Wire form rail adapter

A rail adapter for connecting an electrical component to a mounting rail having two spaced elongate mounting flanges on either side of an elongate middle portion, the rail adapter comprising:

• a back plate comprising:
• a component mounting feature configured to co-act with a mounting feature on the electrical component to fix the electrical component to the back plate;
• a fixed rail mounting feature configured to engage a first of the two mounting flanges to connect the first mounting flange to the back plate;
• a wire spring clip moveably retained in the one or more spring clip mounting features and configured to be moved relative to the back plate between an engagement position in which the wire spring clip captures a second of the two mounting flanges between the wire spring clip and the back plate and a release position in which the wire spring clip is released from the second mounting flange, the wire spring clip comprising a continuous length of wire shaped to form:
• an extension portion formed by two substantially linear portions of the wire disposed parallel to one another and connected to one another at a distal end by a connecting portion of the wire;
• a spring clip body formed by two substantially linear body portions of the wire each connected at a first distal end to the extension portion, each body portion being disposed such that the body portion angles away from the other body portion;
• two U-shaped ears each having two legs, each U-shaped ear being connected at a first leg to one of the body portions and configured to overlay the second mounting flange and capture the second mounting flange against the back plate when the wire spring clip is in the engagement position;
• and
• a flat spring formed by the wire spanning between second legs of each U-shaped ear, the flat spring comprising a portion of the length of wire having a relaxed shape configured to co-act with the spring stop to urge the wire spring clip toward the engagement position;
• and
• where the back plate further comprises:
• an ear guide that defines an opening through which the ear protrudes, the ear guide constraining movement of the ear away from the back plate and sized to guide the ear into contact with a second of the two mounting flanges when the wire spring clip is in the engagement position, the ear guide comprising a bent flange formed by bending a cut portion of the back plate to a substantially perpendicular position with respect to a remainder of the back plate;
• and
• a spring stop comprising a bent finger formed by bending a cut-out portion of the back plate such that the finger protrudes substantially perpendicular to a remainder of the back plate and curls over at a distal end to surround a portion of the flat spring about a diameter of the wire.

A method that connects an electrical component to a mounting rail having two spaced elongate mounting flanges on either side of an elongate middle portion, the method comprising:

• connecting the electrical component to a back plate;
• fixing a first of the two mounting flanges to a fixed rail mounting feature on the back plate;
• applying a force to a wire spring clip that is moveably retained on the back plate, the wire spring clip comprising:
• a length of wire shaped to form a connection portion configured to capture the second mounting flange against the back plate when the wire spring clip is in an engagement position, and
• a flat spring formed by a portion of the length of wire and configured to flex against one or more spring stop features and to provide a biasing force that urges the wire spring clip towards the engagement position;
• the force being sufficient to overcome the urging of the flat spring toward the engagement position and to move the wire spring clip to a release position such that the connection portion is not positioned to capture the second of the two mounting flanges;
• placing the second mounting flange against the back plate;
• and
• releasing the force on the wire spring clip so that the biasing force of the flat spring moves the wire spring clip to the engagement position such that the connection portion captures the second mounting flange against the back plate.

A rail adapter apparatus that connects an electrical component to a mounting rail having two spaced elongate mounting flanges on either side of an elongate middle portion, the method comprising:

• a backing means that provides a mounting means for the electrical component, a fixed mounting means for fixing a first of the two mounting flanges to the backing means, and one or more clip retaining means;
• and
• a moveable clip means moveably attached to the backing means with the clip retaining means, the clip means configured to be moved between an engagement position in which the clip means engages and fixes a second of the two mounting flanges to the backing means and a release position in which the clip means is released from the second mounting flange;
• the clip means comprising a rail engaging means configured to overlay and capture the second mounting flange against the backing means and a biasing means that provides a biasing force that urges the clip means to the engagement position.