Active cover plates
A variety of active cover plate configurations with prongs configured to contact side screw terminals of electrical receptacles are described.
1. An active cover plate comprising:
a face plate; and
a prong extending from the face plate, wherein the prong comprises
an upright comprising at least one aperture, and
a resilient contact comprising a fixed end and a free end,
wherein the upright is wider than the resilient contact, the resilient contact is disposed on an inboard side of the upright, and the fixed end of the resilient contact is secured to the upright and at least a portion of the resilient contact extends over the at least one aperture in the upright.
2. The active cover plate of claim 1 , wherein:
the resilient contact further comprises a middle portion between the fixed end and the free end; and
at least part of the middle portion extends over the at least one aperture in the upright.
3. The active cover plate of claim 2 , in which lateral compression of the resilient contact brings the middle portion closer to the at least one aperture and moves the free end with respect to the upright.
4. The active cover plate of claim 1 , wherein:
the prong further comprises a base extending at an angle from the upright, the base comprising a wire connection feature;
the upright, the resilient contact, and the base are formed from a single piece of sheet metal; and
the active cover plate further comprises
a circuit, and
a wire,
wherein the wire is connected to the base to make an electrical connection between the circuit and the prong.
5. The active cover plate of claim 1 , wherein:
the at least one aperture comprises a generally rectangular aperture through the upright, the generally rectangular aperture comprising a first short side, a second short side, a first long side and a second long side; and
the fixed end of the resilient contact is connected to the upright proximate the first short side of the generally rectangular aperture and the resilient contact extends over the generally rectangular aperture with the free end of the resilient contact more proximate the second short side than the first short side of the generally rectangular aperture.
6. The active cover plate of claim 1 , further comprising electrical insulation, wherein the upright comprises at least one additional aperture and the upright is at least partially secured to the electrical insulation using the at least one additional aperture.
7. The active cover plate of claim 6 , wherein a portion of the electrical insulation extends through the at least one additional aperture in the upright.
8. The active cover plate of claim 1 , further comprising electrical insulation, wherein the upright comprises edges and the edges engage with the electrical insulation to at least partially secure the upright to the electrical insulation.
9. The active cover plate of claim 1 , wherein the upright comprises shoulders proximal to the face plate that are wider than portions of the upright that are more distal from the face plate.
10. The active cover plate of claim 1 , wherein:
the resilient contact comprises a first resilient contact;
the prong further comprises a second aperture and a second resilient contact extending over the second aperture; and
the second resilient contact is longitudinally spaced from the first resilient contact.
11. The active cover plate of claim 1 , further comprising a rear insulator, wherein the rear insulator comprises a wall positioned outboard of the upright and an outboard surface of the upright and an inboard surface of the wall are substantially flat, parallel, contiguous, and fixed relative to each other.
12. An active cover plate extending in longitudinal, lateral, and transverse directions that are orthogonal to one another, the active cover plate comprising:
a front plate comprising a front surface, a back surface, and an electrical receptacle aperture, wherein the electrical receptacle aperture extends through the front plate in the transverse direction;
a prong connecting to the back surface of the front plate at a location outboard of the electrical receptacle aperture, the prong extending rearward away from the back surface of the front plate in the transverse direction; and
a back plate comprising a protrusion extending from a back surface of the back plate in the transverse direction, wherein the protrusion comprises an outboard wall and lateral walls joined to opposite edges of the outboard wall.
13. The active cover plate of claim 12 , wherein the protrusion is an integrally molded feature of the back plate and the outboard wall and the lateral walls define a partially enclosed volume.
14. The active cover plate of claim 12 , wherein the protrusion comprises insulation that covers at least a portion of an outboard side of the prong.
15. The active cover plate of claim 12 , wherein the outboard wall and the lateral walls of the protrusion comprise a U channel with the prong at least partially disposed within an interior volume enclosed by the U channel.
16. The active cover plate of claim 12 , wherein lateral compression of the prong brings the prong into contact with the protrusion.
17. The active cover plate of claim 12 , wherein lateral compression of the prong brings the prong into direct contact with an inner side of the outboard wall of the protrusion.
18. The active cover plate of claim 12 , wherein:
the prong comprises a cantilever comprising a fixed end connected to a support and a free end; and
the free end of the prong is configured to contact an inner side of the outboard wall of the protrusion when the cantilever is deformed.
19. The active cover plate of claim 18 , wherein contact between the free end of the cantilever and the inner side of the outboard wall of the protrusion increases bending stiffness of the prong.
20. The active cover plate of claim 18 , wherein contact between the free end of the cantilever and the inner side of the outboard wall of the protrusion changes bending behavior of the cantilever.