Patent Publication Number: US-2020295801-A1

Title: Wall plate data/power exchange system

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of U.S. Provisional Application No. 62/817,149, filed Mar. 12, 2019, which is hereby incorporated by reference herein in its entirety. 
    
    
     FIELD OF THE DISCLOSURE 
     The present disclosure generally relates to data and/or power transfer mechanisms, such as wires/cables (“cord” or “cords”) and plugs for electronic devices and, more particularly, to cord retention solutions used with sources of data and/or power. 
     BACKGROUND 
     Cords that have been designed for and/or are utilized to connect one or more portable electronic devices (“PED” or “PEDs”), such as but not limited to mobile phones, have indeed taken on many forms with advances in technology. In one current form, a cord includes a connector at a first end thereof that is configured to connect to a PED and another connector at a second end to connect to a data I/O port and/or power I/O port (“data/power port”) and/or second electronic device. One common connector for the second end can be a Universal Serial Bus (USB) connector that allows the PED to be connected to a data/power port having a corresponding port connector technology (“plug” or “plugs”). The USB connector can also be utilized in conjunction with a coupler or electronic coupling device such as, but not limited to a USB AC adapter to connect the PED into a data/power port to perform data exchanging functions and/or to charge the PED and/or devices connected to the data/power port. Unfortunately, with the increase in connections, the chance that one of the connections is inadvertently separated increases. 
     SUMMARY 
     In accordance with one aspect, a wall plate charging system is disclosed that includes a wall plate having a plate portion with a generally planar configuration and a housing portion extending from the plate portion. The system further includes a data and/or power exchanging assembly at least partially disposed within the housing portion and permanently coupled thereto, the assembly including an outlet connector projecting rearwardly through one or more openings in a back surface of the housing and a data and/or power exchanging device. 
     According to some forms, the outlet connector can be a one or multi-prong plug, a USB connector, a fiber optic connector, and/or a magnetic data exchange connector. 
     According to some forms, the wall plate can include a socket opening, where the housing and socket opening are configured to align with respective sockets of an electrical outlet; the wall plate can include a fastener opening extending therethrough to secure the wall plate to an electrical outlet or structure adjacent to an electrical outlet; and/or the data and/or power exchange assembly can include at least one of a converter, a switch mode power supply, a data transducer, a power transducer, a photovoltaic power supply, or a kinetic power supply. 
     According to some versions, the data and/or power exchange device can be a cord having a distal connector that projects forwardly from an opening in a front surface of the housing. In one form, the system can include a cord protector that is mounted to the housing around the opening in the front surface. In another form, the housing portion can project forwardly from the plate portion and can include a flange that projects outwardly from a sidewall thereof. Further, a front surface of the flange can be planar with the front surface of the housing and/or the flange can include one or more slot openings sized to frictionally receive a portion of the cord therein. 
     According to other versions, the data and/or power exchange device can be a transmitter coil that is disposed within the housing portion and has a main surface extending generally parallel with a charging surface of the housing portion. In one form, the housing portion can extend forwardly from plate portion in a generally horizontal orientation such that the charging surface faces upwardly to receive a PED thereon. In other forms, the housing portion can extend upwardly from the plate portion and, if desired, at a rearward angle with respect to a vertical axis of the plate portion. In these forms, the wall plate can include a ledge that extends forwardly from the housing portion to receive a PED thereon. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The above needs are at least partially met through provision of the embodiments described in the following detailed description, particularly when studied in conjunction with the drawings, wherein: 
         FIG. 1  is a front perspective view of a first example wall plate charging system in accordance with various embodiments; 
         FIG. 2  is a rear perspective view of the wall plate charging system of  FIG. 1 ; 
         FIG. 3  is a front perspective view of a second example wall plate charging system in accordance with various embodiments; 
         FIG. 4  is a rear perspective view of the wall plate charging system of  FIG. 3 ; 
         FIG. 5  is a front perspective view of a third example wall plate charging system in accordance with various embodiments. 
     
    
    
     DETAILED DESCRIPTION 
     Wall plates having integrated charging components are described herein. The wall plates include a rearwardly protruding outlet connector to electrically couple the charging components with an electrical outlet and a charging device. In some versions, the charging device can include a wired or wireless connection. The wall plates can be secured to the electrical outlets or structure adjacent thereto to thereby retain the charging components in electrical engagement with the electrical outlets. The wall plates can be secured to the structure using any suitable mechanism, such as by using fasteners, snap fit, and so forth. 
     In one form, the charging components can include one or more data and/or power cord or cords that extend outwardly from the wall plate so that a user can physically connect one or more PEDs to the charging components. In another form, the charging components can include a transmitter coil and associated components configured to inductively charge a PED disposed adjacent to the wall plate. The charging components can include any circuitry to modify voltage and power and/or data and data exchange protocol to a form suitable for a particular PED. In either form, the wall plate is secured to a wall or other substrate to thereby prevent one from walking away from the wall with a charging device. 
     While the depicted forms are designed and configured to accommodate standard one prong or multi-prong electrical outlets, such as two or three prong electrical outlets, the embodiments described herein could be easily modified to accommodate smaller USB connectors, fiber optic connectors, magnetic data exchange connectors, or other suitable plugs. That is, due to the proliferation of PEDs and the need for electrically charging these devices, recent trends in data and/or electrical supply include providing wall power outlets (i.e., electrical sockets) with a USB or other plug connector port in addition to or as a substitute for one of the traditional prong electrical outlets, such as one, two, or three prong electrical outlets. This advantageously enables users to plug the first end of the charging cord directly into the particular outlet without requiring separate adapter circuitry or components. Thus, it should be appreciated that the present invention can be easily modified to accommodate this simple variation. 
     As shown in various ones of the figures, the charging and data exchange systems and methods described herein are configured to perform data and/or power exchange functionalities for a suitable PED  50 , such as a smart phone, tablet, e-reader, and the like. The PED  50  includes electronic components powered and/or instructed by a respective power/data source  52  that can receive data and/or power through a wired connection from a data and/or power supply to a port  54  or through an induction connection from a data and/or power supply transmitter coil, described in more detail below, to a coil  56  as commonly understood. As shown, the coil  56  has a disk-shaped configuration with main surfaces  58  that extend in a direction generally parallel with respect to main surfaces  60  of the device  50 . 
     Referring now to the figures, a corded embodiment of a data/power port wall plate system  100  is in  FIGS. 1 and 2 . The system  100  includes a wall plate or outlet cover  102  having a generally planar plate portion  104  with, optionally, a beveled or tapered edge  106  as shown. The wall plate  102  is configured to be secured adjacent to an electrical outlet  10 , such as to structure of the outlet  10 , a junction box, a wall  12  extending around the outlet  10 , and so forth, by any suitable mechanism. For example, the wall plate  102  can be secured using one or more fasteners, having any desired drive type, such as square, hex, slotted, Phillips, Torx, spline, and the like, extending through an opening  108  in the plate portion  104 . Alternatively, the wall plate  102  can include snap fit, tongue-and-groove, plug, latch, magnetic, and/or threaded structure. 
     In the illustrated form, the wall plate  102  further includes an exchange housing  110  and an opening  112  sized to extend around a socket  14  of the outlet  10 . The housing  110  and opening  112  are spaced from one another to align with the sockets  14  of the outlet  10 . Although a two socket wall plate  102  is shown, additional housings  110  and/or openings  112  can be provided for outlets having sockets in larger or smaller arrays. In another embodiment, the wall plate  102  can include two or more housings  110  in place of one or more of the openings  112 . 
     A power and/or data exchange assembly  114  of the system  100  includes an outlet connector  116  that projects rearwardly from the housing  110  through rear openings  118  to electrically couple with a socket  14  and an exchange device  120 . As shown, the outlet connector  116  can be prongs, but other suitable forms include USB connectors, fiber optic connectors, magnetic data exchange connectors, and so forth. In this form, the exchange device  120  is a cord that projects forwardly from the housing  110  through a front opening  122  to a connector  124  so that the system  100  provides a wired connection with the PED  50 . In some versions, the wall plate  102  can include a cord protection extension  126  that extends around a portion of the cord  120  adjacent to the housing  110 . The cord connector  124  can be adapted to be inserted into the port  54  of the PED  50  to thereby electrically couple the device  50  to the power supply from the outlet  10  to charge the power source  52 . This configuration allows data and/or energy to flow both to and from the PED  50  and the system  100 . The energy can be obtained and transferred by any suitable methods, including a grid power supply, solar energy, kinetic energy, and so forth. 
     According to other forms, the outlet connector  116  may be inter-connected by conventional male/female mechanical friction and/or by latch as is seen with, but not limited to, the CAT 5 connector type. Additionally or alternatively, the outlet connector  116  may be connected by proximity such as, but not limited to, magnetic coupling with data and/or power being transferred via mechanical, biological, chemical, optical, thermal, radio, radioactive and/or electrical transduction. 
     In some versions, cords  120  can be utilized that perform some of the same functions as traditional cords, but by different mechanical, biological, chemical, optical, thermal, radio, radioactive and/or electrical means. 
     The housing  110  can be sized to accommodate any circuitry and/or electrical components to transfer and/or condition the power and/or data from the outlet  10  to the cord  120  for powering, charging, and/or exchanging data with a PED  50 . In one version, the assembly  114  can include converter circuitry to convert an AC power supply to a DC output, such as a 120 VAC or 240 VAC to a 5 VDC output. For example, the assembly  114  can include a step down transformer, rectifying circuits, filter circuits, transduction circuits, and/or regulator circuits. In another version, the assembly  114  can include a switch mode power supply, including the various components thereof. For example, the assembly  114  can include an input rectifier and filter, an inverter with high frequency signal and switching devices, a power transformer, a transducer, an output rectifier and filter, and/or a feedback system and circuit control. In other versions, the assembly  114  can include a data and/or power transducer, a photovoltaic power supply, or a kinetic power supply. For example, the assembly  114  can include any suitable wind-up, spring, or centripetal energy mechanisms. Additionally, for any of the above versions, the system  100  can connect the PED  50  with a second electronic device, such as a second PED. With this connection, the second PED can share data and/or power with the PED  50 . For example, a kinetic or other power supply can supply power to the PED  50  through the system  100 . In one specific example, the system  100  can be utilized to electrically couple the PED  50  with a second PED, such as a smart watch or other energy generating device, and the second PED can provide charging power to the PED  50  through the system  100 . If desired, any excess power within the system  100  can be sold back to the power grid. 
     While the housing  110  is shown projecting forwardly a significant amount from the plate portion  104 , in other forms, the housing  110  can have a reduced depth with respect to the plate portion  104 , including having the same depth such that the housing  110  is planar with respect to an outer surface of the plate portion  104 , having twice the depth of the plate portion  104 , and so forth. 
     The system  100  can be formed using any suitable method. For example, the wall plate  102  can be formed over and around the components of the assembly  114 , including the prongs  116  and cord  120 , using an injection molding or 3D printing system. In another version, the wall plate  102  can be formed with the openings  118 ,  122  and a cavity in the housing  110  sized to receive components of the assembly  114  therein by any suitable method, including injection molding, 3D printing, blow molding, reductive assembly, and so forth. After the charging assembly is installed, the cavity can be closed off in a permanent manner with a housing piece by any suitable method, such as by adhesive, ultrasonic welding, and so forth. It will be understood that either method of formation can be utilized to create a system having an integral charging assembly. In other words, the housing can be integrally formed with the assembly  114  or can permanently receive the assembly  114  therein so that the components of the assembly  114  cannot be separated from the housing. 
     As shown in  FIGS. 1 and 2 , the housing  110  can further include a flange  128  that projects outwardly from all or portions of a sidewall  130  of the housing  110 , such as in a plane generally parallel with the plate portion  104 . In the illustrated form, the flange  128  projects from the sidewall  130  of the housing  110  aligned with a front surface  132  thereof. Of course, the flange  128  can be disposed at other depths of the housing  110 . The flange  128  can provide a convenient finger grip for a user to hold the wall plate  102 . Moreover, the flange  128  can advantageously include one or more slot openings  134  extending therethough and accessible through an edge  136  thereof. In the illustrated form, the flange  128  includes lateral portions extending from sides of the housing  110  and the slot openings  134  open laterally through the edges  136  of the flange  128 . The slot openings  134  can be sized to receive the cord  120  therein in a friction fit. So configured, the portions of the cord  120  extending from the wall plate  102  can be wrapped around the housing  110  and the flange  128  and the slot openings  134  can be utilized to retain the cord  120  in the wrapped configuration. 
     A wireless embodiment of a charging wall plate system  200  is shown in  FIGS. 3 and 4 . The system  200  includes a wall plate or outlet cover  202  having a generally planar plate portion  204  with, optionally, a beveled or tapered edge  206  as shown. The wall plate  202  is configured to be secured adjacent to an electrical outlet  10 , such as to structure of the outlet  10 , a junction box, a wall  12  extending around the outlet  10 , and so forth, by any suitable mechanism. For example, the wall plate  202  can be secured using one or more fasteners, having any desired drive type, such as square, hex, slotted, Phillips, Torx, spline, and the like, extending through an opening  208  in the plate portion  204 . Alternatively, the wall plate  202  can include snap fit, tongue-and-groove, plug, latch, magnetic, or threaded structure. 
     In the illustrated form, the wall plate  202  further includes a charging housing  210  and an opening  212  sized to extend around a socket  14  of the outlet  10 . The housing  210  and opening  212  are spaced from one another to align with the sockets  14  of the outlet  10 . Although a two socket wall plate  202  is shown, additional housings  210  and/or openings  212  can be provided for outlets having sockets in larger or smaller arrays. In another embodiment, the wall plate  202  can include two or more housings  210  in place of one or more openings  212 . 
     A wireless charging assembly  214  of the system  200  includes an outlet connector  216 , prongs in the illustrated embodiment, that projects rearwardly from the housing  210  through rear openings  218  to electrically couple with a socket  14  and a charging device  220 . In this form, the charging device  200  is a transmitter coil that extends within the housing  210  along a length thereof. If desired, the assembly  214  can include shielding to shield components of the assembly  214  and/or outlet  10 . 
     In a first form shown in  FIGS. 3 and 4 , the housing  210  can project forwardly, e.g., in a generally perpendicular orientation, from the plate portion  104 . With this configuration, the wall plate  102  can be secured to or around an outlet  10  and the housing  210  will extend horizontally from the outlet  10  presenting an upwardly facing charging surface  222  that a user can place a PED  50  on to exchange data with and/or charge the power source  52  thereof. Specifically, the user can position the device  50  on the charging surface  222  to align the coil  56  with the transmitter coil  220  to receive data and/or charging power therefrom. In another form as shown in  FIG. 5 , the housing  210  can project upwardly, e.g., generally parallel with or at a rearward angle with respect to, from the plate portion  104 . In this form, the wall plate  202  can further include a ledge or shelf  224  that projects outwardly from the housing  210 . With this configuration, a user can rest a PED  50  on the ledge  224  and the device  50  will extend along a forwardly facing charging surface  226  of the housing  210  to align with the transmitter coil  220  to exchange data and/or charge the power source  52  of the device  50 . Specifically, positioning the device  50  on the ledge  224  aligns the coil  56  with the transmitter coil  220  in the housing  210  to receive data and/or charging power therefrom. As shown, main surfaces  228  of the transmitter coil  220  extend generally parallel to the charging surface  222 ,  226  so positioning the PED  50  thereon aligns the coil  56  within the device  50  with the transmitter coil  220 . 
     The housing  210  can be sized to accommodate any circuitry and/or electrical components to transfer and/or condition the data and/or power from the outlet  10  to the transmitter coil  220  for data exchange, powering and/or charging a PED. Accordingly, while the housing  210  is shown having portions projecting forwardly from the plate portion  204 , in other forms, the housing  210  can have the same depth such that an outer surface of the housing  210  is planar with respect to an outer surface of the plate portion  204 . 
     The system  200  can be formed using any suitable method. For example, the wall plate  202  can be formed over and around the components of the charging assembly  214 , including the prongs  216 , using an injection molding or 3D printing system. In another version, the wall plate  202  can be formed with the openings  218  and a cavity in the housing  210  sized to receive components of the charging assembly  214  therein by any suitable method, including injection molding, 3D printing, blow molding, reductive assembly, and so forth. After the charging assembly is installed, the cavity can be closed off in a permanent manner with a housing piece by any suitable method, such as by adhesive, ultrasonic welding, and so forth. It will be understood that either method of formation can be utilized to create a system having an integral charging assembly. In other words, the housing can be integrally formed with the charging assembly  114  or can permanently receive the charging assembly  214  therein so that the components of the assembly  214  cannot be separated from the housing. 
     It will be appreciated that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions and/or relative positioning of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of various embodiments of the present invention. Also, common but well-understood elements that are useful or necessary in a commercially feasible embodiment are often not depicted in order to facilitate a less obstructed view of these various embodiments. The same reference numbers may be used to describe like or similar parts. Further, while several examples have been disclosed herein, any features from any examples may be combined with or replaced by other features from other examples. Moreover, while several examples have been disclosed herein, changes may be made to the disclosed examples within departing from the scope of the claims. 
     Those skilled in the art will recognize that a wide variety of modifications, alterations, and combinations can be made with respect to the above described embodiments without departing from the scope of the invention, and that such modifications, alterations, and combinations are to be viewed as being within the ambit of the inventive concept.