MODULAR WIRING SYSTEM WITH LOCKING ELEMENTS

• US 20080207046A1
• Filed: 02/29/2008
• Published: 08/28/2008
• Est. Priority Date: 10/27/2006
• Status: Active Grant

• Current Assignee: Leviton Manufacturing Company Incorporated
• Original Assignee: Leviton Manufacturing Company Incorporated
• Inventors: EDER, John, RAFFERTY, Christopher, LINDENSTRAUS, Leslie, ARENAS, Alfredo, TUFANO, Anthony, ODDSEN, Dennis
• Granted Patent: US 7,666,010 B2
• Time in Patent Office: Days
• US Class Current: 439/535
• CPC Class Codes: H01R 13/514 composed as a modular blocks or assembly, i.e. composed of co-operating parts provided with contact members or holding contact members between them
• CPC Class Codes: H01R 13/652 with earth pin, blade or socket
• 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: H01R 9/2491 Terminal blocks structurally associated with plugs or sockets
• CPC Class Codes: Y10T 29/49826 Assembling or joining

Abstract

A modular wiring system comprising a functional unit and a wiring unit. There is also a system for coupling the functional unit to the wiring unit in a rotational manner. This system can be formed from at least one locking prong comprised of electrically conductive material. When the functional unit is coupled to the wiring unit, the locking prong is both electrically and physically coupled to the functional unit at a first end and to the wiring unit at a second end. Alternatively, or in addition, the system for coupling the functional unit to the wiring unit in a rotational manner can include at least one flange coupled to the functional unit and at least one flange coupled to the wiring unit. These flanges operate such that when the functional unit and the wiring unit are coupled together, they are rotated to form a locking connection between the flange on the functional unit and the flange on the wiring unit.

Claims

1. A wiring connector unit for connection to a functional unit comprising:

a) a face;

b) a body coupled to said face; and

c) at least one flange coupled to said body, said flange disposed to rotatably lock said body to a functional unit.

2. The wiring connector device as in claim 1, wherein said face further comprises a plurality of openings wherein at least one of said plurality of openings has at least one receiving region and at least one locking region.

3. The wiring connector device as in claim 1, further comprising at least one removable cover coupled to said face.

4. The wiring connector device as in claim 3, wherein the removable cover is a protective label.

5. The wiring connector device as in claim 3, wherein the removable cover is a cap.

6. The wiring connector device as in claim 4, wherein the protective label has a write-on surface.

7. A wiring connector device comprising:

a) a face wherein said face has a plurality of openings wherein at least one of said plurality of openings has at least one receiving region and at least one locking region;

b) a body coupled to said face; and

c) a plurality of wire connectors disposed between said face and said body.

8. The wiring connector device as in claim 7, further comprising at least one removable cover coupled to said face.

9. The wiring connector device as in claim 8, wherein said at least one removable cover further comprises an adhesive disposed to couple said at least one removable cover to said face, and a tab disposed to allow a user to grip said at least one removable cover and then remove said at least one removable cover.

10. The wiring connector device as in claim 8, wherein said at least one removable cover further comprises a write-on surface.

11. A process for presenting a modular connector comprising:

a) presenting a modular wiring unit having a body and a face having a plurality of openings for receiving prongs and a locking flange;

b) presenting said modular wiring unit with a label attached to said body; and

c) presenting information on said label in the form of instructions for a user.

12. A method for coupling modular electrical components together comprising:

a) presenting a functional unit having a plurality of prongs;

b) presenting a wiring unit having a face adapted to receive said prongs;

c) inserting said prongs into openings of said face of said wiring unit; and

d) rotatably locking said prongs into said wiring unit to keep said functional unit and said wiring unit locked together.

13. A method for assembling a functional unit comprising:

a) positioning receptacle contacts between a front face member and a body;

b) inserting prongs into said body;

c) coupling said front face member, said body, and a strap together with clips mounted on one of said front face member and said body, wherein said clips snap into side flanges on the other of said front face member and said body; and

d) connecting a connector pin by threading said connection pin into a fastener.

14. A functional unit comprising:

a) a body section;

b) at least one connection bracket coupled to said body section; and

c) a plurality of prongs extending out from said body section, wherein the functional unit is connectable to a wiring unit via said at least one connection bracket.

15. The functional unit as in claim 14, wherein said plurality of prongs include at least one locking section.

16. The functional unit as in claim 15, wherein said at least one locking section is a bulb.

17. The functional unit as in claim 15, wherein said at least one locking section is in the form of an overhang.

18. The functional unit as in claim 17, wherein said plurality of prongs further comprise at least one catch coupled to a prong of said plurality of prongs and adjacent to said overhang.

19. The functional unit as in claim 14, wherein said functional unit has a functional element that is selected from the group consisting of:

a switch, a receptacle, a ground fault circuit interrupter, a dimmer, an occupancy sensor, a remote control, a home security control, and a surge protector.

20. A modular wiring system comprising:

a) a functional unit comprising;

i) a functional unit housing;

ii) at least one functional interface disposed within said housing;

iii) at least one connection element extending out from said housing;

b) a wiring unit comprising

i) a wiring unit housing having at least one opening; and

ii) at least one front face forming a connection interface for said at least one connection element wherein said wiring unit housing is smaller than said functional unit housing.

21. The modular wiring system as in claim 20, wherein said at least one connection element is in the form of an arcuate plate made from an electrically conductive material.

22. A modular wiring system comprising:

a) a functional unit;

b) a wiring unit; and

c) a system disposed to couple said functional unit to said wiring unit in a rotational manner, said system comprising a at least one connection element coupled to said functional unit and at least one connection element coupled to said wiring unit such that when said functional unit and said wiring unit are coupled together, they are disposed to be rotated to form a locking connection between said at least one connection element on said functional unit and said at least one connection element on said wiring unit.

23. The system as in claim 22, wherein said functional unit has a functional element that is selected from the group consisting of:

a switch, a receptacle, a ground fault circuit interrupter, a dimmer, an occupancy sensor, a remote control, a home security control, and a surge protector.

24. A modular wiring system comprising:

a) a functional unit;

b) a wiring unit; and

c) an adapter disposed to couple said wiring unit to said functional unit.

25. The modular wiring system as in claim 24, wherein said functional unit has a plurality of prongs and said adapter has a housing with a first face for receiving said plurality of prongs from said functional unit.

26. The modular wiring system as in claim 25, wherein said adapter housing has a second face which is adapted to couple to said wiring unit.

27. The modular wiring system as in claim 24, wherein said adapter has a first face;

a plurality of prongs extending from said first face, wherein said plurality of prongs are adapted to couple to said wiring unit, and a plurality of wires electrically connected to said plurality of prongs.

28. The modular wiring system as in claim 24, wherein said wiring unit has at least one flange, and wherein said adapter is adapted to couple to said wiring unit in a rotatable manner.

29. A process for coupling a wiring unit, a functional unit and an adapter together comprising:

a) coupling a wiring unit to a first face of an adapter; and

b) coupling a functional unit to a second face of said adapter.

30. The process as in claim 29, wherein said step of coupling said wiring unit to said adapter occurs before said step of coupling said functional unit to said adapter.

31. The process as in claim 29, wherein said step of coupling said wiring unit to said adapter occurs before said step of coupling said functional unit to said adapter.

32. The process as in claim 29, wherein said step of coupling said wiring unit to said adapter and said step of coupling said functional unit to said adapter occur substantially simultaneously.