Modular electrical distribution system for a building

• US 20090130879A1
• Filed: 08/11/2008
• Published: 05/21/2009
• Est. Priority Date: 08/09/2007
• Status: Active Grant

• Current Assignee: Haworth Incorporated
• Original Assignee: Haworth Incorporated
• Inventors: Johnson, Ross, Wilson, Harold
• Granted Patent: US 7,841,878 B2
• Time in Patent Office: Days
• US Class Current: 439/215
• CPC Class Codes: H01R 25/006 the coupling part being secured to apparatus or structure, e.g. duplex wall receptacle
• CPC Class Codes: H01R 25/16 Rails or bus-bars provided with a plurality of discrete connecting locations for counterparts
• CPC Class Codes: H02G 3/00 Installations of electric cables or lines or protective tubing therefor in or on buildings, equivalent structures or vehicles installations of bus-bars H02G5/00; overhead installations H02G7/00; installations in or on the ground H02G9/00
• CPC Class Codes: H02G 3/38 the cables or lines being installed in preestablished conduits or ducts

Abstract

A universal power distribution system is provided for routing electrical circuits within a building structure to comprehensively provide electrical power to the building in ceiling configurations, wall-mounted configurations, raised floor configurations and in office furniture configurations. The system components for all of these configurations have common plug connectors that are engagable with each other so as to be readily usable in a wide variety of applications. The system is readily adaptable to form virtually any conventional circuit configuration found within conventional hard-wired systems yet is formed simply through the routing of the cables through the building cavities and interconnection is accomplished merely by plugging components together rather than through labor-intensive manual wiring.

Claims

1. A modular power distribution system for distributing power to a building structure comprising a plurality of removably engagable system components which carry electrical power through each said system component for supplying power throughout said building structure, each of said system components being provided with at least one plug connector wherein said plug connectors of said system components have a common plug section with common electrical contacts therein for completing an electrical connection between two mated plug sections by mating engagement of said plug sections and said respective electrical contacts together, said plug sections having slotted ends defined by longitudinally projecting portions separating alignment slots which said projecting portions and alignment slots in a first said system component are oriented oppositely to said respective projecting portions and alignment slots of a second said system component so as to be engagable together in plugging engagement with said contacts being accessible through the mating engagement of said projecting portions and alignment slots, said plug sections including contact receiving slots which each receive a said contact therein wherein said contacts are disposed in said projecting portions but partially project into said alignment slots so as to contact said contacts of a said system component being mated therewith, said contacts being formed planar in a contact plane substantially within the thickness of a sheet of contact material and being received in tight fitting engagement with a respective one of said contact-receiving slots.

2. The power distribution system according to claim 1, wherein said contact-receiving slots are oriented transverse to said alignment slots.

3. The power distribution system according to claim 2, wherein each adjacent pair of said contact-receiving slots are separated by a thin wall of insulative material wherein opposite sides of said wall define respective interior faces of said contact-receiving slots.

4. The power distribution system according to claim 3, wherein each said contact-receiving slot closely confines opposite faces of said contact disposed therein.

5. The power distribution system according to claim 4, wherein each said contact has a first contact member lying in said contact plane and a movable second contact member which is movable in said contact plane to separate and grippingly receive a mated one of said contacts in gripping engagement between said first and second contact members.

6. The power distribution system according to claim 5, wherein said movable second contact member is resiliently deflectable to permit said movement thereof and effect gripping of said mated contact.

7. The power distribution system according to claim 1, wherein each said contact-receiving slot closely confines opposite faces of said contact disposed therein.

8. The power distribution system according to claim 7, wherein each said contact has a first contact member lying in said contact plane and a movable second contact member which is movable in said contact plane to separate and grippingly receive a mated one of said contacts in gripping engagement between said first and second contact members, said movable second contact member being resiliently deflectable to permit said movement thereof and effect gripping of said mated contact.

9. A modular power distribution system for distributing power to a building structure comprising a plurality of removably engagable system components which carry electrical power through each said system component for supplying power throughout said building structure, each of said system components being provided with at least one plug connector wherein said plug connectors of said system components have a common plug section with common electrical contacts therein for completing an electrical connection between two mated plug sections by mating engagement of said plug sections and said respective electrical contacts together, said plug sections having slotted ends defined by axially projecting portions which define alignment slots therebetween so as to be engagable together in plugging engagement with said contacts being accessible through the mating engagement of said projecting portions and said alignment slots of mating said plug sections, said plug sections each including a stack of spaced contact receiving slots oriented transverse to said alignment slots which each receive a said contact therein wherein said contacts are disposed in said projecting portions but partially project transversely into said alignment slots so as to transversely contact said contacts of a said wiring unit being mated therewith, said contacts being formed planar in a contact plane substantially within the thickness of a sheet of contact material and being received in tight fitting engagement with a respective one of said contact-receiving slots, each said contact-receiving slot closely confining opposite faces of said contact disposed therein with each adjacent pair of said contact-receiving slots being separated by a common thin wall of insulative material to reduce the dimension of said plug portion along said slot.

10. The power distribution system according to claim 9, wherein opposite sides of said wall define respective interior faces of said adjacent pair of said contact-receiving slots.

11. The power distribution system according to claim 9, wherein each said contact has a first contact member lying in said contact plane and a movable second contact member which is movable in said contact plane to separate and grippingly receive a mated one of said contacts in gripping engagement between said first and second contact members within said contact plane.

12. The power distribution system according to claim 11, wherein said movable second contact member is resiliently deflectable within said contact plane to permit said movement thereof and effect gripping of said mated contact.

13. The power distribution system according to claim 12, wherein said plug connector comprises an insulative contact block having a plurality of said contact receiving slots therein in parallel, spaced relation wherein each adjacent pair of said contact-receiving slots is separated by said thin wall of insulative material and opposite sides of said wall define respective interior faces of said adjacent pair of said contact-receiving slots.

14. The power distribution system according to claim 13, wherein said contact-receiving slots are open at opposite ends with said contacts being received through a slotted block section opposite said plug section so that said contacts extend through said contact block to said plug section.

15. A plug connector for system components of a modular power distribution system for distributing power to a building structure which said plug connector is engagable with other said plug connectors of other system components which carry electrical power throughout said building structure, said plug connectors of said system components have a common plug section with common electrical contacts therein for completing an electrical connection between two mated plug sections by mating engagement of said plug sections and said respective electrical contacts together, said plug sections having slotted ends so as to be engagable together in plugging engagement with said contacts being accessible through the mating engagement of said projecting portions and alignment slots, said plug sections including contact receiving slots oriented transverse to said alignment slots which each receive a said contact therein wherein said contacts are disposed in said projecting portions but have edgewise contact edges with side-facing edge faces which partially project into said alignment slots so as to contact the opposing edge faces of said contacts of a said plug connector being mated therewith, said contacts being formed planar in a contact plane substantially within the thickness of a sheet of contact material and being received in tight fitting engagement with a respective one of said contact-receiving slots, each said contact-receiving slot closely confining opposite faces of said contact disposed therein such that said contacts have said opposing edge faces in contact together in the contact plane to reduce the dimension of plug connector in a connector dimension transverse to said contact plane.

16. The plug connector according to claim 15, wherein said plug connector comprises an insulative contact block having a plurality of said contact receiving slots therein in parallel, spaced relation wherein each adjacent pair of said contact-receiving slots is separated by a thin wall of insulative material and opposite sides of said wall define respective interior faces of said adjacent pair of said contact-receiving slots.

17. The plug connector according to claim 16, wherein said contact-receiving slots are open at opposite ends with said contacts being received through a slotted block section opposite said plug section so that said contacts extend through said contact block to said plug section.

18. The plug connector according to claim 15, wherein each said contact has a first contact member lying in said contact plane and a movable second contact member which is movable in said contact plane to separate and grippingly receive a mated one of said contacts in gripping engagement between said first and second contact members within said contact plane.

19. The plug connector according to claim 18, wherein said movable second contact member is resiliently deflectable within said contact plane to permit said movement thereof and effect gripping of said mated contact.

20. In a plug connector for system components of a modular power distribution system for distributing power to a building structure which said plug connector is engagable with other said plug connectors of other system components which carry electrical power throughout said building structure, said plug connectors of said system components have a plug section with electrical contacts therein for completing an electrical connection between two mated plug sections by mating engagement of said plug sections and said respective electrical contacts together, said plug sections comprising insulative terminal blocks formed of an insulative material which includes contact receiving slots which each have a slot mouth that opens end-wise in an end direction and extends sidewardly across said terminal block and each are configured to receive a said contact therein wherein said contacts are positioned to contact said contacts of a said plug connector being mated therewith, comprising the improvement wherein said contact receiving slots are configured as flat slots configured to receive contacts formed as a planar blade so as to be formed in a contact plane substantially within the thickness of a sheet of contact material, each said contact-receiving slot having opposed, spaced apart, planar slot surfaces which are configured to closely confine opposite faces of said contact when disposed therein, said terminal block having elongate end slots which are recessed end-wise into said terminal block to define side-ward opening mouth portions of said contact receiving slot to provide access to a said contact disposed in said contact receiving slot by another said contact of another said plug section.

21. The plug connector according to claim 20, wherein said insulative terminal block has a plurality of said contact receiving slots therein in parallel, spaced relation wherein each adjacent pair of said contact-receiving slots is separated by a single, thin wall of insulative material and opposite sides of said wall define the respective interior slot surfaces of said adjacent pair of said contact receiving slots.

22. The plug connector according to claim 21, wherein said contact-receiving slots are open at opposite ends with said contacts being received through a slotted block section opposite slot mouth of said plug section so that said contacts extend through said contact block to said plug section.

23. The plug connector according to claim 20, wherein said plug connector includes said contacts mounted in said terminal bloc, and each said contact has a first contact member lying in said contact plane and a movable second contact member which is movable in said contact plane to separate and grippingly receive a mated one of said contacts in gripping engagement between said first and second contact members within said contact plane.

24. The plug connector according to claim 23, wherein said movable second contact member is resiliently deflectable within said contact plane to permit said movement thereof and effect gripping of said mated contact.

25. A plug connector for system components of a modular power distribution system for distributing power to a building structure which said plug connector is engagable with other said plug connectors of other system components which carry electrical power throughout said building structure, said plug connectors of said system components have a plug section with electrical contacts therein for completing an electrical connection between two mated plug sections by mating engagement of said plug sections and said respective electrical contacts together, said plug sections including contact receiving slots which each receive a said contact therein wherein said contacts contact said contacts of a said plug connector being mated therewith, said contacts being formed planar in a contact plane substantially within the thickness of a sheet of contact material and being received in tight fitting engagement with a respective one of said contact-receiving slots, each said contact-receiving slot closely confining opposite faces of said contact disposed therein, each said contact having a first contact member lying in said contact plane and a movable second contact member which is movable in said contact plane to separate and grippingly receive a mated one of said contacts in gripping engagement between said first and second contact members within said contact plane.

26. The plug connector according to claim 25, wherein said movable second contact member is resiliently deflectable within said contact plane to permit said movement thereof and effect gripping of said mated contact.

27. The plug connector according to claim 25, wherein said plug connector includes two said plug sections disposed in side-by-side relation and each provided with respective said contacts wherein each sidewardly adjacent pair of said contacts are joined together by a conductive web joined therebetween to define a terminal comprising said pair of said contacts and said respective web.

28. An electrical contact for plug connectors of an electrical system distributing power to a building structure, said contact being configured for engagement within an insulative terminal block, said contacts being formed as a planar blade in a contact plane substantially within the thickness of a sheet of conductive contact material, said contact having an end body defining a connector surface to which a conductor is connectable, said contact further including elongate first and second contact members projecting forwardly from said end body and being sidewardly spaced apart to define a contact-engaging gap therebetween, said gap opening forwardly from between said first and second contact members, and said first and second contact members lying in said contact plane and defining edge faces which face sidewardly into said gap in opposing relation with each other to receive a contact portion of a further said contact therebetween, said contact being deformable within said contact plane to permit limited separation and gripping receipt of said further contact within said gap between said edge faces.

29. The electrical contact according to claim 28, wherein said gap is configured to receive the first contact member of said further contact therebetween, said first contact member having a sideward dimension greater then the sideward dimension of said gap defined between said edge faces.

30. The electrical contact according to claim 28, wherein said contact is slotted proximate said gap to facilitate deformation of said second contact member.

31. The electrical contact according to claim 30, wherein said flex facilitating structure comprises a slot formed in said end body.

32. A plug connector for system components of a modular power distribution system for distributing power to a building structure which said plug connector is engagable with other said plug connectors of other system components which carry electrical power throughout said building structure, said plug connectors of said system components have a common plug section with common electrical contacts therein for completing an electrical connection between two mated plug sections by mating engagement of said plug sections and said respective electrical contacts together when said plug sections are in oppositely opposed orientations, said plug connector and said contacts thereof being configurable to carry a plurality of voltage levels of line power;

said plug connector including a settable keying feature which sets said plug connector in one of a plurality of keying conditions to structurally limit connection of said plug connector to only a further plug connector which is keyed to a like keying condition, said plurality of keying conditions corresponding to a respective plurality of voltage levels wherein setting of said keying feature to a selected keying condition restricts use of said plug connector to the voltage level corresponding thereto;

said keying feature comprising a rotatable key which includes first connector parts engaged to said plug section to permit rotation of said rotatable key while preventing removal thereof from said plug section, alignment parts which prevent rotation of said key upon displacement of said key into said plug section from a rotatable adjustment position to a non-rotatable fixed position, said alignment parts defining a plurality of key orientations which define said plurality of keying conditions corresponding to said voltage levels, and a non-disengagable lock structure which locks said key in said fixed position upon displacement to said fixed position to prevent subsequent resetting of said key condition.

33. The plug connector according to claim 32, wherein said

plug connector comprises a bore, a first set of catches at a first bore depth, and a second set of catches at a deeper second bore depth, said keying feature comprising an elongate key member having stops at an inner end which progressively engage said first catches which prevent removal of said key member from said bore while permitting rotation, and said second catches upon seating of said key member to the fixed position, said second catches preventing removal and resetting of said key member.

34. The plug connector according to claim 33, wherein said first and second catches are defined respectively on free ends of first and second resilient support arms.

35. A modular power distribution system for distributing power to a building structure comprising:

a plurality of removably engagable system components which carry electrical power through each said system component for supplying power throughout said building structure, each of said system components being provided with at least one plug connector wherein said plug connectors of said system components have a common plug section with common electrical contacts therein for completing an electrical connection between two mated plug sections by mating engagement of said plug sections and said respective electrical contacts together;

said plug sections having slotted ends defined by longitudinally projecting portions separating alignment slots which said projecting portions and alignment slots in a first said system component are oriented oppositely to said respective projecting portions and alignment slots of a second said system component so as to be engagable together in plugging engagement with said contacts being accessible through the mating engagement of said projecting portions and alignment slots, said plug sections including contact receiving slots which each receive a said contact therein wherein said contacts are disposed in said projecting portions but partially project into said alignment slots so as to contact said contacts of a said system component being mated therewith, said contacts being formed planar in a contact plane substantially within the thickness of a sheet of contact material and being received in tight fitting engagement with a respective one of said contact-receiving slots;

said system components comprising;

power distribution assemblies mountable in raceways of office furniture components installed within an interior of said building structure, said power distribution assemblies comprising an elongate main body having elongate main conductors extending longitudinally therethrough, said power distribution assemblies further including end ones of said plug connectors at each opposite end thereof for serial connection to additional system components, and side ones of said plug connectors which are disposed intermediate the opposite ends of the power distribution assembly for the connection of receptacles thereto; and

receptacles connectable to said power distribution assemblies for supplying power outlets within said building structure, each said receptacle including a further one of said connector plugs for connecting the receptacle to a respective one of said side plug connectors.

36. The power distribution system according to claim 35, wherein said main body includes a casing and elongate conductive conductor straps extending therethrough, said conductor straps including side terminals which project sidewardly from said casing into said side connector plug for supplying power thereto, and end terminals at opposite strap ends which electrically connect to said contacts of said end connector plugs.