Wiring device with heat removal system

Patent metadata

Field	Value
Publication number	US-10433455-B2
Application number	US-201615085060-A
Country	US
Kind code	B2
Filing date	Mar 30, 2016
Priority date	Mar 30, 2016
Publication date	Oct 1, 2019
Grant date	Oct 1, 2019

Abstract

A wiring device includes a housing that encloses a line voltage port and/or a low voltage port for providing power to at least one removable load. The housing has an intake opening and an exhaust opening for drawing cooling air into the housing and for exhausting heated air. A fan is disposed within the housing and operates to move the air through the housing. A thermal load such as a heat sink or a transformer is positioned within the housing and receives cooling air to reduce the temperature of the load. The fan is energized when a sensed temperature in the housing exceeds a first predetermined threshold. Power to the line and/or low voltage port is reduced or shut off if the sensed temperature in the housing exceeds a predetermined value that is greater than the first predetermined threshold.

First claim

What is claimed is:

1. An in-wall electrical outlet comprising:
a housing arranged and configured to be received within a single gang wall box located in a wall or ceiling, the housing including at least one of a line voltage port and a low voltage port for providing power to a removable load, the housing having an intake opening in a first surface thereof for directing cooling air into an internal portion of the housing, the housing having an exhaust opening in a second surface thereof for exhausting heated air from the internal portion of the housing,
a strap to fasten the housing to the single gang wall;
a fan disposed within the housing, the fan operable to draw the cooling air in through the intake opening and to exhaust the heated air through the exhaust opening;
a thermal load disposed within the housing, the thermal load positioned to receive the cooling air to reduce a temperature of the thermal load;
a temperature sensor for determining a sensed temperature of the internal portion of the housing;
a microcontroller logic circuit for energizing the fan based on the sensed temperature of the internal portion of the housing; and
a safety shut off to reduce or disconnect power to the low voltage port if the fan is determined to have failed;
wherein the microcontroller logic circuit energizes the fan when the sensed temperature of the internal portion of the housing is determined to exceed a first predetermined threshold; and
wherein the microcontroller logic circuit determines the fan has failed when the sensed temperature exceeds the first predetermined threshold by a predetermined value and controls the safety shut off to reduce or disconnect power to the low voltage port.

2. The electrical outlet of claim 1 , wherein energizing the fan comprises adjusting a speed of the fan.

3. The electrical outlet of claim 1 , wherein the microcontroller logic circuit is configured to de-energize the fan when the sensed temperature of the internal portion of the housing is determined to be below a second predetermined threshold, the second predetermined threshold being lower than the first predetermined threshold.

4. The electrical outlet of claim 3 , wherein the microcontroller logic circuit is configured to adjust a speed of the fan dependent upon the sensed temperature of the internal portion of the housing.

5. The electrical outlet of claim 1 , wherein a current to the at least one of a line voltage port and a low voltage port is reduced when the sensed temperature of the internal portion of the housing is determined to be above the first predetermined threshold.

6. The electrical outlet of claim 5 , wherein the microcontroller logic circuit is configured to vary a speed of the fan dependent upon the sensed temperature of the internal portion of the housing.

7. The electrical outlet of claim 5 , wherein the microcontroller logic circuit compares the sensed temperature of the internal portion of the housing to the first predetermined threshold and a second predetermined threshold and to command the fan to be energized or de-energized based on the comparison.

8. The electrical outlet of claim 1 , wherein the thermal load is at least one of a transformer and a heat sink.

9. The electrical outlet of claim 1 , wherein the intake opening and exhaust opening are disposed in a side surface of the housing.

10. The electrical outlet of claim 9 , wherein the intake opening is disposed in a rear cover portion of the housing and the exhaust opening is disposed in a front cover portion of the housing.

11. The electrical outlet of claim 1 , wherein the low voltage port is configured to provide one of: a predetermined amount of power to the removable load, an amount of power required by the removable load, and a level of power based on the removable load.

12. The electrical outlet of claim 1 further comprising a cover plate, wherein the in-wall electrical outlet is flush mounted within the electrical box and the cover plate is configured to conceal at least a portion of the strap and at least a portion of the housing.

13. The electrical outlet of claim 1 further comprising a fan control circuit coupled to the fan and microcontroller logic circuit, fan control circuit is a switching circuit configured to selectively energize the fan.

14. The electrical outlet of claim 1 , wherein the fan is positioned between the intake opening formed in the first surface of the housing and the exhaust opening formed in the second surface of the housing so that air moves through the housing in a desired manner to cool the thermal load disposed within the housing.

15. The electrical outlet of claim 1 , wherein the housing includes a front cover portion and a rear cover portion, the rear cover portion including the intake opening and the first surface, the front cover portion including the exhaust opening and the second surface, the fan being positioned in the rear cover portion.

16. The electrical outlet of claim 15 , wherein the fan is positioned adjacent to the thermal load disposed within the housing.

17. The electrical outlet of claim 16 , wherein the fan is arranged and configured to draw air in through the intake opening in the rear cover portion, the air moving across the thermal load and through the exhaust opening in the front cover portion.

18. The electrical outlet of claim 1 , wherein the intake opening and exhaust opening each comprise a plurality of louvers.

19. An in-wall electrical outlet comprising:
a housing enclosing a low-voltage electrical port for providing power to a removable load, the housing including a rear cover portion and a front cover portion coupled to the rear cover portion, an intake opening for directing cooling air into an internal portion of the housing, the intake opening being formed in one of the rear and front cover portions, the housing having an exhaust opening for exhausting heated air from the internal portion of the housing, the exhaust opening being formed in the other one of the rear and front cover portions;
a strap to fasten the housing to an electrical box located in a wall or ceiling;
a fan disposed within the rear cover portion of the housing, the fan operable to move air between the intake opening and the exhaust opening;
a temperature sensor for determining a sensed temperature of the internal portion of the housing;
a microcontroller logic circuit;
a thermal load disposed within the housing, the fan being positioned adjacent to the thermal load so that the thermal load receives the cooling air to reduce a temperature of the thermal load; and
a safety shut off to reduce or disconnect power to the low-voltage electrical port if the fan is determined to have failed;
wherein the microcontroller logic circuit:

energizes the fan when the sensed temperature of the internal portion of the housing is determined to exceed a first predetermined threshold;
de-energizes the fan when the sensed temperature of the internal portion of the housing is determined to be below a second predetermined threshold, the second predetermined threshold being lower than the first predetermined threshold; and
determines the fan has failed when the sensed temperature of the internal portion of the housing is determined to exceed a third predetermined threshold, the third predetermined threshold being greater than the first predetermined threshold, and controls the safety shut off to reduce or disconnect power to the low-voltage electrical port.

20. The electrical outlet of claim 19 , wherein the i

Assignees

• Leviton Manufacturing Co

Inventors

• Jansen Ronald
• Freeman Scott
• Kevelos Adam
• Ziegler Will
• Moadel Ben

Classifications

• H01R24/76

  with sockets, clips or analogous contacts and secured to apparatus or structure, e.g. to a wall · CPC title

• H01R2107/00

  Four or more poles · CPC title

• H05K7/20209

  Thermal management, e.g. fan control · CPC title

• H05K7/20136 Primary

  Forced ventilation, e.g. by fans (H05K7/202 takes precedence) · CPC title

• H01R2103/00

  Two poles · CPC title