Safety electrical outlet and switch system

• US 20020055301A1
• Filed: 12/17/2001
• Published: 05/09/2002
• Est. Priority Date: 01/05/2000
• Status: Abandoned Application

• Current Assignee: Michael P. Gorman
• Original Assignee: Michael P. Gorman
• Inventors: Gorman, Michael P.
• Application Number:
  US10/023,393
• Publication Number:
  US 20020055301A1
• Time in Patent Office: Days
• US Class Current: 439/535
• CPC Class Codes: H01R 13/652 with earth pin, blade or socket
• CPC Class Codes: H01R 13/70 with built-in switch
• CPC Class Codes: H01R 2103/00 Two poles
• CPC Class Codes: H01R 24/78 with additional earth or shield contacts
• CPC Class Codes: H01R 25/006 the coupling part being secured to apparatus or structure, e.g. duplex wall receptacle
• CPC Class Codes: Y10T 29/49128 Assembling formed circuit to base
• CPC Class Codes: Y10T 29/49169 Assembling electrical component directly to terminal or elongated conductor

Abstract

An electrical outlet and switch system allows snap-in installation and snap-out removal of outlet and switch modules without exposure to high-voltage conductors. The system includes an electrical box, a wiring panel, an outlet or switch module and a corresponding face plate. The wiring panel back side has attachment points for a power cable to be routed through a back portion of the electrical box. The wiring panel front side has a fixture configured to accept an outlet or switch module. The wiring panel physically isolates, yet electrically connects the attached power cable and the module. Module contacts provide electrical connection to the panel contacts. The panel fixture has protective structures that prevent inadvertent exposure to and short circuiting of the panel contacts.

The electrical box is configured for internal placement of the wiring panel, allowing electrical box wiring and verification and electrical system activation prior to wall panel construction. The installed wiring panel has a socket configured to accept a standard AC plug, providing a convenient electrical source prior to outlet module installation. The system also includes a shield configured to fit inside the electrical box and to conform to the wiring panel front side, protecting the electrical box and the installed wiring panel during the makeup phase of construction. After wall panels are installed, the modules can be snapped into the electrical box without the aid of a journeyman electrician. Should a module be damaged at a later date, a homeowner or layman can easily remove and replace the damaged module.

The electrical box has an associated box mount providing installation to studs during rough framing of a residential or commercial building. The box mount has a stud alignment guide for accurate placement of the electrical box on a wall stud. In conjunction with this stud alignment feature, the electrical box slides relative to the box mount and is removably locked in one of several fixed positions in order to locate the electrical box front face flush with the exterior surface of wall panels having various thicknesses.

Claims

12. A method of wiring an electrical box located within a wall panel to provide electrical service, said electrical box having a back face that receives a power cable and an open front face generally flush with an exterior wall panel surface, said method comprising the steps of:

fastening a generally planar wiring panel within said electrical box so as to partition the interior of said electrical box into a user inaccessible wiring compartment and a user accessible module compartment;

attaching said power cable to a cable connector within said wiring compartment;

snapping a module into a panel fixture portion of said wiring panel within said module compartment, said module providing a user operable electrical function; and

routing a conductive buss portion of said wiring panel between said cable connector and said panel fixture so as to provide electrical power to said module via said power cable.

13. The method of claim 12 wherein said snapping step comprises the substeps of:

providing a contact surface and an associated latch within said panel fixture;

providing a spring contact within a module fixture portion of said module;

coupling said module fixture and said panel fixture; and

pressing said module against said wiring panel until said spring contact engages said latch and connects with said contact surface.

securing with handles

14. The method of claim 12 further comprising the steps of:

placing an extractor handle in a closed position; and

securing said module to said electrical box utilizing a fastener retained by said handle.

15. The method of claim 13 further comprising the steps of:

placing an extractor handle in an open position;

gripping said extractor handle so as to apply a pulling force on said module directed away from said wiring panel until said spring contact disengages said latch; and

removing said module from said module compartment.

20. A method of wiring an electrical box during the rough framing phase of building construction, said method comprising the steps of:

attaching an electrical box to a wall stud, said electrical box having an open front face and a back face;

securing a wiring panel within said box, said panel located a recessed distance from said front face sufficient to avoid interfering with wall panel installation during the subsequent makeup phase of building construction, said wiring panel having a front side facing said front face and a back side facing said back face, said back face having a cable connector and said front face having a socket configured to accept a standard AC plug, said socket having contacts electrically connected to said cable connector;

routing a power cable through said back face and connecting said power cable to said cable connector; and

supplying electrical power to said power cable so that electrical service is available via said socket during the makeup phase.

21. The method of claim 20 further comprising the step of shielding said wiring panel with a protective cover generally conforming to said front face, said protective cover having a plug opening corresponding to said socket and configured to allow a standard AC plug to be inserted through said plug opening and into said socket.

22. The method of claim 20 wherein said attaching step comprises the substeps of:

attaching a box mount to a wall stud so that an alignment guide of said box mount matches a wall stud edge;

mounting said electrical box onto said box mount so that said electrical box slides relative to said box mount in a direction generally perpendicular to the wall stud;

locating a plurality of fixed positions for said electrical box along said box mount, each of said positions providing a specific distance between said front face and said alignment guide; and

releasably locking said box in one of said positions so as to accommodate the thickness of a wall panel installed on the wall stud.

23. The method of claim 22 further comprising the step of providing a plurality of position indicators on said box mount, a particular one of said positions associated with a particular one of said indicators, said particular one of said indicators visibly showing a specific distance from said alignment guide to said box front face for said particular one of said positions.

30. A method of installing an electrical box having an open front face, said method comprising the steps of:

attaching a box mount to a wall stud so that an alignment guide of said box mount matches a wall stud edge;

mounting said electrical box onto said box mount so that said electrical box slides relative to said box mount in a direction generally perpendicular to the wall stud;

locating a plurality of fixed positions for said electrical box along said box mount, each of said positions providing a specific distance between said front face and said alignment guide; and

latching said box in one of said positions so as to accommodate the thickness of a wall panel installed on the wall stud.

31. The method of claim 30 wherein said latching step comprises the substeps of:

measuring a specific distance from the exterior surface of said wall panel and the proximate edge of said wall stud;

releasing a latch portion of said box;

sliding said box to a position relative to said box mount where a position indicator corresponding to said specific distance is displayed; and

engaging said latch in a corresponding catch slot of said box mount so as to lock said box in a fixed position associated with said position indicator.