Abstract:
An electrical device such as a plug or a connector has a housing with electrical contacts coupled thereto. The housing also has a nameplate permanently affixed thereto by adhesive and mechanical fasteners. The mechanical fasteners are attached to the housing, which is constructed of a plastic material, in such a manner that the plastic material of the housing completely conceals the metal fasteners of screws. In the preferred embodiment, the nameplate as a curved label section with adhesive on one side such that the nameplate can be secured to a frustoconical section of the housing. A pair of mounting tabs with mounting holes extend from one of the curved edges such that they may be bent or folded and then fastened to a hidden wall of the electrical connector housing. In the preferred embodiment, the electrical housing has a center section, with a shroud section coupled to one end and a cord clamping section coupled to another end. The mounting tabs of the nameplate are secured between the center section and the cord clamping section such that the mounting fasteners of the nameplate are completely enclosed within the non-conductive, dielectric materials forming the center section of the housing and the cord clamping section of the housing.

Description:
This application is a continuation of U.S. patent application Ser. No. 09/345,895 filed on Jul. 1, 1999, now U.S. Pat. No. 6,283,788, which is a divisional of U.S. patent application Ser. No. 09/038,941, filed on Mar. 12, 1998, now U.S. Pat. No. 6,254,967, the subject matter of both of which are herein incorporated by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention generally relates to nameplates or labels for electrical devices such as plugs and connectors. More specifically, the present invention relates to nonmetallic nameplates or labels with product identifying information thereon for permanently securing to electrical plugs and connectors. 
     2. Background Information 
     Electrical plugs used to deliver electrical current from an energized receptacle to an electrical device, such as a motor, piece of machinery, etc., are well known in the art. Generally, they consist of a cable or cord containing two or more conductor wires that are attached to an equal number of terminals fixed in a connector housing. Once the plug is inserted into the receptacle, current travels through the conductor wires to the electrical device. 
     The wiring device industry continues to suffer from an excess of serious injuries to consumers caused by electrical shocks. Accordingly, manufacturers of electrical devices have been required to provide consumers with various information so that they may properly use the electrical plug or connector. This information is typically provided on either packaging or packing slips which are sold with the electrical plug or connector. The problem with putting such information only on the packaging and packing slips is that the packaging and packing slips are often discarded when the plug or connector is being coupled to an electrical cord or the like. According to the industry, it is required that the plug or connector be labeled with the information to allow the consumer to properly use the plug or connector. This has resulted in nameplates and the like being developed which are permanently fixed to the body or housing of the electrical device. For example, in the past, metal nameplates have been screwed to the housing of the electrical device to provide the appropriate information to the consumer. One problem with metal nameplates is that they conduct electricity which can be dangerous to the consumer in certain circumstances. Accordingly, it is desirable to avoid having metal located on the exterior of the housing. 
     In other prior electrical devices, the information to the consumers have been molded directly in the plastic housing of the device. By molding the information into the housing of the electrical device, the information is permanently affixed to the electrical device. The consumer will always have the information available to ensure proper use of the electrical device. However, since the indicia is molded with the housing of the electrical device, the indicia and housing typically have the same color. Therefore, it is often difficult to read the information that is molded into the housing of the electrical device. This can result in the consumer either misreading the information or failing to notice certain warnings. Failure to follow such warnings can result in the consumer being seriously injured due to improper use of the electrical device. 
     In view of the above, there exists a need for an improved method in which to permanently secure a nameplate or label to the housing to provide the consumer with sufficient information on the appropriate uses of the electrical device. This invention addresses this need in the art as well as other needs in the art which will become apparent to those skilled in the art from this disclosure. 
     SUMMARY OF THE INVENTION 
     One object of the present invention is to provide an electrical device with a nameplate which is permanently secured to the exterior of the electrical device to provide information to the consumer. 
     Another object of the present invention is to produce a non-metallic label which is mechanically fastened to the housing of the electrical device in such a manner that the mechanical fasteners are not exposed. 
     Another object of the present invention is to provide a nameplate which is relatively inexpensive and simple to manufacture. 
     The foregoing objects can basically be attained by providing a nameplate for an electrical device comprising a dielectric layer having a first side with product identifying indicia thereon, a second side for engaging the electrical device and at least one mounting hole extending between the first and second sides, the dielectric layer including a label section with the product identifying indicia thereon, a mounting section with the mounting hole being formed therein and folding section connecting the mounting section to the label section; and adhesive overlying the second side of the label section of the dielectric layer for attaching the dielectric layer to an exterior surface of the electrical device. 
     The foregoing objects can also be attained by providing an electrical device, comprising a housing adapted to be coupled to an electrical cord, and having an exterior surface; electrical contacts mounted within the housing and adapted to be coupled to electrical conductors of the electrical cord; and a nameplate coupled to the exterior surface of the housing, and having a dielectric layer with a first side with product identifying indicia thereon, second side with adhesive thereon and at least one mounting hole with a fastener extending therethrough, the housing being constructed to completely conceal the fastener. 
     Other objects, advantages and salient features of the present invention will become apparent to those skilled in the art from the following detailed description, which, taken in conjunction with the annexed drawings, discloses preferred embodiments of the present invention. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Referring now to the attached drawings which form a part of this original disclosure: 
     FIG. 1 is a rear end perspective view of an electrical plug with a nameplate or label coupled thereto in accordance with a first embodiment of the present invention; 
     FIG. 2 is an exploded, rear perspective view of the electrical plug illustrated in FIG. 1; 
     FIG. 3 is an enlarged, exploded perspective view of the center section of the housing, the nameplate and the fasteners for the electrical plug illustrated in FIGS. 1 and 2 or for the electrical connector illustrated in FIGS. 7 and 8. 
     FIG. 4 is a left end elevational view of the center section of the housing for the electrical devices illustrated in FIGS. 1-3 and  7 - 8  with the nameplate coupled thereto; 
     FIG. 5 is a top plan view of the nameplate for the electrical plug illustrated in FIGS. 1 and 2, prior to installation; 
     FIG. 6 is a side edge elevational view of the nameplate of FIG. 5 for the electrical plug illustrated in FIGS. 1 and 2, with the thicknesses of the layers being exaggerated for purposes of illustration; 
     FIG. 7 is a rear end perspective view of an electrical connector with a nameplate or label coupled thereto in accordance with a second embodiment of the present invention; 
     FIG. 8 is an exploded rear perspective view of the electrical connector illustrated in FIG. 7; and 
     FIG. 9 is a top plan view of the nameplate for the electrical connector illustrated in FIGS. 7 and 8. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring initially to FIGS. 1 and 2, an electrical plug  10  with a nameplate or label  12  is illustrated in accordance with a first embodiment of the present invention. Electrical plug  10  is especially designed for hazardous locations with nameplate  12  fixedly attached thereto. As discussed below, nameplate  12  is designed to be both adhesively and mechanically secured to electrical plug  10  so that the nameplate  12  is permanently secured thereto. 
     Basically, electrical plug  10  includes a housing  14 , a contact retainer body  16  secured within housing  14  and a set of electrical contacts  18  retained within contact retainer body  16 . Electrical plug  10  is adapted to be coupled to electrical cord  20  such that each conductor  22  of electrical cord  20  is coupled to one of the contacts  18  of electrical plug  10 . Electrical plugs, such as electrical plug  10 , are well known in the art. Therefore, electrical plug  10  will not be discussed and/or illustrated in detail herein. Moreover, the scope of the claims appended hereto should not be limited to the electrical plugs illustrated and discussed herein. 
     As seen in FIG. 2, housing  14  includes a tubular center section  28 , a locking ring  30 , a shroud section  32 , a cord clamping section  34  and a moisture seal  36 . Preferably, center section  28 , locking ring  30  and cord clamping section  34  are constructed of non-conductive, dielectric materials such as a hard, rigid thermoset plastic material. The center section  28  is a tubular member having a first open end  38  and a second open end  40 . First open end  38  has threads for screwing shroud section  32  thereto. Locking ring  30  can rotate on center section  28 . Second open end  40  has cord clamping section  34  fixedly secured thereto via a pair of screws  42 , only one seen in FIG.  2 . The interior of center section  28  of the housing  14  has a cord receiving cavity for connecting conductors  22  to contacts  18 . The exterior surface of center section  28  has an axially tapering surface  48 , i.e., a frustoconical surface, located adjacent second open end  40 . This frustoconical surface  48  forms a label receiving surface or area in which label or nameplate  12  is permanently secured thereto as discussed below. 
     As seen in FIGS. 3 and 4, second open end  40  of center section  28  has an end face with a first set of screw holes  50  for fixedly securing clamping section  34  thereto via screws  42 , and a second set of screw holes  52  for securing nameplate  12  thereto. Preferably, a pair of metallic screws  54  are threaded into holes  52  for fixedly securing nameplate  12  thereto. When cord clamping section  34  is coupled to second end  40  of center section  28  of housing  14 , screws  54  are completely encased by the plastic of center section  28  and the plastic of cord clamping section  34 . Of course, screws  54  can be replaced with other types of fasteners, including but not limited to a frictionally retained pin. 
     Shroud section  32  is preferably a cylindrical member constructed of a conductive material such as aluminum. Shroud section  32  has one of its ends threaded for screwing to the first end  38  of center section  28  of housing  14 . Shroud section  32  is designed to cover electrical contacts  18 . Shroud section  32  of housing  14  has contact retainer body  16  coupled thereto by screws  46  when center section  28  and shroud section  32  are coupled together. Contact retainer body  16  is held within center section  28  by shroud section  32 , while portions of contacts  18  are located within shroud section  32 . Contact retainer body  16  and contacts  18  are relatively conventional parts which are well known in the art. Therefore, the construction of contact retainer body  16  and contacts  18  will not be discussed or illustrated in detail herein. 
     As seen in FIGS. 1 and 2, cord clamping section  34  is preferably constructed of a non-metallic, non-conductive, dielectric material such as a hard, rigid thermoplastic material. Cord clamping section  34  has a first fixed member  60  and a pair of second movable clamping members  62  which are movably coupled to the fixed member  60  via a pair of screws  64  and nuts  66 . Cord clamping section  34  is designed to provide strain relief to the connections between electrical conductors  22  and electrical contacts  18 . More specifically, cord clamp section  34  grips electrical cord  20  so that when a pulling force is applied to electrical cord  20 , the pulling force is not transmitted to the connection of electrical connectors  22  to electrical contacts  18 . 
     As seen in FIG. 2, cord seal  36  is preferably an elastomeric seal which is sandwiched between second end  40  of center section  28  and cord clamping section  34 . Cord seal  36  is doughnut-shaped with a center hole for receiving electrical cord  20  therethrough. When fixed member  60  is coupled to second end  40  of center section  28  via screws  42 , cord seal  36  is compressed therebetween. This compression of cord seal  36  causes cord seal to deform and create a sealing action against the cord  20  and center section  28 . 
     Referring now to FIGS. 3-6, nameplate  12  basically includes a curved label section  70 , which is designed to overlie the frustoconical surface  48  of center section  28  of housing  14 , and a pair of mounting sections or tabs  72 , which are designed to overlie the axial face of second end  40  of center section  28 . Mounting tabs  72  are coupled to curved label section  70  at spaced locations. Preferably, curved label section  70  and tabs  72  are integrally constructed as a one-piece, unitary member with one side coated with an adhesive layer  74  as seen in FIG.  6 . Preferably, label section  70  and tabs  72  are constructed of a non-conductive, dielectric material such as a polyester film which is produced by Du Pont. Preferably, the polyester film or layer  76  is approximately 0.003 inch thick. 
     Tabs  72  are coupled to label section  70  by a pair of folding sections  77  which are preferably reduced areas located between tabs  72  and label section  70 . Reduced areas or folding sections  77  are designed to permit tabs  72  to be folded relative to label section  70  for overlying the axial end face of second open end  40 . It will be apparent to those skilled in the art that reduced areas  77  can be provided with a fold line to further assist in folding tabs  72  relative to label section  70 . Of course, a fold line can also be used instead of reduced areas  77 . The term “fold line” as used herein refers to any structure which creates a fold in the nameplate such as, but not limited to a crease or a fold. 
     Nameplate  12  has a first side with indicia  78  imprinted thereon. This indicia  78  should include all information required by Underwriters Laboratories (UL) and Canadian Standards Association (CSA) as well as any additional information which the manufacturer or the consumer desires. Preferably, the label  12  includes rating information, manufacturer information, part number, the UL marking and the CSA marking as seen in FIG.  5 . 
     The other side of nameplate  12 , opposite the indicia, is preferably coated with an adhesive layer  74  for securing nameplate  12  to center section  28  of housing  14 . The adhesive layer  74  is preferably a pressure sensitive adhesive which is thermally laminated onto the layer  76 . The pressure sensitive adhesive can be a continuous layer or a spot coating. Accordingly, the label should be able to be used in both indoor and outdoor locations. In particular, the second side of the label section  70  of nameplate  14  overlies the frustoconical surface  48  of center section  28  of housing  14 , while the mounting tabs  72  overlie the end surface of second end  40  of center section  28  such that they overlie the screw holes which receive screws  54  to secure nameplate  12  center section  28  of housing  14 . Preferably, the adhesive layer  74  is approximately 0.01 inch thick. The adhesive layer  74 , together with the layer  76  creates a label or nameplate  12  which is approximately 0.004 inch thick. 
     Curved label section  70  has a first side edge  80 , a second side edge  82 , a first end edge  84  and a second end edge  86 . Side edges  80  and  82  are preferably curved edge with the distance between the side edges  80  and  82  being at least approximately 0.50 inch, preferably 0.585 inch. The curvature of side edges  80  and  82  will depend upon the slope of frustoconical section  48  of center section  28  of housing  14 . In particular, when nameplate  12  is wrapped about frustoconical surface  48 , label section  70  of nameplate  14  forms a frustoconical label having substantially the same slope as frustoconical surface  48 . 
     Preferably, the length of label or nameplate  12  between first and second end edges  84  and  86  is such that when curved label section  70  is wrapped around frustoconical surface  48  of center section  28  of housing  14 . The end edges  84  and  86  substantially abut each other. In other words, label section  70  extends approximately 360° about frustoconical surface  48  of center section  28 . Of course, label section  70  can be constructed to extend less than 360° such that the end edges  84  and  86  do not meet. Of course, label or nameplate  12  can be constructed to extend more than 360° such that end edges  84  and  86  are circumferentially spaced from each other and overlap a portion of label section  70 . 
     Tabs  72  each have a mounting hole  90  formed therein for receiving screws  54  therethrough to permanently secure nameplate  12  to the end of second end  40  of center section  28  of housing  14 . Tabs  72  extend from first side edge  80  and are preferably spaced 180° apart when coupled to the second end  40  of center section  28  such that label section  70  overlies frustoconical surface  48  of center section  28 . 
     The mounting tabs  72  are coupled to the first side edge  80  of curved label section  70  by a reduced portion or area  77  which forms a fold line for bending tabs  72  substantially perpendicular to curved label section  70 . Of course, since curved label section  70  is frustoconical, the angle between tabs  72  and curved label section  70  is preferably slightly larger than 90°. Of course, if nameplate  12  was to be secured to a cylindrical portion of an electrical connector, the side edges  80  and  82  would be straight and parallel to each other, instead of curved, such that when label section  70  is wrapped around a cylindrical housing, a cylindrical nameplate is formed. 
     Second Embodiment 
     Referring now to FIGS. 7-9, an electrical connector  110  with a nameplate or label  112  is illustrated in accordance with a second embodiment of the present invention. Electrical connector  110  is especially designed for hazardous locations and is substantially identical to electrical plug  10 . Since some of the parts are identical between connectors  110  and electrical plug  10  of the first embodiment, similar parts will be given the same reference numeral. For example, electrical connector  110  utilizes tubular center section  28 , cord clamping section  34  and moisture seal  36  of the first embodiment. In view of the similarities between the second embodiment and the first embodiment, this second embodiment will not be discussed and/or illustrated in detail herein. Rather, it will be apparent to those skilled in the art from this disclosure that the description of the first embodiment applies to the second embodiment to the extent that it does not conflict therewith. 
     Basically, electrical connector  110  includes a housing  114 , a contact retainer body  116  secured within housing  114  and a set of electrical contacts  118  retained within contact retainer body  116 . As seen in FIG. 8, housing  114  includes a tubular center section  28 , a shroud section  132 , a cord clamping section  34  and a moisture seal  36 . 
     Referring to FIG. 9, nameplate  112  is basically identical to nameplate  12 , and includes a curved label section  170 , which is designed to overlie the frustoconical surface  48  of center section  28  of housing  114 , and a pair of mounting sections or tabs  172 , which are designed to overlie the axial face of second end  40  of center section  28 . Mounting tabs  172  are coupled to curved label section  170  at spaced locations. Preferably, curved label section  170  and tabs  172  are integrally constructed as a one-piece, unitary member with one side coated with an adhesive layer. 
     Tabs  172  are coupled to label section  170  by a pair of folding sections  177  which are preferably reduced areas located between tabs  172  and label section  170 . Reduced areas or folding sections  177  are designed to permit tabs  172  to be folded relative to label section  170  for overlying the axial end face of second open end  40 . Holes  190  in tabs  172  receive screws  54  for mechanically securing nameplate  112  to housing  114 . It will be apparent to those skilled in the art that reduced areas  177  can be provided with a fold line to further assist in folding tabs  172  relative to label section  170 . Of course, a fold line can also be used instead of reduced areas  177 . 
     Nameplate  112  should include all information required by Underwriters Laboratories (UL) and Canadian Standards Association (CSA) as well as any additional information which the manufacturer or the consumer desires. Preferably, the label  112  includes rating information, manufacturer information, part number, the UL marking and the CSA marking as seen in FIG.  9 . 
     Various modifications, improvements and other embodiments will become apparent to those skilled in the art once given this disclosure. Such modifications, improvements and other embodiments are considered to be within the scope and spirit of this invention as defined by the following claims.