
[00031 Outlets and switches are typically installed during
construction, remodeling,
or maintenance of a home or building. To install outlets and switches, an
electrical box
is mounted to a stud or other structural portion of the building. Electrical
wiring is
routed to the electrical box. The electrical wiring is connected to an
electrical power
source such as the residential grid or a local power source such as a
photovoltaic
array/battery. The wall covering (such as drywall or paneling) is then placed
over the
wall with an opening that exposes the interior of the electrical box. The
outlet or switch
body is then connected to the electrical wiring and secured to the electrical
box. These
connections can be made in a variety of ways, including using stab-in
connectors on the
back of the outlet/switch or using screw terminals on the sides of the
outlet/switch.
[00041 A cover plate (also known as a "wall plate") is then attached
over the
opening in the wall covering. Cover plates are typically held in place by one
or more
screws that pass through the cover plate and screw into the outlet body,
switch body, or
other electrical device. The cover plate serves a number of purposes,
including covering
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the electrical connections between the building wiring and electrical device
and covering the
opening in the wall. When in place, the cover plates give a finished
appearance to the wall.
The cover plates are typically made from a piece of molded plastic that has
appropriate
openings to expose the switch lever and/or receptacles.
[0004a] According to one aspect of the present invention, there is
provided a modified
electrical device comprising: a body; at least one connector on the body to
make power
connections and a control connection with an active cover plate, wherein the
body of the
modified electrical device comprises step down circuitry to supply a voltage
to the active
cover plate via at least one connector.
10004b1 According to another aspect of the present invention, there is
provided a
system comprising: an active cover plate comprising low voltage circuitry and
a first
interface; and a modified electrical device comprising: high voltage
circuitry; and a second
interface to connect to the first interface to supply low voltage to the
active cover plate.
[0004c] According to still another aspect of the present invention, there
is provided a
method for controlling a flow of electrical power comprising: making
electrical contact
between an active cover plate and a modified electrical device by pressing at
least one
connector on the active cover plate into a mating connector on the modified
electrical device;
generating, with internal circuitry in the active cover plate, a control
signal; and sending the
control signal from the active cover plate through the male prong to the
female port to control
a flow of electricity through the modified electrical device, wherein the body
of the modified
electrical device comprises step down circuitry to supply a voltage to the
active cover plate
via at least one connector.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] The accompanying drawings illustrate various examples of the
principles
described herein and are a part of the specification. The illustrated examples
are merely
examples and do not limit the scope of the claims.
[0006] Figures 1A and 1B show an illustrative modified electrical device
and mating
active cover plate, according to one example of principles described herein.
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[0007] Figure 2 shows an interconnection between a male prong and a
female port,
according to one example of principles described herein.
[0008] Figure 3 shows a prong with a spring loaded tip, according to one
example of
principles described herein.
[0009] Figures 4A-4D show one example of an electrical system that
includes an
active cover plate and a modified electrical device, according to one example
of principles
described herein.
[0010] Figures 5A-5D show examples of electrical systems that include an
active
cover plate and a modified decora switch body, according to one example of
principles
described herein.
[0011] Figures 6A and 6B shows one example of an electrical system that
includes an
active cover plate and a modified duplex outlet, according to one example of
principles
described herein.
[0012] Figure 6C shows internal wiring in a modified duplex outlet,
according to one
example of principles described herein.
[0013] Figure 7 is a block diagram of various distributions of
functionality between an
active cover plate and a modified electrical device that are connected by a
defined interface
according to one example of principles described herein.
[0014] Figure 8 is a perspective view of a multiport connector,
according to one
example of principles described herein.
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[0015] Figures 9A and 9B show an electrical system that includes an active
cover
plate and modified toggle switch, according to one example of principles
described
herein.
[0016] Figures 10A and 10B show wiring diagrams of the modified toggle
switch,
according to one example of principles described herein.
[0017] Figures 11A and 11B are diagrams of multiport connectors and
electrical
wiring of a modified decora outlet and the mating active cover plate,
according to one
example of principles described herein.
[0018] Figure 11C is a side view of a modified duplex outlet showing wiring
between various components, according to one example of principles described
herein.
[0019] Figures 12A-12D are various diagrams of principles for laying
out/describing
connector patterns on the face of a modified electrical device, according to
one example
of principles described herein.
[0020] Figures 13A and 13B show a cover plate with surface contacts and a
mating
modified duplex outlet with nub contacts, according to one example of
principles
described herein.
[0021] Figures 14A and 14B show a modified outlet with internal coils and
an
active cover plate that receives power from the internal coils, according to
one example
of principles described herein.
[0022] Figures 15A-15C show additional examples of coil systems
transferring
power to active cover plates, according to one example of principles described
herein.
[0023] Figure 16 is a flow chart of a method for installing an electrical
system that
includes a modified electrical device and a mating active cover plate,
according to one
example of principles described herein.
[0024] Figure 17 is a flow chart of a method for controlling the flow of
electrical
power through a modified electrical device, according to one example of
principles
described herein.
[0025] Throughout the drawings, identical reference numbers designate
similar, but
not necessarily identical, elements.
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DETAILED DESCRIPTION
[0026] Modified electrical devices ("MEDs") are any energized device that
is
designed to supply or control power or to supply electrical signals and is
also configured
to receive an active cover plate. For example, modified electrical devices may
be an
outlet or switch bodies that are modified to power and communicate with an
active
cover plate. An active cover plate is a cover or wall plate that contains
electrical
components or supplies functionality that is not available in a traditional
wall or cover
plate. The active cover plate may obtain electrical energy from a variety of
sources,
including outlet or switch bodies. Additionally or alternatively, the active
cover plate
may be battery powered or powered wirelessly. The active cover plates may
include
functional elements such as lights, sensors, input/output devices, and
communication
elements. For example, an active cover plate mounted to an outlet in a room
may
include a number of light emitting diodes (or other light generating elements)
and a light
sensor. When the room is illuminated, the light sensor turns the light
emitting diodes
off. When the room is dark, the light sensor turns the light emitting diodes
on. The
active cover plate may supply electrical power to the light emitting diodes
from the
outlet body or a battery. For example, during normal operation, the active
cover plate
may interface with the outlet body (or switch body) to extract power from the
building
wiring. However, when there is no electrical power in the building wiring, the
active
cover plate may draw on a battery for power to illuminate the light emitting
diodes.
[0027] A variety of elements may be included in an active cover plate,
including
sensors such as temperature sensors, humidity sensors, smoke detectors, motion
detectors, microphones, radon detectors, cameras, and a variety of other
sensors. The
active cover plates may include input/output elements such as additional
switches, touch
sensitive elements, microphones, display screens, speakers or other elements.
The
active cover plates may also include communication elements such as wireless
communication circuits (such as BLUETOOTH, ZIGBEE, cellular circuits) or wired
communication circuits (such as communication over power line technology). For
example, in some embodiments the active cover plate may function or interface
with a
thermostat. The active cover plate may include a temperature sensor and
communicate
with a home automation system or thermostat to control the temperature of a
room or
rooms. In some instances the thermostat setting the room or an extended area
may be
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altered through an interface on a cover plate. Additionally, the active cover
plates in a
building may act as a sensor network that learns behavior patterns of the
occupants and
may anticipate their needs based on past behavior.
[0028] The interface between the active cover plate and the device body
that allows
for the extraction of power out of the building wiring may take a variety of
forms,
including wired interfaces or wireless interfaces. Wireless interfaces have a
number of
advantages, including the potential for a sealed cover plate with no exposed
electrical
contacts. Wired interfaces have a number of advantages including almost
lossless
energy transfer, simplicity, cost effectiveness and the ability to transfer
large amounts of
electrical energy if desired.
[0029] The description below focuses on, but is not limited to, modified
electrical
devices that incorporate additional electrical interfaces that are
specifically designed to
power an active cover plate. These interfaces are "wired" interfaces where
conductive
elements in the active cover plate are brought into contact with mating
conductive
elements in the device body. Electrical power is transferred through the
contacting
conductive elements to power the functionality of the cover plate.
[0030] There are a number of design considerations that can be taken into
account
when designing a modified electrical device for powering an active cover
plate. For
example, in some implementations there may not be a preferred orientation for
installing
a device body (i.e the outlet or switch body). The device body may be
installed right-
side up or upside down. If there is a preferred orientation for the active
cover plate, the
device body/active cover plate may be designed to connect to the modified
device body
in either its upside down or right side up orientation. For example, if the
active cover
plate includes a nightlight, it may be desirable for the nightlight to be
pointed downward
to illuminate the floor rather than upward. Consequently, the active cover
plate should
be able to connect to modified outlet bodies that are right side up or upside
down with
the active cover plate remaining upright with the nightlights pointing
downward. For
active cover plates that do not have a preferred orientation, the ability to
connect the
active cover plate in both the upside down and right side up orientations can
still
simplify installation.
[0031] In addition to power connections, the modified electrical devices
may also
include communication connections between the active cover plates and the
modified
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electrical devices. For example, the communication ports may allow for control
of a
relay inside the modified electrical device or other communication between the
active
cover plate and the modified electrical device it is connected to.
100321 Ideally, the interface between the modified electrical device and
the active
cover plate would be self-aligning, mechanically robust, and electrically
reliable. For
example, one consideration in making a connection between the modified
electrical
device and an active electrical device is that there may be a variable
distance between
the modified electrical device and the cover plate. The electrical box may be
mounted
at varying depths on the stud and the wall covering may have variable
thickness.
However, the active cover plate is mounted flush with the exterior of the wall
covering.
Thus there can be a variable distance between the active cover plate and the
modified
electrical connections. Various designs below account for these and other
factors to
produce modified electrical outlets and active cover plates that are easy to
install,
versatile, and reliable.
[0033] In the following description, for purposes of explanation, numerous
specific
details are set forth in order to provide a thorough understanding of the
present systems
and methods. It will be apparent, however, to one skilled in the art that the
present
apparatus, systems, and methods may be practiced without these specific
details. It is
understood that the figures are diagrammatic and schematic representations of
some
embodiments of the invention, and are not limiting of the present invention,
nor are they
necessarily drawn to scale. Reference in the specification to "an example" or
similar
language means that a particular feature, structure, or characteristic
described in
connection with the example is included in at least that one example, but not
necessarily
in other examples. Features shown and/or described in connection with one
figure may
be combined with features shown and/or described in connection with other
figures.
[0034] In general, the terms "active cover plate," "active wall plate," or
"interactive
cover plate" are used broadly to include anything that is not plugged into the
designated
outlet receptacles themselves, but is something that is still powered by the
outlet in any
other way except being powered by the original designated receptacles. An
active cover
plate allows original designated receptacles and switches to still be
accessible. Also it
does not matter how the wall plate is attached to the outlet whether it be
with a screw,
snapped in, magnetic connections, or any other way. For example, the cover
plate may
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have high strength magnets that are attracted to metal in the outlet or outlet
box (such as
the metal brackets that are used to connect the outlet to the outlet box). The
cover plate
may simply be placed over the outlet and be held in place by magnetic
attraction
between the magnets in the cover plate and the brackets on the outlet.
[0035] The term "human interface element" refers to any components on an
installed device body (e.g. switch/outlet body) that are designed for a human
to interface
with. For example, human interface elements may include plug in receptacles
that are
designed for a human to press prongs of an electrical cord into. Other types
of human
interface elements include toggle switches, buttons, sliders, touch screens,
displays and
other components that a human touches, manipulates, or manipulates another
object into
contact with. In general, active cover plates installed over outlet/switch
bodies leave
human interface elements of the outlet/switch bodies exposed and accessible
for human
interaction. In one example, an active cover plate may be installed over a
duplex outlet
body. Both outlet receptacles ("human interface elements") can be exposed
through the
active cover plate. However, in some embodiments the active cover plate may
cover or
replace some of the human interface elements on an outlet body.
[0036] The term "NEMA receptacle" refers to the blade or blade/prong
configurations defined by U.S. National Electrical Manufactures Association
(NEMA)
5-15R standard. NEMA receptacles are the standard electrical outlet found in
almost
every home and building in the United States. Similar and interchangeable
connectors
are used in Canada and Mexico. NEMA 1 connectors have two blades while NEMA 5
connectors have two blades and a ground prong. The dimensional standard for
these
electrical connectors is ANSUNEMA WD-6.
[0037] As discussed above, an outlet or switch may be used as a source of
power for
an active cover plate. For simplicity, an outlet, switch, or other interface
with building
electrical wiring will be called "an electrical device". The electrical
devices may be
modified, changed, or customized in a variety of ways to accommodate powering
of the
active cover plate.
[0038] The term "building wiring" refers to a range of electrical wiring
that carries
electrical power through a structure to outlets/switches for use/control by a
user. For
example, "building wiring" refers to electrical wiring in homes, businesses,
commercial
buildings, schools, and other structures. The building wiring may carry a
range of
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voltages depending on the electrical system the building wiring is connected
to and the
standard of the country the building wiring is used in. For example, building
wiring
may have voltages of 100, 110, 115, 120, 127, 208, 220, 230, 240, 277 and 480
volts
with frequencies of 60 or 50 hertz. Other building wiring systems may utilize
DC
voltages.
[0039] A variety of electrical devices can be modified to provide
connectivity to an
active cover plate. For example, electrical devices that could be modified
include
decora light switches, duplex light switches, ganged light switches, outlet
and switch
combinations, outlets/switch that include USB ports, ground fault circuit
interrupter
(GFCI) outlets, surge protector outlets, arc-fault outlets, relay switch type
outlets (such
as ZIGBEE enabled outlets), single outlets, keyed/locking outlets, and a
variety of other
outlets and switches.
[0040] The modified electrical device may include internal circuitry to
step down
the input voltage from the building electrical wiring. For example, the input
voltage
may be 120 volts, 240 volts or some other standard input voltage. Electronics,
such as
coils, diodes, transformers, rectifiers, resistors, capacitors or other
electronic
components may be included inside the modified electrical device itself. These
electronics may step down the voltage for use by the active cover plates. For
example,
the lower voltage may be a voltage between 1 and 36 volts. This output voltage
may be
selected to be the highest voltage that an active cover plate may require.
Alternatively,
the output voltage may be designed to specifically supply a desired voltage
for a
particular active cover plate. The active cover plate may further reduce this
voltage if
necessary. In some examples, part of the cover plate may operate at a first
voltage and
other parts of the cover plate may operate at a different voltage. For
example, the output
voltage from the electrical circuitry may be 12 volts and the cover plate may
use 12
volts to power an external device that is connected to the cover plate (such
as a security
system) while the other parts of the cover plate may use 2 to 4 volts to power
nightlights.
[0041] Active cover plates could make electrical connections to the
outlet/switch
bodies in a variety of ways. For example, the outlet/switch body may include
an
electrical contact on a surface. The active cover plate has corresponding
contacts.
When the active cover plate is fastened over the outlet/switch body, the
contacts meet
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and the active cover plate receives electrical power from the outlet/switch
body. In
other examples, the outlet/switch body may communicate power/signals to the
cover
plate wirelessly.
100421 In one implementation, the modified outlet/switch body may include a
number of female ports that are incorporated into the bodies of the
outlets/switches. For
each design, the active cover plate has a corresponding pattern of prongs that
are
configured to interface with all or a portion of the ports. In most cases, the
connection
between the active cover plate and the outlet is configured so that the
outlet/switch can
be installed right side up or upside down without adversely affecting the
cover plate
performance. The female ports on the outlet/switch body and the prongs on the
cover
plate can be located in any convenient location that is safe and functional.
Although
circular prongs and female ports are shown in the figures, the prongs/ports
could have a
variety of configurations, including rectangular or square blades.
[0043] Fig. 1A shows an active cover plate (100) for a duplex outlet with
four
prongs (110) extending rearward from the back surface of the cover plate.
These prongs
(110) are electrically connected to internal circuitry in the active cover
plate (100). Fig.
1B shows one example of a modified electrical device (160) with female
receptacles or
ports (120) that correspond to the prongs (110, Fig. 1A) on the active cover
plate (100,
Fig. 1A). When the active cover plate (100) shown in Fig. 1A is fastened over
the
modified electrical device (160), the prongs (110, Fig. 1A) interface with the
female
ports (120) and transfer electrical power from the modified electrical device
(160) to the
circuitry in the active cover plate (100, Fig. 1A). In this example, the
modified
electrical device is a duplex outlet body. As discussed above, the outlet body
(160) may
be mounted right side up (with slots (130) in the outlet above the ground
aperture (140)
as shown in Fig. 1B) or the outlet body (160) may be mounted upside down (with
the
slots (130) in the outlet face below the ground aperture (140). Either
orientation is
operable. The active cover plate (100, Fig. 1A) may or may not have a
preferred
orientation. For example, if the active cover plate (100, Fig. 1A) is designed
for
illumination, the active cover plate (100, Fig. 1A) may need to be oriented in
a
particular direction to have the light emitted in the desired direction. For
maximum
versatility, the active cover plate (100, Fig. 1A) can be designed to connect
in the
desired orientation to outlet bodies that are right side up or upside down. In
some
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examples, only two of the prongs (110, Fig. 1A) may need to make contact to
form the
desired interface with the outlet body (160). Current flow through the other
two prongs
(110, Fig. 1A) can be blocked in a variety of ways, including using diodes.
[0044] The configurations described above are only illustrative. The
prong/port
(110/120) configurations and arrangements may take any suitable form.
[0045] Fig. 2 shows additional details of one technique for making
electrical contact
between a prong (110) and a female port (120) in an outlet body. The prong
(110) may
include a support/base (125), a conductive body (135), and a tip (145). For
clarity, the
connection between the prong (110) and the active cover plate (100, Fig. 1A)
is not
shown in this example. In this example, the prong (110, Fig. 1A) is axially
symmetric
and includes a conical support/base (125), a conductive body (135), and a tip
(145) with
a 180 degree radius. The conductive body (135) in this example is a tubular
copper/brass body. The support/base (125) provides mechanical stability to the
prong
(110) and allows for a larger cross sectional area to be connected to the back
of the
active cover plate (100, Fig. 1A). The copper/brass conductive body (135)
extends
away from the support/base (125) and terminates at the tip (145). The rounded
tip (145)
may provide a number of advantages including guiding the prong (110) into a
matching
female receptacle or port (120).
[0046] The male prong (110) is inserted into the female port (120). The
female port
(120) may include a funnel shaped opening ("guide") (210) that is designed to
interact
with a tip (145) of a prong to guide the prong (110) into alignment with a
central cavity
of the female port (120). As the tip (145) of the male prong enters the
central cavity of
the female port (120), it is pressed against the electrical contact (240).
This particular
design is configured to make electrical contact even when the male prong (110)
is only
partially inserted (as shown in Fig. 2) and also to make electrical contact
when the male
prong (110) is completely inserted. This can be advantageous because there may
be a
variable distance between the active cover plate (100, Fig. 1A) and the outlet
body (160,
Fig. 1B). As discussed above, this variable distance can result from the
modified outlet
body (160, Fig. 1B) being mounted at different depths with respect to the
outer surface
of the wall covering. By allowing the male prong (110) to make electrical
contact with
the wire when the male prong (110) is only partially inserted into the female
port (120),
these variable distances can be accommodated and the connection can be more
robust.
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100471 Fig. 2 also shows a diagram of the electrical components in an
outlet or
switch body that are used to connect the building wiring to the electrical
contact in the
female port (120). In this example, there is a direct electrical connection
between the
building wiring and the female port (120). The screw (270) is on the exterior
of the
outlet body (160, Fig. 1B) and passes through a threaded hole in the
conductive strip
(260). The building wiring is placed between the head of the screw and the
conductive
strip (260) and the screw (270) is tightened to sandwich the building wiring
between the
head of the screw (270) and the conductive strip (260). An electrical contact
(240) is
connected to the conductive strip (260). The connection (230) may be formed in
any of
a variety of ways, including pressing, soldering, or riveting the conductive
strip (260) to
the electrical contact (240). The electrical contact (240) extends into the
cavity of the
port (120) to make an electrical connection with an inserted male prong (110).
[0048] Fig. 3 shows an alternative embodiment of a prong (110). In this
example,
the prong is a spring loaded prong (310) that includes a base (325) that has a
cavity
through its center. A spring (315) is contained within the cavity. One end of
a plunger
(320) interfaces with the spring (315), which exerts a force that tends to
push the
plunger (320) out of the cavity. The spring loaded prong (310) may have a
number of
advantages including a greater range of contact with the female port (120,
Fig. 1B).
[0049] A variety of other prong designs could be used. For example, the
prong may
have a square or rectangular cross section. In one example, the prong may
incorporate
spring elements that press outward against the walls of the female port.
[0050] Figs. 4A-4D show one example of an active cover plate (100) and
modified
electrical device (400) designed to interface with the active cover plate
(100). In this
example, the active cover plate (100) and modified outlet body (400) have a
"decora"
style. The decora style includes a single rectangular outlet face that
includes two
NEMA type receptacles ("human interface elements"). Each NEMA style receptacle
includes two slots (130) and a ground opening (140).
100511 The active cover plate shown in Fig. 4A is a rear view. In this
example, the
active cover plate (100) includes an aperture (410) to receive the rectangular
outlet face,
through holes (415) to accept screws to secure the active cover plate (100)
over the
decora outlet body (400), and a 2-port connector (420). The 2-port connector
(420) in
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this rear view is located at the upper right hand side of the aperture (410).
The 2-port
connector (420) includes two prongs (110).
[0052] The modified electrical device (400) shown in Fig. 4B includes two 2-
port
connectors (430): Connector A (430-1) and Connector B (430-2). When the decora
outlet body (400) and the active cover plate (100) are both in the right side
up
configuration, the cover plate connector (420) will interface with connector A
(430-1)
on the outlet body. When either the active cover plate (100) or the decora
outlet body
(400) is upside down, the cover plate connector (420) will interface with
connector B
(430-2). Consequently, the active cover plate (100) can be connected in the
desired
orientation regardless of the orientation of the decora outlet body (400).
[0053] Fig. 4C is a cutaway front view of a decora outlet body (400)
showing the
electrical connections between the screw terminals (460, 470, 480), the NEMA
connectors (440, 450), and the 2-port connectors (430). The screw terminal on
the right
is the hot screw terminal (480) and is connected to the hot electrical
building wire. The
neutral screw terminal (460) on the left is connected to the neutral
electrical building
wire. A ground wire is connected to the ground screw terminal (470) on the
bottom left
of Fig. 4C. The wiring from the ground terminal (470) is not shown in the
figure. An
electrical connector from the hot screw terminal (480) is shown as a dark
trace that
connects to the hot blade receptacle (490) in the NEMA connectors and to hot
port A
(450-1) and hot port B (450-2) in the connectors (430-1, 430-2). The
electrical
connections from the neutral screw terminal (460) are shown as lighter trace
that is
connected to the neutral blade receptacle (495) on the left and the neutral
port A (440-1)
and neutral port B (440-2). When the active cover plate (100, Fig. 4A) is
connected
over the modified outlet body (400), the active cover plate connector (420,
Fig. 4A) will
interface with one of connector A (430-1) or connector B (430-2). This will
make a
connection between the active cover plate (100, Fig 4A) and the hot (450) and
neutral
(440) electrical wiring. Fig. 4D shows a front view of the the active cover
plate (100)
connected over the decora outlet body (400). The active cover plate (100)
covers the
both connector A (430-1, Fig. 4C) and connector B (430-2, Fig. 4C).
[0054] Figs. 5A and 5B are diagrams of a "decora" style active cover plate
(100)
and a "decora" style modified switch (510). In this case, the press button
rocker is the
"human interface element." The decora style active cover plate (100) can be
similar or
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identical to the active cover plate shown in Fig. 4A and includes a cover
plate connector
(420). This decora style active cover plate (100) can be used with a decora
style
modified switch (510), a modified decora outlet body (400), and other decora
style
devices such as arc-fault outlets and GFCI outlets. Light switches or any
other devices
that usually do not have an electrical path of return (i.e. connection to a
"neutral" wire)
may have an additional terminal for connection to the neutral building wire or
other path
of return. For example, light switches may not have a neutral return screw
terminal on
the light switch body.
[0055] In this
example, the decora style active cover plate (100) in Fig. 5A will be
connected over a decora style switch body (510) in Fig. 5B. The decora switch
body
(510) includes 2-port connectors A and B (530-1, 530-2) in the same location
as the
decora outlet body (400) shown in Fig. 4B. Consequently, the same decora style
active
cover plate (100) can be used for both types of modified electrical devices
(400, Fig. 4B;
510). Although the ports (530) in Fig. 5B are shown in the upper left hand
corner and
lower right hand corner, the ports (530) could be located at any convenient
location on
the modified electrical device (510). For example, the upper port could be on
the right
and the lower port could be on the left.
[0056] Figs. 5C and 5D show an alternative embodiment. In this example, the
active cover plate (100) includes two cover plate connectors (420-1, 420-2)
and the
switch body (510) includes only one connector (530). The cover plate (100) can
still be
connected upside down or right side up to the switch body. For example, when
the
cover plate (100) is connected right side up with the switch body, the first
cover plate
connector (420-1) will connect with the switch body connector (530). When the
active
cover plate (100) is connected to the switch body upside down, the second
cover plate
connector (420-2) will connect to the switch body connector (530). The
principle of
using two connectors on an active cover plate and only one connector on the
receptacle
body can be generally applied. For example, in the description below, a
variety of
different cover plates and modified electrical devices are described. The
modified
electrical devices generally include two separate connectors and the active
cover plates
include only one connector. However, this arrangement could be reversed as
shown in
Figs. 5C and 5D so that the active cover plates include two connectors and the
modified
electrical devices include only one connector.
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[0057] Figs. 6A and 6B show a modified electrical device (160) with its
corresponding active cover plate (100). In this example the modified
electrical device
(160) is a modified duplex outlet body and the active cover plate (100) is a
duplex style
active cover plate. The modified duplex outlet body (160) includes two 2-port
connectors (430): connector A (430-1) and connector B (430-2). These two 2-
port
connectors (430) are located on either side of a threaded hole (610) in the
center portion
of the outlet body (160). In this example, the corresponding active cover
plate (100)
has only one 2-port connector (420) with prongs (110). The 2-port connector
(420) is
offset from a through hole (415). The active cover plate (100) also includes
two
apertures (625) to receive the two corresponding NEMA style receptacles of the
outlet
body (160). As discussed above, the cover plate connector (420) can connect to
either
one of the outlet connectors (430) depending on the relative orientation
between the
outlet body (160) and the active cover plate (100).
[0058] The configuration shown in Fig. 6A and 6B may have a number of
advantages, including forming a more secure electrical connection between the
active
cover plate (100) and the outlet body (160) due to the proximity between the 2-
port
connectors (430) and the screw passing through the through hole (415) in the
active
cover plate (100) into the threaded hole (610) in the outlet body (160).
[0059] Fig. 6C is a diagram showing one example of electrical wiring inside
the
modified electrical device (160) shown in Fig. 6A. The modified outlet body
(160)
includes a number of screw terminals: a hot screw terminal (480), a ground
screw (470)
terminal and a neutral screw terminal (460). As discussed above, the
appropriate wires
from the building wiring are connected to the screw terminals. The hot
terminal (480) is
electrically connected to the two hot NEMA blade receptacles (490) and to one
of the
two hot female ports (450) in each of connector A (430-1) and connector B (430-
2).
The neutral screw terminal (460) is connected to the two neutral NEMA blade
receptacles (495) and to the two neutral female ports (440) in connector A
(430-1) and
connector B (430-2).
[0060] The two hot ports (450) are kitty corner from each other rather than
straight
across from each other. The hot port (450) is in the lower position in
connector A (430-
1) and in the upper position in connector B (430-2). The neutral port (440) is
in the
upper position in connector A (430-1) and in the lower position in connector B
(430-2).
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This allows for the same male prong (110, Fig.6B) on the active cover plate
(100, Fig.
6B) to interface with a hot port (450) regardless of whether the active cover
plate (100,
Fig. 6B) is put on right side up or upside down.
100611 Fig. 7 is a block diagram of an electrical system that includes an
active cover
plate (100) and a modified electrical device (160). The active cover plate
(100)
interfaces with the modified electrical device (160) through a defined
interface (740).
The defined interface (740) includes power supplied to the active cover plate
(100) and
may include signal or data communication between the active cover plate (100)
and the
modified electrical device (160). In general, the interface may include a
mechanical
connection and one or more electrical connections. For example, the
mechanical/electrical connectors could be a multiport male/female connection.
Additionally or alternatively, the mechanical connection may be made through a
fastener (such as a screw threading into an outlet body), magnets, or through
other
means. The electrical connection may be wired or wireless. For example, in the
embodiments illustrated above, the electrical connections are wired and are
made using
a plurality of male pins that are grouped to interface with corresponding
female ports in
the outlet body.
100621 The system may include a number of modules or functionalities that
can be
distributed between the modified electrical device (160) and the active cover
plate (100).
The modules shown in the figures are only illustrative. The illustrated
modules could be
reordered, replaced, eliminated, or new modules could be added. Further, the
distribution of the modules between the active cover plate (100) and the
modified
electrical outlet (160) could be changed. In this example, the active cover
plate (100)
includes processor/control electronics (710), power conditioning (715),
sensors (720), a
wireless transmitter/receiver (725), and output/actuator devices (730). The
active cover
plate (100) may also include an energy management system (735) that may
measure
and/or act to conserve energy within the active cover plate (100) and/or the
modified
electrical device (160). In this example, the modified electrical device (160)
includes
only its own functionality (outlet/switch functionality) (750) and a relay
(755) and/or
dimmer (757). The relay (755) selectively breaks the electrical connection to
the
NEMA receptacles. The relay (755) may be controlled in a variety of ways,
including
through the use of control signals received from the active cover plate (100)
through the
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defined interface (740). In some examples, the relay (755) may be used to turn
on and
off devices that are connected to the NEMA receptacles.
[0063] One example of a system that may be configured as shown in Fig. 7 is
an
active cover plate (100) with a carbon monoxide detector. A fan may be plugged
into
the NEMA receptacle. The active cover plate (100) receives power from the
modified
electrical device (160) through the defined interface (740) and conditions the
power for
its own use. When the active cover plate (100) detects carbon monoxide, it
analyzes the
amount of the carbon monoxide. If the carbon monoxide exceeds a predetermined
level
or threshold, the active cover plate (100) sends a control signal through the
interface
(740) to the relay (755). The relay (755) closes, thereby allowing electrical
current to
flow through the NEMA receptacle to the fan. The fan removes the carbon
monoxide
from the area. In some circumstances, the active cover plate (100) may also
wirelessly
transmit data reporting the buildup of carbon monoxide to a base station, home
automation system, internet or other device. The active cover plate (100) may
also
control output/actuator devices (730). For example, the active cover plate
(100) may
illuminate a light or sound an alarm indicating the presence of carbon
monoxide.
100641 Thus in Fig. 7, most of the circuitry and functionality resides in
the active
cover plate (100). This may have a number of advantages. The active cover
plate (100)
can be very easy to replace. This can allow for very easy updating and
modification of
the system. If a cover plate with a new sensor (720) or communication module
is
available and desired, the old active cover plate (100) can be removed and the
new
active cover plate (100) installed by simply removing/refastening one or two
screws.
Thus a home security system can be converted from a ZIGBEE based system to a
Wi-Fi
based system in a matter of minutes by simply replacing the ZIGBEE cover
plates with
new cover plates containing Wi-Fi transmitter/receivers. In general, Fig. 7
shows an
embodiment where the active cover plate (100) can also control the
functionality of the
modified electrical device (160). The sensors (720) in the active cover plate
(100) could
sense light, sound, motion or accept control signals to switch the relay (755)
in the
modified electrical device (160) ON or OFF according to the sensed
conditions/commands.
[0065] Alternatively, more of the functionality is contained in the
modified
electrical device (160). For example, the active cover plate (100) may contain
only two
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modules/functionalities: sensors (720) and output/actuator devices (730). The
active
cover plate (100) receives its power and control from the modified electrical
device
(160) through the defined interface (740). The modified electrical device
(160) includes
its own outlet/switch functionality (750) and also power conditioning (715)
functionality. The power conditioning circuitry (715) delivers electrical
power with the
desired characteristics to the active cover plate (100) through the defined
interface
(740). For example, the active cover plate (100) may require 12V DC. The power
conditioning circuitry (715) converts 120 V DC (or other power) to the
required 12 volts
DC. The modified electrical device (160) may also include communication
circuitry.
For example, the modified electrical device (160) may communicate with other
modified electrical devices (160) using the building power (760). The modified
electrical device (160) may also include processor/control electronics (710)
for
analyzing data and making control decisions. As discussed above, the modified
electrical device (160) may also include a relay (755), dimmer (757) or other
high
voltage circuitry to control a flow of electrical current through the device.
[0066] In some examples, the modified electrical device may be constructed
so that
a standard cover plate can fit over it. The standard cover plate has no
electrical load or
functionality. It simply fits onto the modified electrical device and covers
openings to
the electrical box. If a user later wants to add functionality to their
electrical system,
they can simply replace the standard cover plate with an active cover plate
containing
the desired functionality. The active cover plate then interfaces electrically
with the
modified electrical device to provide the desired functionality. Thus, in one
embodiment, the modified electrical device is configured to accept both
standard (non-
active) cover plates and active cover plates. Further, the active cover plate
may or may
not interface with the connectors on the face of the receptacle body. For
example, the
active cover plate may include a number of prongs that contact screw terminals
on the
sides of the receptacle body.
[0067] As discussed above, there may be a variety of active cover plates
that could
be used in conjunction with the modified electrical device and these active
cover plates
could be readily swapped out to provide the desired functionality. For
example, when a
new sensing or communication technology becomes available, an old active cover
plate
can be swapped out with a new active cover plate that contains the new sensing
or
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communication technology. This allows for the same modified electrical device
to
remain in place, together with any power, communication, and sensing
technology that
it contains. For example, a modified electrical device may include a relay
that is
controlled by a control signal received from an active cover plate.
Originally, the active
cover plate that communicates using ZIG-BEE technology may be used for short
range
wireless monitoring and control. The owner then decides that a longer distance
technology would be desirable and selects a Z-WAVE active cover plate to
replace the
ZIG-BEE active cover plate. By simply replacing the cover plate and without
any need
to purchase or replace the modified electrical device, the system can be
converted from
ZIG-BEE to Z-WAVE technologies.
[0068] Thus,
separating the functionality of the electrical system between an active
cover plate and a modified electrical device can provide significant
flexibility and cost
savings in upgrading the electrical system. Swapping active cover plates can
be
accomplished by removing one or two screws that hold the active cover plate in
place,
pulling the active cover plate away from the modified electrical device to
break
electrical contact with the modified electrical device and replacing it with a
different
active cover plate. For example, the modified electrical device may contain
high
voltage components such as relays, dimmers, fuses, breakers, and power
conditioning
circuitry. In this case the term "high voltage" refers to the voltage
delivered by the
building wiring to the modified electrical device. The active cover plate
paired with the
modified electrical device may contain low voltage circuitry such as wireless
communication modules, sensors and control circuitry. This separation of
functionality
between an active cover plate and a modified electrical device may also
provide a
number of safety and manufacturing benefits. Because the high voltage
circuitry is
encased in the modified electrical device, there is minimal risk of shock or
arcing in the
active cover plate or at the interface between the modified electrical device
and the
active cover plate. This reduces safety risks associated with the active cover
plate.
Additionally, when an active cover plate only contains low voltage components
there
can be more latitude in the design of the active cover plate and can reduce
the overall
cost of producing the active cover plate.
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[0069] The examples given above show various distributions of functionality
and
components throughout the system. A variety of other elements/functionalities
could be
included and various other distribution arrangements could be used.
[0070] The incorporation of control and signal lines between the modified
electrical
device (160, Fig 1B) and the active cover plate (100, Fig. 1A) may require
additional
conductive paths in the interface. Fig. 8 shows one example of a connector
that includes
multiple male prongs (110) and mating female ports (120). In this example, the
male
prongs (110) are arranged in a linear array. However, they could be arranged
in any
desired configuration. The male prongs (110) are surrounded by an inner wall
(820). In
some examples, the inner wall (820) may extend beyond the prongs (110) to
protect
them from accidental damage. The male prongs (110) and inner wall (820) are
connected to the active cover plate (100, Fig 1A).
100711 The outlet/switch connector (860) is designed to mate with the cover
plate
connector (810). The outlet/switch connector (860) includes a block (830) with
a
number of female ports (120) disposed in the block (830). The block (830) is
surrounded by a trench (840) between the block (830) and an outer wall (850)
that is
sized to receive the inner wall (820) of the cover plate connector (810). When
the two
connectors are brought together, the inner wall (820) fits into the trench
(840) and the
male prongs (110) make electrical connections with the female ports (120). In
this
example, there are five electrical connections made when the connectors are
mated.
However, there may be any number of other electrical connections. For example,
there
may be one, two, three, four, five or more electrical connections formed in
the interface.
[0072] Fig. 9A shows one example of an active cover plate (100) that
includes a
three prong/port connector (920). In this example, the active cover plate
(100) is for
covering a toggle switch. The active cover plate (100) includes: an aperture
(925) for
the toggle switch to extend through, two through holes (415) to receive screws
to secure
the cover plate to the switch body, and a three pronged connector (920).
[0073] In the example shown in Fig. 9B, the modified electrical device
(160) is a
switch body that includes two connectors (930), each with three female ports
(910, 440,
450). One connector (930-1) is located above the toggle switch and one
connector (930-
2) is located below the toggle switch. The switch body includes multiple screw
terminals, including two separate hot terminals (480), a neutral terminal
(460), and a
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ground terminal (470). The switch body is slightly more complex to interface
with than
an active cover plate (100, Fig. 9a) because the switch has two states: "ON"
and "OFF".
In the ON configuration electrical current can flow between the two hot
terminals (480).
In the OFF configuration, the circuit is broken and there is no electrical
path through the
switch. To overcome this, three power connections are made between the cover
plate
and the switch body: ground (910), neutral (440), and hot (450). These three
power
ports allow the active cover plate (100) to receive electrical power
regardless of the state
of the switch and without "back-feeding" through the light when the light
switch is in
the OFF position. The ground port (910) may or may not be used. Typically, the
return
path of the electricity is through the neutral port (440).
100741 Fig. 10A is a wiring diagram of an illustrative modified electrical
device
(160). In this example, the modified electrical device (160) is a switch body
that
includes 4-port connectors (1020). As discussed above, the modified switch
body
includes a ground terminal (470), hot screw terminals (480), and a neutral
screw
terminal (460). The two 4-port connectors (1020) are located above and below
the
toggle switch. Each of the connectors (1020) includes a hot port (450),
neutral port
(440), a first control line port ("Cl") (1050-1) and a second control line
port ("C2")
(1050-2). The appropriate connections are made between the various screw
terminals
and the ports to connect the neutral screw terminal (460) and hot screw
terminal (480) to
the designated ports. The switch body also includes an internal relay (1075).
The relay
(1075) controls connectivity between the two hot terminals (480). The relay
(1075) is
controlled by control lines/ports "Cl" (1050-1) and "C2" (1050-2). The relay
(1075)
can cut power to a connected device by creating an open circuit. This bypasses
the
manual switch remotely. Also shown are control junction points (1025) and hot
points
(1030, 1040).
[0075] Fig. 10B shows a partially cut away side view of the modified
electrical
device (160) shown in Fig. 10A, which is a switch body. The switch body
includes a
printed circuit board (PCB) (1080) mounted by standoffs (1085) extending from
the
housing of the switch body. On the PCB (1080) there is a relay (1070) and
various
power conditioning/control circuits. In this example, a "hot" return line
(1040) is
connected to the relay (1070) and low voltage signal connections (470) from
the control
junction points (1025) are connected to the PCB (1080) to control the action
of the relay
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(1070). The PCB (1080) also receives power inputs through power lines (1090)
that
conditions power on the circuit board and supplies the power to the
appropriate ports at
the interface/connectors.
[0076] Fig. 11A and 11B show a decora style system with multiport
connectors. In
this example, the active cover plate (100) has a 4-port connector (1120)
located in the
upper right side of the plate. This 4-port connectors (1120) include a hot
prong (440-1),
neutral prong (450-1), and two control ports (1050-1, 1050-2). The modified
electrical
device (160) in this example is a decora outlet body that includes two 4-port
connectors
(1125-1, 1125-2), one located on the upper left of the body and one located on
the lower
right of the body.
[0077] In Fig. 11B, a cutaway top view of the electrical connections
between the
various ports and terminals are shown. Two "hot" connections (1130-1, 1130-2)
bring
power into an internal relay (1070, Fig. 11C) in the outlet body. There are
two return
lines from the internal relay (shown below in Fig. 11C), one for the top
outlet (1150)
and one for bottom outlet (1155). These two return lines are controlled by the
internal
relay and only deliver electricity to the outlet receptacles when the internal
relay is
closed.
[0078] In general, the term "multiport connector" refers to connectors that
include,
in addition to power ports, communication or control ports. A multiport
connector may
include a hot port, a neutral or ground port, and one or more
communication/control
ports. The control ports allow communication back and forth between the
modified
electrical device and the active cover plate. This communication may include,
for
example, power consumption data sensed by the modified electrical device or a
room
temperature detected by the active cover plate. In one implantation, a heater
is being
run in a room. The cover plate may sense a buildup of heat in the room and
instruct the
modified outlet to turn off power to the heater.
[0079] In another example, if the active cover plate detects that a room is
not being
used, the modified electrical device could be instructed to turn off the
lights.
Additionally, the active cover plate and/or the modified electrical device
could be in
communication with a network or wireless device that could be used to receive
signals/sensor data from system. Additionally, the external device could send
signals
controlling the function of the modified electrical device and active cover
plate.
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[0080] Fig. 11C is similar to Fig. 10B and shows a partially cutaway side
view of
the outlet (in this case a decora outlet body). Power lines (1090) to the PCB
(1080) are
brought from the upper portions of the decora outlet body. The PCB (1080) is
mounted
to a housing of the outlet by standoffs (1085) extending from the housing of
the outlet
body, with wireless components (1082) and a relay (1070) mounted to the PCB
(1080).
The control port lines (1145) make control connections between the active
cover plate
(100, Fig. 11A) and the decora outlet body. The control port lines (1145) may
be used
to control elements on the active cover plate (100, Fig. 11A) or elements
within the
outlet body. The control port lines (1145) may also be used to transfer data
between the
active cover plate (100, Fig. 11A) and the decora outlet body.
100811 In many outlets, there are break off tabs (1140-1, 1140-2, Fig. 11B)
between
the two neutral screw terminals (460-1, 460-2) and the two hot screw terminals
(480-1,
480-2). The break off tabs (1140) can be removed to electrically separate the
two
neutral screws and/or the two hot screw terminals. In this case one of the hot
screw
terminals is labeled "common" and will always be powered when the outlet is
correctly
installed. By connecting the port wiring to the common hot/neutral screw
terminal, the
ports will receive power regardless of whether the breakout tab is removed or
not.
[0082] Figs. 12A-12D are simplified diagrams of illustrative patterns and
configurations for connectors on the face of the modified electrical device
(160). Fig.
12A shows a modified electrical device (160) that includes two device
connectors;
connector A (1210-1) and connector B (1210-2), each with N ports (1215). The
modified electrical device (160) could be based on any of a number of
electrical outlets,
switches, or terminals. The two device connectors (1210) could be any of a
number of
connector types, including surface contacts, male prongs, female ports, or
other
appropriate connectors. The device connectors (1210) may have any number of
ports/prongs/contacts that are arranged in any of a number of geometries. In
the
example shown in Fig. 12A, the device connector A (1210-1) includes port 1,
port
2... .to port N, where N can be zero or any positive integer. For example, the
device
connector A (1210-1) may include 2, 3, 4, 5, 6 or more ports, prongs, or
contacts. In
some embodiments, the device connector B (1210-2) is identical to the device
connector
A (1210-1) except that it is oriented on the face of the modified electrical
device (160)
in a different way. In general, the term "face" refers to any exposed surface
of the
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modified electrical device (160) that is presented for connection when the
modified
electrical device (160) is installed in an electrical box. The orientation of
the connectors
allows a modified electrical device to be mounted upside down or right side up
and
active cover plate (100, Fig. 1A) to be connected in either a right side up or
upside down
configuration while maintaining the same polarity on the electrical
connections in the
active cover plate (100, Fig. 1A). The term "same polarity" means that a
voltage with
the same positive sense is consistently applied to the same electrical
conductor in the
active cover plate, irrespective of the relative orientation of the active
cover plate with
respect to the receptacle body. Similarly the term "same polarity" means that
a voltage
with the same negative sense is consistently applied to a particular
electrical conductor
in the active cover plate, irrespective of the relative orientation of the
active cover plate
with respect to the receptacle body. If alternating current is supplied from
the receptacle
body to the active cover plate, the term "same polarity" means that the "hot"
terminal
and the "neutral" terminal on the receptacle body are each connected to a
particular
conductor in the active cover plate regardless of the relative orientation of
the active
cover plate with respect to the receptacle body.
[0083] The arrangement of the connectors can be described in a variety of
ways.
For example, the orientation of connector B (1210-2) with respect to connector
A (1210-
1) may be mirrored about a vertical axis (1220) and mirrored about a
horizontal axis
(1230). This results in connector B (1210-2) being upside down on an opposite
side of
the face of the modified electrical device (160).
[0084] Fig. 12B shows another way of describing the orientation of the
connectors
A (1210-1) and B (1210-2) on the face of the modified electrical device (160).
Connector B (1210-2) is an axially rotated version of connector A (1210-1).
This can be
shown by defining a geometric center (1240) of the face of the modified
electrical
device (160) and drawing a line between the geometric center of the device
(1240) and a
geometric center of connector A (1250-1). To obtain the orientation of
connector B
(1210-2), the line is rotated 180 degrees about the geometric center (1240) of
the
modified electrical device (160). This achieves the identical results as shown
in Fig.
12A. Specifically, connector B (1210-2) is upside down and on an opposite side
of the
face of the modified electrical device (160) from connector A (1210-1). A
straight line
passes through the geometric center (1240) of the connector A (1250-1), the
geometric
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center (1240) of the modified electrical device (1240), and the geometric
center of
connector B (1250-2).
[0085] Fig. 12C shows different positions of connectors A and B (1210) on
the face
of the modified electrical device (160) that follows the same rules as Fig.
12A.
Specifically, connector B (1210-2) is a vertically and horizontally mirrored
version of
connector A (1210-1). However, in this case, the connectors are located closer
to the
center of the modified electrical device (160) than the example shown in Figs.
12A and
12B. The resulting pattern has a number of distinct characteristics, including
connectors
that are equally distant from the center and edges of the modified electrical
device (160).
Fig. 12D shows a different way of describing the orientation of the connectors
(1210) on
the face of the modified electrical device (160) that is comparable to that
used in Fig.
12B. Specifically connector B (1210-2) is an axially rotated 180 degrees about
a
geometric center (1240) to describe the location of connector A (1210-1).
[0086] Connectors (1210) are positioned so that the active cover plate
(100, Fig. 1A)
hides the connection when installed. The active cover plates (100, Fig. 1A)
can leave
the original functionality of the electrical device accessible and usable. For
example, if
the modified electrical device (160) is a duplex or decora outlet, both NEMA
receptacles are accessible and ready to be connected to an electrical cord.
[0087] The prong /port interfaces described above are only examples of one
type of
interface. A variety of other interface types could be used. For example,
Figs. 13A and
13B show a modified electrical device (160) with surface nubs (1320) that
supply low
voltage power to an active cover plate (100) with matching surface contacts
(1310). The
nubs (1320) are supplied with low voltage power from internal circuitry in the
modified
electrical device. For example, the nubs (1320) may be electrified with 1.8 to
6 volts.
The nubs (1320) in this example are small exposed bumps of metal. The surface
contacts (1310) on the cover plate may be metallic leaf springs that extend
away from
the surface of the active cover plate (100). When the active cover plate (100)
is
mounted to the modified electrical device (160), the nubs (1320) depress the
surface
contacts (1310) to make a secure electrical contact.
[0088] Because of the low voltage applied to the nubs, the exposure of the
nubs
when the cover plate is not in place does not pose a safety risk. Examples of
various
locations for nubs and their polarities are shown in the figures. However, a
number of
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other configurations could be used. The nubs could have any of a variety of
locations
and may or may not follow one or more of the symmetrical rules described
above. For
example the nubs may be distributed over the face of the modified electrical
device as
shown in Figs. 12A-12D so that the outlet/cover plate can be mounted either
right side
up or upside down.
[0089] Figs. 14A and 14B show an electrical outlet (1400) (a "modified
electrical
device") that includes internal inductive coils (1410). Two power wires (1425)
are
shown connected to the screw terminals (1412) on either side of the outlet
(1400). The
internal inductive coils (1410) are located near the perimeter of the outlet
(1400). The
internal inductive coils (1410) are connected to internal conductors (1405).
In this
example, the inductive coils (1410) are shown as being electrically connected
to the
internal conductors (1405) of the stab-in connectors (1420).
[0090] In one implementation, a magnetic reed switch (1415) is placed in
the line
between the coils (1410). A magnetic reed switch (1415) is ordinarily open and
no
current flows through the internal inductive coils (1410). When a magnet
(1434) is
placed near the reed switch (1415), the reed switch (1415) closes and allows
electrical
current to flow.
[0091] Fig. 14B shows an active cover plate (100) placed over the modified
electrical outlet (1400) that includes internal coils. The active cover plate
(100) includes
two insulated tabs (1432-1, 1432-2). In this example, both insulated tabs
(1432) have
embedded low voltage coils (1438-1, 1438-2). The tab (1432-2) nearest the reed
switch
(1415) also contains a permanent magnet (1434). The permanent magnet (1434)
closes
the reed switch (1415) inside the outlet (1400) to allow electrical energy to
flow through
the high voltage coils (1436) in the outlet (1400). Electrical energy can then
be
inductively coupled out of the high voltage coils (1436) and into the active
cover plate
(100). Thus, when an active cover plate (100) is not in place over the outlet
(1400),
there is no energy dissipation in the outlet (1400). When the active cover
plate (100)
with an embedded magnet (1434) is placed over the outlet (1400), the reed
switch
(1415) closes and allows the electrical current to flow through the device. In
this
example, the power extractors comprise the insulating tabs (1432), the low
voltage coils
(1438) and the permanent magnet (1434).
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100921 Figures 15A-15C show another example of an inductive coupling
between an
outlet and a cover plate. Figure 15A shows a modified outlet (1500) configured
to
accept a Europlug style cord. The modified outlet (1500) includes an internal
coil
(1502) around its perimeter.
[0093] Figure 15B shows an active cover plate (100) that surrounds the
outlet
(1500). The active cover plate (100) contains a low voltage coil (1506) that
inductively
extracts power from the internal coil (1502). This powers any of a number of
devices
that may be present in the active cover plate (100). In this example, the
active cover
plate (100) includes a light sensor (1510) and a number of lights (1508).
However, the
cover plate (100) could include any of a number of components, including those
described above. For example the active cover plate (100) could include a
smoke
detector, speaker, camera, wireless connectivity, carbon monoxide detector, or
other
device.
[0094] Figure 15C shows a switch assembly (1520) that includes a double
gang of
switches (1522) and an active cover plate (100). A bezel (1532) runs around
the
perimeter of the switches and is an integral part of the switch assembly
(1520). In this
example, a high voltage coil (1528), represented by a dashed line, has been
formed
inside the bezel (1532). After the switches (1522) have been installed in the
outlet box,
the active cover plate (100) can be installed around the switches (1522).
Around the
inner perimeter of the active cover plate (100), a low voltage coil (1526) has
been
installed to inductively extract power from the high voltage coil (1528). In
this
example, the active cover plate (100) includes a light sensor (1510) and a
number of
lights (1508). The lights (1508) may be arranged in any of a variety of
locations and
point in any direction. In this example, three of the lights are arranged to
point
downward to illuminate the floor and two of the lights point to the right to
illuminate an
adjacent doorway.
[0095] Inductive coupling of energy out of the outlet may have a number of
advantages. Where the high voltage coils are an integral part of the outlet,
the active
cover plate does not include any high voltage components. This can reduce the
design
requirements of the active cover plate. Further, simple modifications of the
outlet, such
as attaching a clip containing high voltage coils to the outlet, allows
production outlets
to have the desired inductive coupling capabilities.
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100961 Fig. 16 is a flow chart of an illustrative method (1600) for
installing an
electrical system that includes a modified electrical device and an active
cover plate.
The electrical power is turned off to the electrical box, room, or area in
which the
installation will take place (step 1605). This may be done by throwing the
appropriate
breaker switch into an OFF position or turning the electrical power off to the
entire
building. If the modified electrical device is to replace an existing
outlet/switch, remove
the existing cover plate and outlet/switch by removing the fasteners and
disconnecting
the building wiring. For new construction there are no existing cover plates
or
outlet/switches and the process can proceed to the next step. Connect the
modified
electrical device to the building or commercial wiring by making the
appropriate
connections between the building wiring and electrical terminals on the
modified
electrical device (step 1610). In most instances, the electrical terminals on
the modified
electrical device will be in the same position as the electrical terminals in
the old device.
The terminals may be screw terminals on the sides of the modified electrical
device, stab
in connectors on the rear of the device, or other connections. The modified
electrical
device is mechanically connected to the electrical box or other structural
element(s)
(step 1615). In most instances the orientation (right side up; upside down) of
the
modified electrical device is not critical. The desired orientation of the
active cover
plate is determined (step 1620) and the active cover plate is placed over the
modified
electrical device in the desired orientation and the connectors are aligned
(step 1625). If
the active cover plate uses prong/port connections, the male connector on the
active
cover plate is pushed into contact with one of the female connectors on the
modified
electrical device (step 1630). This creates electrical contact between the
prongs of the
male connector and ports in the female connector. The other female connector
is not
used because it does not align with a male connector on the active cover
plate. The
active cover plate is mechanically secured in place over the modified
electrical device
(step 1635). The power can then be turned on (step 1640) and the active cover
plate and
the modified electrical device begin to operate. The modified electrical
device retains
the original functionality of the outlet/switch, including access to all power
receptacles
present on the modified outlet. For example, if the modified electrical device
replaces a
duplex NEMA outlet, both of the NEMA receptacles are accessible and available
to
power external appliances.
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[0097] The steps described above are only one illustrative example. The
method
may be performed in any of a variety of ways. Steps in the method may be
reordered,
combined, omitted, or new steps may be added. For example, in some examples
where
the prongs/ports transfer only low voltages or there are no exposed contacts
in the
design, it may be unnecessary for the power to be turned off/on during the
installation
process.
[0098] Figure 17 is a flow chart of an illustrative method for controlling
the flow of
electrical power through a modified electrical device. The method may include
making
electrical contact between an active cover plate and a modified electrical
device by
pressing a connector on the active cover plate into a mating connector on the
outward
face of the modified electrical device (block 1705). The internal circuitry in
the active
cover plate generates a control signal (block 1710). The control signal can
then be sent
from the active cover plate through the connector on the active cover plate
and mating
connector to control a flow of electricity through the modified electrical
device (block
1715).
[0099] In summary, a modified electrical device includes a body and at
least one
connector on the body to make power and control connections with an active
cover
plate. The body may be any type of electrical receptacle or energized device
that is
designed to supply or control power or to supply electrical signals and is
also configured
to receive an active cover plate. The body may interface with the active cover
plate
through any of a number of interfaces/connectors. The interface/connector may
include
any of a variety of different types of connectors capable of transmitting
electrical power
and/or signals. For example, the connector may include surface contacts, wired
connections, pin/prong connections or wireless connections. In one example,
the
connection is used to send electrical signals over a power connection. For
example, the
modified electrical device and active cover plate may communicate using
communication over power line technology.
[00100] The modified electrical device includes internal control circuitry
for
controlling a flow of electrical current through the modified electrical
device such as
power conditioning circuitry, dimmers, relays, fuses, circuit breakers, or
other circuitry.
The active cover plate supplies control signals to the internal control
circuitry in the
modified electrical device via the at least one connector. For example, the
modified
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electrical device may include step down circuitry to supply a low voltage to
the active
cover plate via the at least one connector.
[00101] In general, the at least one connector is configured to supply power
to the
active cover plate with a first polarity when the active cover plate is in a
first orientation
with respect to the modified electrical device and to supply power with the
same
polarity to the active cover plate when the active cover plate is in a second
orientation
with respect to the modified electrical device. For example, the first
orientation may be
a right side up orientation and the second orientation may be an upside down
orientation. In one example, the body comprises a switch body and the at least
one
connection comprises a hot port and a neutral port. The use of a neutral port
allows the
body to supply electrical power to the active cover plate regardless of
whether the light
switch is on or off In one example, an active cover plate that is adapted to
be connected
over a switch body may include a ground contact that is configured to contact
a
grounded surface of the switch body. For example the ground contact may be a
spring
or leaf style contact that is positioned to make an electrical connection to a
grounded
yoke of the switch body.
1001021 In some
examples, the modified electrical device is configured to accept
both the active cover plate and a standard cover plate that does not include
internal
circuitry. Additionally or alternatively, the modified electrical device may
be
configured to accept an active cover plate with prongs that make electrical
contact with
screw terminals on the sides of the receptacle body.
[00103] The connector on the modified electrical device may include female
ports
adapted to receive male prongs extending from a surface of the active cover
plate,
wherein the female ports comprise at least two power ports and at least one
control port.
There may be two connectors on the modified electrical device and/or on the
active
cover plate. The two connectors may include a first connector and a second
connector,
wherein the second connector is a horizontally and vertically mirrored copy of
the first
connector. These connectors allow the modified electrical device to be in two
way
communication of electrical signals with the active cover plate.
[00104] In some examples, the circuitry to support a particular function may
be split
between the active cover plate and the modified electrical device. For
example, an
active cover plate may include low voltage circuitry and a first interface and
a modified
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high voltage circuitry and a second interface to connect to the first
interface to supply
low voltage to the active cover plate. These interfaces may be wired or
wireless. For
example, the interfaces (ports) may include a power interface, a communication
interface, and a control interface. For example, the interface on a modified
electrical
device may include 6 ports, two power ports, two communication ports, and two
control
ports. The high voltage circuitry in the outlet body may include a relay or a
dimmer
controlled by a control signal received from the active cover plate. The
modified
electrical device may be configured to accept both an active cover plate and a
standard
cover plate that does not include internal circuitry. The modified electrical
device may
be in two way communication with an active cover plate. For example, the
modified
electrical device may report power consumption to the active cover plate which
may
send a signal to open the relay to turn off the power.
[00105] The preceding description has been presented only to illustrate and
describe
examples of the principles described. This description is not intended to be
exhaustive
or to limit these principles to any precise form disclosed. Many modifications
and
variations are possible in light of the above teaching. For example, the
number, size,
and geometry of the pins/female ports can be selected to best accommodate the
system
requirements. Further, the functionality of the various devices can be
selected and
distributed between the active cover plate and the switch body to best meet
the needs of
the system.
