Patent ID: 12224565

While the disclosure is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the disclosure to the particular examples described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the disclosure.

DESCRIPTION

The following description should be read with reference to the drawings, in which like elements in different drawings are numbered in like fashion. The drawings, which are not necessarily to scale, depict examples that are not intended to limit the scope of the disclosure. Although examples are illustrated for the various elements, those skilled in the art will recognize that many of the examples provided have suitable alternatives that may be utilized.

All numbers are herein assumed to be modified by the term “about”, unless the content clearly dictates otherwise. The recitation of numerical ranges by endpoints includes all numbers subsumed within that range (e.g., 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.80, 4, and 5).

As used in this specification and the appended claims, the singular forms “a”, “an”, and “the” include the plural referents unless the content clearly dictates otherwise. As used in this specification and the appended claims, the term “or” is generally employed in its sense including “and/or” unless the content clearly dictates otherwise.

It is noted that references in the specification to “an embodiment”, “some embodiments”, “other embodiments”, etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is contemplated that the feature, structure, or characteristic is described in connection with an embodiment, it is contemplated that the feature, structure, or characteristic may be applied to other embodiments whether or not explicitly described unless clearly stated to the contrary.

FIG.1is a perspective view of an illustrative assembly10andFIG.2is an exploded view of the illustrative assembly10. As can be seen, the illustrative assembly10includes a DIN rail device12that is secured within an electrical junction box14. It will be appreciated that the DIN rail device12may be any sort of electrical device such as a switch, relay, or controller, for example, that is configured to be secured to a traditional DIN rail. As illustrated, the electrical junction box14is a double gang electrical junction box. In some cases, the electrical junction box14may be a triple gang electrical junction box or an even larger electrical junction box14. A double gang electrical junction box is an electrical junction box that is configured to accommodate two electrical components such as two light switches or two power receptacles. A triple gang electrical box, therefore, is an electrical junction box that is configured to accommodate three such electrical components. In some cases, the electrical junction box14may be a single gang electrical junction box.

As will be discussed with respect to subsequent drawings, an adaptor plate16is configured to be releasably secured to the DIN rail device12and to be releasably secured to the electrical junction box14. As a result, the adaptor plate16secures the DIN rail device12to the electrical junction box14without requiring any special adaptations to the electrical junction box14itself. While the illustrative assembly10shows a single adaptor plate16securing a DIN rail device12to the electrical junction box14, it will be appreciated that depending on how large the electrical junction box14is, it may be possible, for example, to secure a pair or more) of DIN rail devices12within a sufficiently large electrical junction box14, with an adaptor plate16secured to each of the DIN rail devices12.

The illustrative assembly10also includes a cover18that may be secured to the electrical junction box14and/or adaptor plate16to help prevent accidental contact with any electrical contacts/wires of the DIN rail device12. The cover18may also provide a more finished appearance to the illustrative assembly10. The illustrative cover18includes mounting apertures20through which fasteners22may extend in order to secure the cover18relative to the electrical junction box14and/or adaptor plate16. While illustrated as screws, the fasteners may also be bolts or any other threaded or non-threaded fastener. In some cases, the fasteners22extending through the mounting apertures20may extend through mounting features24that are formed within the adaptor plate16and may threadedly engage threaded apertures26that are formed within the electrical junction box14. It will be appreciated that the threaded apertures26may be considered as being configured to threadedly engage screws or other fasteners that could be used to secure traditional components such as a light switch or a receptacle within the electrical junction box14. In some cases, the cover18may be secured to the electrical junction box14and/or adaptor plate16via a snap fit, such as a latch, or other securement mechanism.

FIG.3is a rear perspective view of the DIN rail device12. The illustrative DIN rail device12includes a housing30with a rear surface32. As can be seen, a DIN rail mounting recess34is formed within the rear surface32of the housing30. In some instances, the DIN rail mounting recess34may be considered as being an elongate DIN rail mounting recess34. It will be appreciated that the DIN rail mounting recess34may be considered as being configured to permit the DIN rail device12to be secured in a traditional manner to a standard DIN rail. Accordingly, the DIN rail device12can include certain components that allow the DIN rail device12to be snapped onto a standard DIN rail.

In some cases, the DIN rail mounting recess34may be considered as being rectilinear, with a first side wall36on the left (in the illustrated orientation) side of the DIN rail mounting recess34and a second side wall38on the right side of the DIN rail mounting recess34. Along the first side wall36, the illustrative DIN rail mounting recess34includes a first stationary mounting latch40and a second stationary mounting latch42. In some cases, there may be only one stationary mounting latch, or there may be three or more stationary mounting latches. Along the second side wall38, the illustrative DIN rail mounting recess34includes a moveable mounting latch44. The moveable mounting latch44may be considered as being biased into its illustrated configuration, in which the moveable mounting latch44extends over the DIN rail mounting recess34. For example, a resilient spring may provide a biasing force to the moveable mounting latch44.

It will be appreciated that the stationary mounting latches40and42allow the DIN rail device12to be hooked over a top edge of a standard DIN rail and pivoted downward such that the moveable mounting latch44first moves back against its biasing and then returns to its biased configuration as the DIN rail device12is “snapped” into position on a standard DIN rail. As will be discussed, the stationary mounting latches40and42as well as the moveable mounting latch44allow the DIN rail device12to be secured to the illustrative adaptor plate16.

FIG.4is a perspective view of an illustrative assembly50that includes the adaptor plate16secured to the DIN rail device12, whileFIG.5shows the illustrative assembly50secured within the electrical junction box14.FIG.6is a front plan view of the illustrative adaptor plate16, showing the features that facilitate the adaptor plate16to be secured to both the DIN rail device12as well as the electrical junction box14. The adaptor plate16may be considered as including a front plate52that is configured to span across at least a portion of a front of the electrical junction box14. A DIN rail engagement portion54extends backward (in the illustrated orientation into the junction box14) from the front plate52. As will be shown, the DIN rail engagement portion54is configured to fit at least partially into the DIN rail mounting recess34of the DIN rail device12. The illustrative DIN rail engagement portion54includes a first side56, and a second side58that is spaced from the first side56. The second side58may be considered as being parallel to the first side56, for example. The first side56may be configured to extend lengthwise along the first side wall36of the DIN rail mounting recess34and the second side58may be configured to extend lengthwise along the second side wall38of the DIN rail mounting recess34.

A first mounting slot60may be seen as being disposed along the first side56of the DIN rail engagement portion54. The first mounting slot60may be configured to accommodate a first mounting latch (such as but not limited to the stationary mounting latch40). A second mounting slot62may be seen as being disposed along the second side58of the DIN rail engagement portion54. The second mounting slot62may be configured to accommodate a second mounting latch (such as but not limited to the moveable mounting latch44). In some cases, a third mounting slot64may be disposed along the first side56of the DIN rail engagement portion54, and may be spaced from the first mounting slot60. The third mounting slot64may be configured to accommodate a third mounting latch (such as but not limited to the stationary mounting latch42). In some cases, there may only be a single mounting slot on each side56,58of the DIN rail engagement portion54. The mounting slots60,62,64may each be elongated slots that extend lengthwise relative to the DIN rail mounting recess34, for example. With reference toFIG.4, the stationary mounting latch40may be seen extending into the first mounting slot60and the stationary mounting latch42may be seen extending into the second mounting slot62.

While the DIN rail engagement portion54shown in the Figures is elongated in the vertical direction with respect to the electrical junction box14, it is contemplated that the DIN rail engagement portion54may extend in the horizontal direction relative to the electrical junction box14and may be configured to accommodate a DIN rail device12that has a DIN rail mounting recess34that also extends in the horizontal direction. When so configured, the3or4gang electrical junction box may be used to secure a larger DIN rail device12(larger controller) that has a width dimension that spans3or4gangs.

The illustrative front plate52includes mounting features24. In some cases, the mounting features24may be elongated slots that are aligned at an acute angle relative to either the first side56or the second side58of the DIN rail engagement portion54. In a particular case, as illustrated, the mounting features may be elongated slots that are disposed at an angle of about 45 degrees relative to either the first side56or the second side58of the DIN rail engagement portion54. This is illustrated inFIG.6, in which an angle α (alpha) is clearly labeled.

FIG.7is a left side view of the illustrative adaptor plate16, andFIG.8is a right side view of the illustrative adaptor plate16.FIG.7clearly shows the mounting slots60and64formed within the first side56andFIG.8clearly shows the mounting slot62formed within the second side58.FIG.9is a cross-sectional view taken along the line9-9ofFIG.6. The illustrative adaptor plate16includes a feature70that extends from the first side56of the DIN rail engagement portion54to the second side58of the DIN rail engagement portion54. In some cases, the feature70may provide additional strength to the adaptor plate16. The feature70may not be needed in all cases.

FIG.10is a schematic cross-sectional view of an illustrative adaptor plate116that is similar to the adaptor plate16, but does not include the feature70. In this example, the mounting slots (not visible in this orientation) may be formed within the first and second side walls156,158. The first and second side walls156,158may be considered as extending perpendicular to a front plate152of the adaptor plate116.

FIG.11is a schematic enlarged cross-sectional view of an illustrative DIN rail engagement portion254that extends back from a front plate252. A first side wall256includes a first linear portion260and a first C-shaped portion262. Similarly, a second side wall258includes a second linear portion270and a second C-shaped portion272. A mounting latch such as but not limited to the stationary mounting latches40or42may fit under the first C-shaped portion262and engage first linear portion260, while a mounting latch such as but not limited to the moveable mounting latch44may fit under the second C-shaped portion272and engage second linear portion270. In some cases, the DIN rail engagement portion254may include a feature280that extends between the first linear portion260and the second linear portion270, but this is not required. In some cases, the DIN rail engagement portion254may include a feature282that extends between the first C-shaped portion262and the second C-shaped portion272, but this is not required. When so provided, some or all of the mounting slots, such as mounting slots60,62and64, may not be needed or desired.

ADDITIONAL EMBODIMENTS

An example of the disclosure is an adaptor plate for securing a DIN rail device inside of an electrical junction box. The adaptor plate is securable to a front of the electrical junction box with the DIN rail device disposed within the electrical junction box and includes a front plate that is configured to span across at least a portion of a front of the electrical junction box, the front plate including one or more adaptor plate mounting features located relative to the front plate such that the one or more adaptor plate mounting features align with corresponding mounting features on the electrical junction box. A DIN rail engagement portion extends backward from the front plate and is configured to fit at least partially into an elongated DIN rail mounting recess of a DIN rail device, the DIN rail engagement portion having a first side spaced from a second side, wherein the first side is configured to extend lengthwise along a first side of the DIN rail mounting recess of the DIN rail device, and wherein the second side is configured to extend lengthwise along a second side of the DIN rail mounting recess of the DIN rail device. A first mounting slot is disposed within the first side of the DIN rail engagement portion for receiving a first mounting latch of the DIN rail device that extends into the DIN rail mounting recess from the first side of the DIN rail mounting recess. A second mounting slot is disposed within the second side of the DIN rail engagement portion for receiving a second mounting latch of the DIN rail device that extends into the DIN rail mounting recess from the second side of the DIN rail mounting recess.

Alternatively or additionally, the adaptor plate may further include a third mounting slot disposed within the first side of the DIN rail engagement portion for receiving a third mounting latch of the DIN rail device that extends into the DIN rail mounting recess from the first side of the DIN rail mounting recess.

Alternatively or additionally, the first mounting slot and the second mounting slot may be elongated slots extending lengthwise relative to the DIN rail mounting recess.

Alternatively or additionally, the adaptor plate mounting features may include elongated slots.

Alternatively or additionally, the adaptor plate mounting features may include elongated slots that extends at an acute angle relative to either the first side and the second side of the DIN rail engagement portion.

Alternatively or additionally, the adaptor plate mounting features may include elongated slots that are disposed at an angle of about 45 degrees relative to either the first side and the second side of the DIN rail engagement portion.

Alternatively or additionally, the adaptor plate may be configured to be secured to a double gang electrical junction box.

Alternatively or additionally, the adaptor plate may be configured to be secured to a triple gang or larger electrical junction box.

Alternatively or additionally, the first side of the DIN rail engagement portion may include a first side wall extending perpendicular to the front plate, and the first mounting slot may be formed in the first side wall.

Alternatively or additionally, the second side of the DIN rail engagement portion may include a second side wall extending perpendicular to the front plate and parallel to the first side wall, and the second mounting slot may be formed in the second side wall.

Another example of the disclosure is an assembly that includes an adaptor plate as described herein for securing a DIN rail device inside of an electrical junction box and a cover plate configured to extend over the adaptor plate and to be secured relative to the electrical junction box.

Another example of the disclosure is an assembly for mounting a DIN rail device relative to an electrical junction box. The assembly includes a DIN rail device that is configured to fit within the electrical junction box and an adaptor plate. The DIN rail device includes a housing that includes a rear portion and a recess formed within the rear portion of the housing and configured for securement to a DIN rail, the recess including a stationary mounting latch and a movable mounting latch, the movable mounting latch positioned across the recess and offset from the stationary mounting latch. The adaptor plate includes a front plate that is configured to span across at least a portion of a front of the electrical junction box, the front plate including one or more adaptor plate mounting features located relative to the front plate such that the one or more adaptor plate mounting features align with corresponding mounting features of the electrical junction box. The adaptor plate also includes a DIN rail engagement portion extending backward from the front plate and configured to fit into the recess of the DIN rail device, the DIN rail engagement portion including a first mounting slot for receiving at least part of the stationary mounting latch and a second mounting slot for receiving at least part of the movable mounting latch.

Alternatively or additionally, the DIN rail engagement portion may have a rectilinear profile with at least a first long side and a second long side, with the first mounting slot is disposed within the first long side and the second mounting slot is disposed within the second long side.

Alternatively or additionally, the adaptor plate mounting features within the front plate may include elongated slots that are disposed at an acute angle relative to either the first long side or the second long side of the DIN rail engagement portion.

Alternatively or additionally, the first long side of the DIN rail engagement portion may include a first side wall perpendicular to the front plate, and the first mounting slot may be formed within the first side wall.

Alternatively or additionally, the second long side of the DIN rail engagement portion may include a second side wall perpendicular to the front plate, and the second mounting slot may be formed within the second side wall.

Alternatively or additionally, the assembly may further include a cover plate that is configured to extend over the adaptor plate and to be secured relative to the electrical junction box.

Alternatively or additionally, the stationary mounting latch and the movable mounting latch of the DIN rail device may be configured to extend into the first mounting slot and the second mounting slot, respectively, of the DIN rail engagement portion of the adaptor plate to form a sub-assembly.

Alternatively or additionally, the sub-assembly may be configured to be mounted in the electrical junction box by securing fasteners through the adaptor plate mounting features.

Another example of the disclosure is a method of securing a DIN rail device having an elongated DIN rail mounting recess within an electrical junction box. An adaptor plate is provides that includes a front plate configured to span across at least a portion of a front of the electrical junction box, the front plate including one or more adaptor plate mounting features located relative to the front plate such that the one or more adaptor plate mounting features align with corresponding mounting features on the electrical junction box. The adaptor plate also includes a DIN rail engagement portion extending backward from the front plate and configured to fit at least partially into the elongated DIN rail mounting recess of the DIN rail device, the DIN rail engagement portion having a first side spaced from a second side, wherein the first side is configured to extend lengthwise along a first side of the DIN rail mounting recess of the DIN rail device, and wherein the second side is configured to extend lengthwise along a second side of the DIN rail mounting recess of the DIN rail device. A first mounting slot is disposed within the first side of the DIN rail engagement portion for receiving a first mounting latch of the DIN rail device that extends into the DIN rail mounting recess from the first side of the DIN rail mounting recess. A second mounting slot is disposed within the second side of the DIN rail engagement portion for receiving a second mounting latch of the DIN rail device that extends into the DIN rail mounting recess from the second side of the DIN rail mounting recess. The first mounting latch and the second mounting latch of the DIN rail device are placed in the first mounting slot and the second mounting slot, respectively, of the DIN rail engagement portion of the adaptor plate to form a sub-assembly and the sub-assembly is secured to the electrical junction box by extending fasteners through the one or more adaptor plate mounting features.

Having thus described several illustrative embodiments of the present disclosure, those of skill in the art will readily appreciate that yet other embodiments may be made and used within the scope of the claims hereto attached. It will be understood, however, that this disclosure is, in many respects, only illustrative. Changes may be made in details, particularly in matters of shape, size, arrangement of parts, and exclusion and order of steps, without exceeding the scope of the disclosure. The disclosure's scope is, of course, defined in the language in which the appended claims are expressed.