Patent Publication Number: US-7223122-B2

Title: Electrical connectivity system capable of being mounted to an object, and method of manufacturing same

Description:
FIELD OF THE INVENTION 
   This invention relates generally to electrical connectivity systems, and relates more particularly to such systems that are capable of being mounted to an object. 
   BACKGROUND OF THE INVENTION 
   Electric devices require electric power and/or data signals in order to function, and electrical connectivity systems of many descriptions have been developed for the purpose of delivering such power and data signals. Electrical connectivity systems include wall outlets, power strips, and surge protectors that deliver electric power in the form of alternating current (AC), and further include phone jacks, Ethernet ports, USB and FireWire hubs, and other products containing outlets, jacks, or ports that deliver electric power and/or data required by an electronic device. 
   Power and data delivery issues often arise at a work area where a computer and computer peripherals are in use. Conveniently positioning an electrical connectivity system capable of such delivery can be a challenge in light of the great variety in the arrangement of furniture, the set-up and placement of equipment, and other factors that have a bearing on the comfort and efficiency of a work area. Most electrical connectivity systems, including most power strips and surge protectors, are designed with the idea that they will simply sit on the floor, or on a work surface next to the computer. At the same time, the relatively few electrical connectivity systems that are mountable tend to be one-dimensional and limited to a single mounting situation, such as being capable only of being mounted flush with a wall. Accordingly, there exists a need for an electrical connectivity system that is capable of being securely mountable in a wide variety of potential mounting situations, and further capable of being move from one such situation to another when such is desired. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The invention will be better understood from a reading of the following detailed description, taken in conjunction with the accompanying figures in the drawings in which: 
       FIG. 1  is a perspective view of an electrical connectivity system—in disassembled form—capable of being mounted to an object according to an embodiment of the invention; 
       FIGS. 2A–2D  are side views of various mounting scenarios for an electrical connectivity system according to an embodiment of the invention; 
       FIG. 3  is a perspective view of an electrical connectivity system having a cord manager bracket connected thereto according to an embodiment of the invention; 
       FIG. 4  is a perspective view of an electrical connectivity system having a cord wrap post connected thereto according to an embodiment of the invention; 
       FIG. 5  is a perspective view of an electrical connectivity system having a hinged door connected thereto according to an embodiment of the invention; 
       FIG. 6  is a perspective view of the hinged door of  FIG. 5  according to an embodiment of the invention; and 
       FIG. 7  is a flowchart illustrating a method of manufacturing an electrical connectivity system capable of being mounted to an object according to an embodiment of the invention. 
     For simplicity and clarity of illustration, the drawing figures illustrate the general manner of construction, and descriptions and details of well-known features and techniques may be omitted to avoid unnecessarily obscuring the invention. Additionally, elements in the drawing figures are not necessarily drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help improve understanding of embodiments of the present invention. The same reference numerals in different figures denote the same elements. 
     The terms “first,” “second,” “third,” “fourth,” and the like in the description and in the claims, if any, are used for distinguishing between similar elements and not necessarily for describing a particular sequential or chronological order. It is to be understood that the terms so used are interchangeable under appropriate circumstances such that the embodiments of the invention described herein are, for example, capable of operation in sequences other than those illustrated or otherwise described herein. Furthermore, the terms “comprise,” “include,” “have,” and any variations thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements is not necessarily limited to those elements, but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. 
     The terms “left,” “right,” “front,” “back,” “top,” “bottom,” “over,” “under,” and the like in the description and in the claims, if any, are used for descriptive purposes and not necessarily for describing permanent relative positions. It is to be understood that the terms so used are interchangeable under appropriate circumstances such that the embodiments of the invention described herein are, for example, capable of operation in other orientations than those illustrated or otherwise described herein. The term “coupled,” as used herein, is defined as directly or indirectly connected in an electrical, mechanical, or other manner. 
   

   DETAILED DESCRIPTION OF THE DRAWINGS 
   In one embodiment of the invention, an electrical connectivity system capable of being mounted to an object in a variety of configurations comprises a housing, a power cord, and a mounting bracket. The housing comprises a first threaded aperture at a first surface of the housing, a second threaded aperture at a second surface of the housing, and an electrical connection port at a third surface of the housing. The mounting bracket comprises a first portion, a second portion adjacent to and extending substantially perpendicularly away from the first portion, and a first aperture in the first portion. The power cord is integral with the housing and is capable of delivering electric power to the electrical connection port. As will be explained in detail below, the mounting bracket may be used to mount the housing in a variety of locations, with the electrical connection port oriented in any one of a variety of orientations. The mounting bracket may also receive a variety of accessories, including cord management accessories, useful when used in connection with the housing. 
   Referring now to the figures,  FIG. 1  is a perspective view of an electrical connectivity system  100  capable of being mounted to an object according to an embodiment of the invention. Electrical connectivity system  100  is shown in disassembled form in  FIG. 1  so that various components of the system that would otherwise be hidden from view may be shown and described. Electrical connectivity system  100  comprises a housing  110  comprising a surface  111 , a surface  112 , and a surface  113 . In the illustrated embodiment, surfaces  112  and  113  are substantially parallel to each other, and are substantially perpendicular to surface  111 . 
   Threaded apertures  151  are located at surface  111 . Additional threaded apertures are located at surface  112 , but these additional threaded apertures are not visible in  FIG. 1 . Any subsequent discussion or description herein of threaded apertures  151  applies equally to the hidden additional threaded apertures, unless otherwise explicitly or contextually indicated. 
   Although two threaded apertures  151  are at surface  111  in the illustrated embodiment, other embodiments may comprise one, three, or some other number of threaded apertures at surface  111  and at surface  112 . In one embodiment, threaded apertures  151  comprise threaded rings made of metal, plastic, or another suitable material around which housing  110  is molded or otherwise formed. Alternatively, the threaded rings may be inserted into housing  110  after its formation, such as by pressing or forcing the threaded rings into the material of housing  110 . In another embodiment, threaded apertures  151  are formed during the formation of housing  110 , such as by molding threads into the material of housing  110  during an injection molding process. 
   An electrical connection port  171  is located at surface  113 . In the illustrated embodiment, electrical connection port  171  is one of a plurality of electrical connection ports at surface  113 . Electrical connection port  171  can be an electrical power outlet, a phone jack, an Ethernet port, a USB or FireWire port, or some other outlet, jack, or port that delivers electric power and/or data required by an electronic device. Each such outlet, jack, or port contains or is associated with circuitry and/or other material that enables, supports, or enhances its functionality. Such circuitry and other associated material, however, is known in the art, and will therefore not be further discussed herein. In a preferred embodiment, electrical connectivity system  100  is a power strip or a surge protector having multiple electrical connection ports delivering AC electric power. 
   Electrical connectivity system  100  further comprises a power cord  130  integral with housing  110  and capable of delivering electric power to electrical connection port  171 . Power cord  130  may be constructed of standard and/or known materials, and it may be connected to housing  110  using standard and/or known techniques. Electrical connectivity system  100  still further comprises a mounting bracket  120  comprising a portion  121  and a portion  122  adjacent to and extending substantially perpendicularly away from portion  121 . Portion  121  comprises apertures  127 . Portion  122  comprises apertures  128 , arranged in a column  191  and an opposite column  192 . Apertures  127  and  128  are not necessarily threaded, but may in other ways be similar to threaded apertures  151  in housing  110 . 
   The illustrated embodiment shows two apertures  127  at portion  121 . Different embodiments may have one, three, or some other number of apertures in portion  121 . As shown, adjacent ones of apertures  127  are separated from each other by a distance  129 . In one embodiment, one of apertures  128  from column  191  and a corresponding aperture  128  from column  192  are also separated by distance  129 . In the same or another embodiment, adjacent ones of threaded apertures  151  and/or adjacent ones of the additional threaded apertures at surface  112  are also separated by distance  129 . With all adjacent apertures separated by a common distance, electrical connectivity system  100  becomes more versatile that it would be otherwise. For example, the multiple connection configurations and mounting scenarios mentioned below are greatly simplified by the fact that a single separation distance is used. The attachment and use of the various accessories to be described below is also simplified by the single separation distance. 
   In this context, the word “adjacent” is used to refer to two apertures that do not have an aperture between them. The description is less important for the illustrated embodiment, where only two apertures are shown on surface  111  and on surface  125 , than for a non-illustrated embodiment where three or more apertures are included at those and/or other surfaces of housing  110  and mounting bracket  120 . As an example, two apertures at each surface may be used for a housing having three electrical connection ports, like the one shown in  FIG. 1 , while three or more apertures at each surface may be used for a housing (not illustrated in  FIG. 1 ) having four, eight, twelve, or some other number of electrical connection ports greater than three. 
   The dimensions of portions  121  and  122  relative to each other may vary from one to another embodiment of electrical connectivity system  100 . In one embodiment, portions  121  and  122  have lengths that are similar to each other, widths that are similar to each other, and thicknesses that are similar to each other. In the illustrated embodiment, portion  121  comprises a dimension  131  and a dimension  132  substantially perpendicular to dimension  131 . Portion  122  comprises a dimension  141  and a dimension  142  substantially perpendicular to dimension  141 . Housing  110  comprises a dimension  181 , a dimension  182  substantially perpendicular to dimension  181 , and a dimension  183  substantially perpendicular to dimension  181  and to dimension  182 . Dimension  141  is at least twice as large as dimension  131 . Dimensions  132  and  142  are substantially equal to each other. Dimensions  181  and  182  are substantially equal to each other and to dimension  131 . Dimension  183  is substantially equal to dimensions  132  and  142 . 
   The electrical connectivity system of the illustrated embodiment, having the dimensions just described, may be mounted securely and firmly to a wall, a table, a cabinet, a desk, or the like in a manner to be described immediately below. Further, the described dimensions allow for the mounting of accessories, as will be described below. 
   Housing  110  and mounting bracket  120  are connected to each other using apertures  127  and either threaded apertures  151  or the additional threaded apertures at surface  112 . To use threaded apertures  151 , surface  111  of housing  110  and a surface  125  of mounting bracket  120  are brought together such that they are facing each other and threaded apertures  151  are aligned with apertures  127 . Surface  112  of housing  110  is positioned adjacent to portion  122  of mounting bracket  120 . Fastening devices (not shown in  FIG. 1 ) such as screws or the like are then inserted through apertures  127  and screwed into threaded apertures  151 . To use the additional threaded apertures at surface  112 , surfaces  125  and  112  are brought together and apertures  127  and the additional threaded apertures are aligned and screws or the like inserted therethrough. 
   It may be seen that housing  110  and mounting bracket  120  may be connected to each other in other configurations in addition to the two configurations just described. In a first additional connection configuration, surface  111  is adjacent to and facing a surface of portion  121  opposite surface  125 . In a second additional connection configuration, surface  112  is adjacent to and facing the surface of portion  121  opposite surface  125 . In each connection configuration, the direction in which electrical connection port  171  faces may also be varied according to the circumstances. 
   Each connection configuration may be useful for one or more particular mounting scenarios for electrical connectivity system  100 .  FIGS. 2A–2D  depict some such mounting scenarios.  FIG. 2A  illustrates electrical connectivity system  100  mounted against a wall and under a cabinet or the like.  FIG. 2B  illustrates electrical connectivity system  100  mounted below the surface of an article of furniture.  FIG. 2C  illustrates electrical connectivity system  100  mounted to the underside of a table or the like.  FIG. 2D  illustrates electrical connectivity system  100  mounted above the surface of an article of furniture. Additional mounting scenarios not illustrated herein are also possible. For example, electrical connectivity system  100  may be mounted such that housing  110  is oriented vertically with respect to the floor or ground. 
   As may be seen, for the mounting scenarios of  FIGS. 2A and 2B , surfaces  112  and  125  are mounted adjacent to and facing each other. For the mounting scenario of  FIGS. 2C and 2D , it is surfaces  111  and the surface of portion  121  opposite surface  125  that are mounted adjacent to and facing each other. 
   As an example, housing  110  may be constructed of acrylonitrile butadiene styrene (ABS), polycarbonite, extruded aluminum, sheet metal over plastic, or the like. ABS, for example, is strong, relatively inexpensive, and has pleasing tactile properties. Mounting bracket  120  may be formed from metal, such as cold rolled steel, aluminum, or the like, or it may be formed from a strong plastic material such as ABS, polycarbonite, or the like. 
   It was mentioned above that mounting bracket  120  may receive a variety of accessories, including cord management accessories, useful when used in connection with housing  110 . The accessories are capable of being attached to mounting bracket  120  using at least one of apertures  128 . Some, though not all, of the possible accessories will now be discussed, in connection with  FIGS. 3–6 . 
     FIG. 3  is a perspective view of electrical connectivity system  100  having a cord manager bracket  310  connected thereto according to an embodiment of the invention. As illustrated in  FIG. 3 , cord manager bracket  310  comprises cord manager arms  311  that extend away from a base  312  to form a cord management aperture  313 . Power cords  320 , which for clarity are depicted in dotted lines in  FIG. 3 , extend through cord management aperture  313  and are retained therein by cord manager arms  311 . As an example, cord manager arms  311  may be flexed in order to allow the passage of a power cord  320  either into or out of cord management aperture  313 . In one embodiment, cord manager bracket  310  is formed of plastic, such as ABS, polyvinyl chloride (PVC), or the like. In another embodiment, cord manager bracket  310  is formed of rubber, such as thermoplastic elastomer (TPE) or the like. 
     FIG. 4  is a perspective view of electrical connectivity system  100  having a cord wrap post  410  connected thereto according to an embodiment of the invention. As illustrated in  FIG. 4 , cord wrap post  410  comprises a post  411  topped with a cap  412 . As an example, post  411  can have a threaded and hollow interior so as to receive a screw. As another example, post  411  itself can be threaded, and can screw into aperture  128  (see  FIG. 1 ). As yet another example, post  411  can snap into aperture  128 . Cord wrap post  410 , as an example, can be formed of the same materials from which cord manager bracket  310  (see  FIG. 3 ) is formed. 
   As illustrated, a portion of power cord  420  may be wrapped around cord wrap post  410 , and caps  412  will retain the portion of power cord  420  in place. In this way, excess cord may be stored neatly where it is less likely to become tangled and/or unsightly than if it were not wrapped as described. Power cord  420  may be wrapped around two cord wrap posts  410 , as shown, or wrapped around all four of the cord wrap posts, just three, a different set of two, or some other configuration. In a non-illustrated embodiment, fewer than four cord wrap posts  410  are inserted into apertures  128 , and the cord wrap pattern may be adjusted accordingly. 
     FIG. 5  is a perspective view of electrical connectivity system  100  having a hinged door  510  connected thereto according to an embodiment of the invention.  FIG. 6  is a perspective view of hinged door  510  according to an embodiment of the invention. As illustrated in  FIGS. 5 and 6 , hinged door  510  comprises a front panel  511 , a side panel  512 , and a top panel  513 . Side panel  512  is coupled to a hinge  611  which has an aperture  612  therein. Hinge  611  allows hinged door  510  to open as indicated by directional arrows  551  and  552 , and close by traveling in an opposing direction. 
   Aperture  612  may be aligned with aperture  128  (see  FIG. 2 ) and a fastening device such as a screw inserted therethrough in order to attach hinged door  510  to mounting bracket  120 . In a different embodiment, hinged door  510  may be provided with pegs or the like suitable for being snapped into place in apertures  128 . 
   Top panel  513  comprises arms  618  that define a cord management aperture  515  in top panel  513 . Power cords  520  may be maintained in place by cord management aperture  515 , as shown. As an example, power cords  520  may be positioned as shown in  FIG. 5 , and hinged doors  510  may then be closed around power cords  520 . The result is that power cords  520  are neatly constrained to lie in the same general direction and space, while the plugs (not shown) at the end of power cords  520  are hidden from view. Hinged door  510 , as an example, can be formed of the same materials from which cord manager bracket  310  (see  FIG. 3 ) is formed. Hinge  611  may be formed of metal or the like according to industry standards. 
   In a non-illustrated embodiment, top panel  513  does not have arms  618  and does not define cord management aperture  515 . Instead, in that non-illustrated embodiment, hinged door  510  with a continuous top panel  513  is attached to mounting bracket  120  as described and, when closed, obscures from view the power plugs as well as cord manager bracket  310  (see  FIG. 3 ) or the like that performs the same function that arms  618  and cord management aperture  515  perform in the illustrated embodiment. 
     FIG. 7  is a flowchart illustrating a method  700  of manufacturing an electrical connectivity system capable of being mounted to an object according to an embodiment of the invention. A step  710  of method  700  is to provide a housing comprising a first surface, a second surface, and a third surface. As an example, the housing, the first surface, the second surface, and the third surface can be similar to, respectively, housing  110 , surface  111 , surface  112 , and surface  113 , all of which were first shown in  FIG. 1 . 
   A step  720  of method  700  is to insert a first plurality of threaded apertures into the first surface of the housing. As an example, each one of the first plurality of threaded apertures can be similar to threaded aperture  151 , first shown in  FIG. 1 . In one embodiment, step  720  comprises molding the housing around the threaded aperture. In another embodiment, step  720  comprises inserting the threaded aperture into the housing after the formation of the housing, such as by pressing or forcing the threaded rings into the material of the housing. In yet another embodiment, step  720  comprises forming the threaded apertures are formed during the formation of the housing, such as by molding threads into the material of the housing during an injection molding process or the like. In a particular embodiment, step  720  comprises forming adjacent ones of the threaded apertures to be separated by a distance such as distance  129 , first discussed in connection with  FIG. 1 . 
   A step  730  of method  700  is to insert a second plurality of threaded apertures into the second surface of the housing. As an example, each one of the second plurality of threaded apertures can also be similar to threaded aperture  151 . In one embodiment, step  730  comprises forming adjacent ones of the threaded apertures to be separated by the same distance that separates adjacent ones of the first plurality of threaded apertures. In the same or another embodiment, steps  730  and  720  are performed simultaneously with each other. 
   A step  740  of method  700  is to mount an electrical connection port in the housing such that a face of the electrical connection port is accessible at the third surface of the housing. As an example, the electrical connection port can be similar to electrical connection port  171 , first shown in  FIG. 1 . 
   A step  750  of method  700  is to physically and electrically connect to the housing a power cord capable of delivering electric power to the electrical connection port. As an example, the power cord can be similar to power cord  130 , first shown in  FIG. 1 . 
   A step  760  of method  700  is to form a mounting bracket comprising a first portion, a second portion adjacent to and extending substantially perpendicularly away from the first portion, and a first plurality of apertures in the first portion. As an example, the mounting bracket, the first portion, and the second portion can be similar to, respectively, mounting bracket  120 , portion  1212 , and portion  122 , all of which were first shown in  FIG. 1 . As another example, each one of the first plurality of apertures can be similar to apertures  127 , which were also first shown in  FIG. 1 . 
   In one embodiment, step  760  comprises forming the mounting bracket such that adjacent ones of the first plurality of apertures are separated by the same distance that separates adjacent ones of the first plurality of threaded apertures. In the same or another embodiment, step  760  or another step comprises forming the mounting bracket to have a second plurality of apertures in the second portion. As an example, each one of the second plurality of apertures can be similar to apertures  128 , first shown in  FIG. 1 . In a particular embodiment, step  760  or the other step comprises forming the mounting bracket such that adjacent ones of the second plurality of apertures are separated by the same distance that separates adjacent ones of the first plurality of threaded apertures. 
   A step  770  of method  700  is to provide an accessory and attach the accessory to the mounting bracket using the second plurality of apertures. As an example, the accessory can be similar to cord manager bracket  310 , first shown in  FIG. 3 . As another example, the accessory can be similar to cord wrap post  410 , first shown in  FIG. 4 . As still another example, the accessory can be similar to hinged door  510 , first shown in  FIG. 5 . 
   Although the invention has been described with reference to specific embodiments, it will be understood by those skilled in the art that various changes may be made without departing from the spirit or scope of the invention. Various examples of such changes have been given in the foregoing description. Accordingly, the disclosure of embodiments of the invention is intended to be illustrative of the scope of the invention and is not intended to be limiting. It is intended that the scope of the invention shall be limited only to the extent required by the appended claims. For example, to one of ordinary skill in the art, it will be readily apparent that the electrical connectivity system discussed herein may be implemented in a variety of embodiments, and that the foregoing discussion of certain of these embodiments does not necessarily represent a complete description of all possible embodiments. Rather, the detailed description of the drawings, and the drawings themselves, disclose at least one preferred embodiment of the invention, and may disclose alternative embodiments of the invention. 
   All elements claimed in any particular claim are essential to the invention claimed in that particular claim. Consequently, replacement of one or more claimed elements constitutes reconstruction and not repair. Additionally, benefits, other advantages, and solutions to problems have been described with regard to specific embodiments. The benefits, advantages, solutions to problems, and any element or elements that may cause any benefit, advantage, or solution to occur or become more pronounced, however, are not to be construed as critical, required, or essential features or elements of any or all of the claims. 
   Moreover, embodiments and limitations disclosed herein are not dedicated to the public under the doctrine of dedication if the embodiments and/or limitations: (1) are not expressly claimed in the claims; and (2) are or are potentially equivalents of express elements and/or limitations in the claims under the doctrine of equivalents.