Modular electrical distribution system for a building

• US 20100328852A1
• Filed: 04/09/2010
• Published: 12/30/2010
• Est. Priority Date: 08/09/2007
• Status: Active Grant

• Current Assignee: Haworth Incorporated
• Original Assignee: Haworth Incorporated
• Inventors: Johnson, Ross, Gingrich, Bryan, Wilson, Harold R.
• Granted Patent: US 8,172,588 B2
• Time in Patent Office: Days
• US Class Current: 361/641
• 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 building power wiring system comprising:

elongate cables having opposite A-ends and B-ends wherein each said cable includes a single A-end connector on said A-end of said cable and at least two B-end connectors on the opposite B-end thereof, said cables having mating structures to allow said A-end connectors to connect to any said B-end connector but said mating structures do not allow said A-end connector to connect with any other said A-end connector or said B-end connector to connect to any other said B-end connector, a plurality of said cables being serially connectable together by serial interconnection of the A-end connector of one said cable to a said B-end connector of the other said cable;

a box fixture having one of an A-end connector and a B-end connector; and

one or more fixture boxes each provided with connector mounts which allow for the interconnection of one or more of said cables thereto, said connector mounts permitting at least one of said A-end connectors or said B-end connectors to be fixedly attached to said fixture box for routing of electrical power to said fixture box so that either of said A-end or B-end connectors are accessible in said fixture box for connection of said box fixture thereto.

2. The system according to claim 1, which further includes a first said fixture box wherein a first said cable has the B-end connector fixedly attached to said first fixture box so that a plurality of connection access points providing access to the B-end connections are defined within said fixture box.

3. The system according to claim 2, wherein said box fixture comprises an outlet receptacle which includes an integral plug connection defining a said A-end connector that is plug-connected to one of the B-end connectors of said first cable supported on said fixture box.

4. The system according to claim 3, wherein a second one of said cables has its A-end connector connected to the other of said B-end connectors of said first cable within said fixture box and exits therefrom to route power away from said fixture box.

5. The system according to claim 4, wherein the B-end of said second cable is fixedly attached to a second of said fixture boxes and a second said receptacle is plug-connected to one of the B-end connectors of said second cable on said second fixture box.

6. The system according to claim 2, which include a pigtail device including an integral plug connection and pigtail wires is plug-connected to one of the B-end connectors of said first cable and the pigtail wires are connected to a standard direct-wired receptacle.

7. The system according to claim 1, which includes a first said fixture box wherein a first said cable has the A-end fixedly attached to said first fixture box so that a connection access point providing access to the A-end connector is defined within said fixture box.

8. The system according to claim 7, wherein said box fixture comprises a switch device having an integral B-end connector is attached to said A-end of said first cable within said fixture box.

9. The system according to claim 7, including a switch pigtail device having an integral B-end connector and pigtail wires wherein said B-end connector is attached to the A-end of said first cable and the pigtail wires are attached to a standard direct-wired switch defining a first standard switch.

10. The system according to claim 9, wherein the A-end of a second said cable is fixedly attached to said first fixture box and including a second said switch pigtail device having an integral B-end connector and pigtail wires wherein said B-end connector is attached to the A-end of said second cable and the pigtail wires are attached to a second said standard switch wherein said first and second switches are spaced side to side in the same increment as industry standard spacing.

11. The system according to claim 2, including a second said cable having said A-end thereof fixedly connected to said first fixture box so that the connection access point to the A-end connector are located within said fixture box and wherein a switch device having an integral B-end connector is attached to said A-end of said second cable within said fixture box.

12. The system according to claim 11, wherein said receptacle and said standard switch are spaced side to side in the same increment as present industry standard spacing.

13. A building power wiring system comprising:

elongate cables having opposite A-ends and B-ends wherein each said cable includes one or both of an A-end connector on said A-end of said cable and a multi-connector configuration of at least two B-end connectors on the opposite B-end thereof, said cables having mating structures to allow any said A-end connector to connect to any said B-end connector but said mating structures do not allow said A-end connector to connect with any other said A-end connector or said B-end connector to connect to any other said B-end connector;

a box fixture having an A-end connector; and

one or more fixture boxes each provided with one or more connector mounts which allow for the interconnection of one or more of said cables thereto, said connector mounts at least permitting said B-end connectors in said multi-connector configuration of a first said cable to be fixedly attached to said fixture box for routing of electrical power to said fixture box so that said B-end connectors are accessible in said fixture box for connection of said box fixture to a respective one of said B-end connectors, the other of said B-end connectors being accessible next to said box fixture for the connection of an additional said A-end connector thereto.

14. The system according to claim 13, wherein a first one of said cables is connected to a first said fixture box, said A-end connector of a second one of said cables defining said additional A-end connector, which said A-end connector is connected to the other of said B-end connectors of said first cable within said fixture box, said second cable exiting said fixture box to route power away from said fixture box.

15. The system according to claim 14, wherein said box fixture comprises an outlet receptacle which includes a said A-end connector which defines an integral plug connection that is plug-connected to one of the B-end connectors of said first cable supported on said fixture box.

16. The system according to claim 14, wherein each of said cables includes a single said A-end connector on said A-end of said cable and at least two said B-end connectors on the opposite B-end thereof, a plurality of said cables being serially connectable together by serial interconnection of the A-end connector of one said cable to a said B-end connector of the other said cable, said B-end of said first cable being connected to said fixture box, said A-end of said second cable being connected to said B-end of said first cable in said first fixture box, and said B-end of said second cable being connected to a second said fixture box to permit the simultaneous connection of a said box fixture and a further one of said cables to said second cable within said second fixture box.

17. The system according to claim 13, which includes a first said fixture box wherein a first said cable has the B-end connector thereof fixedly attached to said first fixture box so that a plurality of connection access points providing access to the B-end connections are defined within said fixture box, said box fixture comprising an outlet receptacle which includes an integral plug connection defining a said A-end connector that is plug-connected to one of the B-end connectors of said first cable supported on said fixture box, a second one of said cables having a said A-end connector thereof defining said additional A-end connector which is connected to the other of said B-end connectors of said first cable within said fixture box and exits therefrom to route power away from said fixture box.

18. The system according to claim 17, wherein the B-end of said second cable is fixedly attached to a second of said fixture boxes and a second said receptacle is plug-connected to one of the B-end connectors of said second cable on said second fixture box.

19. In a system of plug connectors for interconnecting system components of a modular power distribution system for distributing power to a building structure wherein each said plug connector is engagable with other said plug connectors of other system components which carry electrical power throughout said building structure, comprising the improvement wherein said plug connectors of said system components have a common plug section with common electrical contacts respectively therein for completing an electrical connection between a mated pair of said plug sections by mating engagement of said plug sections and said respective electrical contacts together when said plug sections are in oppositely opposed orientations forming a mated pair of plug connectors, said plug connectors and said contacts thereof being configured to carry a plurality of voltage levels of line power;

said plug connectors including a settable keying structure which sets a mated pair of said plug connectors in one of a plurality of keying conditions to structurally limit connection of one said plug connector of said pair of plug connectors to only a further said plug connector which is set to a matable one of said keying conditions, said plurality of keying conditions corresponding to a respective plurality of said voltage levels wherein setting of said keying structure to a selected said keying condition limits the voltage level intended for use through said plug connector to the voltage level corresponding thereto;

said keying structure comprising movable segments which include first connector parts engaged with said plug section which permit relocation of said key segments while preventing removal of said key segments from said plug section and include alignment parts which prevent relocation of said key segments upon displacement of said key segments relative to said plug section from an adjustable position to a fixed position, said alignment parts defining a plurality of key segment positions which define said plurality of keying conditions corresponding to said voltage levels.

20. A plug connector of claim 19, wherein one said plug connector of said pair of plug connectors includes at least two said key segments that are displacable side to side through at least two optional keyed positions, and wherein the other of said pair of plug connectors includes at least one said key segment that can be displaced side to side through at least two optional keyed positions, wherein said keying segments of said pair of plug connectors, when set to indicate the same voltage level, are positioned so that said key segments will not occupy the same keyed locations, thereby allowing said pair of said plug connectors to fully mate and wherein said keying segments of said pair of plug connectors, when set to indicate a different voltage level, are positioned so that said key segments would occupy the same keyed locations, thereby interfering with each other and not permitting said pair of said plug connectors to fully mate together.

21. A plug connector of claim 20, wherein a portion of each of said key segments projects from one said plug connector into the other said plug connector of said mated pair and wherein said key segment portions occupy space adjacent said key segments of said plug connector into which each said key segment projects.

22. A plug connector of claim 19, wherein said key segments include side to side locking structures, and a removable barrier plate is provided adjacent said locking structures which said removable barrier plate prevents said key segments from engaging said side to side locking structures, and wherein said key segments lock into selected said fixed positions when said barrier plate has been removed.

23. A plug connector of claim 21, wherein each said plug connector includes a movable guide plate having guide channels that control positioning of said key segments wherein said movable guide plate has front and rear operative positions, wherein, in said rear position, said channels allow side to side movement of said key segments and wherein, in said front position, said channels prevent said key segments from side to side movement.

24. A plug connector of claim 23, wherein said guide plate includes an exposed handle portion that serves as a handle for movement of the plate initially from said rear position to said front locking position.

25. A plug connector of claim 24, wherein said key segments include a locking pawl that engages a slot edge in said guide plate when said guide plate is moved from said rear position to said front position, thereby preventing said guide plate from being returned to said rear position.

26. A plug connector of claim 25, wherein said exposed handle portion of said guide plate has frangible formations that allow manual break-off of said exposed handle portion from a remaining portion of said guide plate.

27. A plug connector of claim 26, wherein a portion of said break-off handle is formed as a barrier to prevent mating of a plug connector pair when said break-off portion is present, and wherein the barrier portion of said break-off handle includes extended edge portions wherein said barrier portion is substantially wider then said plug connector plugging face width so that said break-off barrier portion prevents installation of said plug connector into a substantially close fitting knockout opening in a junction box, when said break-off portion is present.

28. A building power wiring system comprising:

elongate cables having opposite A-ends and B-ends wherein each said cable includes an A-end connector on said A-end of said cable and a B-end connector on the opposite B-end thereof, said cables having plug sections that define mating plug structures to allow said A-end connectors to connect to any said B-end connector but said mating plug structures do not allow said A-end connector to connect with any other A-end connector or a B-end connector to connect to any other B-end connector, a plurality of said cables being serially connectable together by serial interconnection of the A-end connector of one said cable to a said B-end connector of the other said cable; and

one or more junction boxes each provided with A-end and/or B-end box connectors which allow for the interconnection of a plurality of said cables thereto, said box connectors permitting said A-end connectors and/or said B-end connectors to be fixedly attached to said junction box for routing of electrical power through said junction box and between said junction box and each said cable attached thereto;

said A-end and/or B-end box connectors each including a settable keying feature which sets said box connectors in one of a plurality of keying conditions to structurally limit connection of said box connectors to only a further said end connector which is keyed to a matable keying condition, said plurality of keying conditions corresponding to a respective plurality of voltage levels wherein setting of said keying feature to a selected said keying condition limits the voltage level intended for use with said end connector to the voltage level corresponding thereto;

said keying feature comprising movable segments which include first connector parts engaged to said plug section to permit relocation of said key segments while preventing removal thereof from said plug section, alignment parts which prevent relocation of said key segments upon displacement of said key segments relative to said plug section from an adjustable position to a fixed position, said alignment parts defining a plurality of key segment positions which define said plurality of keying conditions corresponding to said voltage levels.

29. A building power wiring system of claim 28, wherein said junction box includes a plurality of said box connectors having said respective keying feature and wherein said keying features of at least two of said box connectors of said junction box are interlinked so that the keyed voltage configuration of at least two of said included box connectors are simultaneously selected to the same voltage indication.

30. A building power wiring system of claim 28, wherein at least some of said box connectors are substantially aligned so that the respective plug face openings each have an orientation that is substantially the same so that a respective plug-mating motion that engages a plug section with a box connector is substantially in the same direction for all said substantially aligned box connectors.

31. A building power wiring system of claim 30, wherein said key segments include side to side locking structures, and a removable barrier plate is provided adjacent said locking structures which said removable barrier plate prevents said key segments from engaging said side to side locking structures, and wherein said key segments lock into selected said fixed positions when said barrier plate has been removed.

32. A building power wiring system of claim 31, wherein said barrier plate is a single plate with projecting portions that provide said barrier portions within each respective substantially aligned box connector of said junction box.

33. A building power wiring system comprising:

elongate cables having opposite A-ends and B-ends wherein each said cable includes a single A-end connector on said A-end of said cable and at least one B-end connector on the opposite B-end thereof, said cables having mating structures to allow said A-end connectors to connect to any said B-end connector but said mating structures do not allow said A-end connector to connect with any other said A-end connector or said B-end connector to connect to any other said B-end connector, a plurality of said cables being serially connectable together by serial interconnection of the A-end connector of one said cable to a said B-end connector of the other said cable;

wherein said A-end and B-end connectors have housings with matingly telescoping end portions and wherein said telescoping end portion of said B-end connector overlaps said telescoping end portion of said A-end connector when one said A-end connector is mated with one said B-end connector, and wherein said mating connection includes a substantially “

C”

shaped spring retaining latch having opposed inwardly projecting portions that engage aligned openings in the walls of both the housing of said B-end connector and the housing of said A-end connector thereby locking said mating end connectors together by the penetration of said spring inwardly projecting portions into the substantially aligned openings of the mated telescoping housing walls.

34. A building power wiring system of claim 33, wherein said telescoping end portion of said B-end connector outwardly overlaps said telescoping end portion of said A-end connector

35. A building power wiring system of claim 34, wherein said spring retaining latch is formed from spring steel wire, the perimeter of the cross section of said spring steel wire being substantially rounded.

36. A building power wiring system of claim 35, wherein said system includes metallic junction boxes to which said connectors can be fixedly mounted, and wherein said housings are of metallic material and wherein said housings include at least one opening for attachment of said connector to a junction box.

37. A building power wiring system of claim 36, wherein said junction boxes attached to a said connector, includes at least one metallic projection that engages said opening in said connector housing.

38. A building power wiring system of claim 37, wherein said metallic projections of said junction box are configured to provide a snap-action latching engagement with said opening in said connector housing.

39. A building power wiring system of claim 38, wherein said engagement of said junction box projection with said connector housing opening provides an electrical grounding path between said junction box and said connector housing.

40. A building power wiring system of claim 39, wherein said junction boxes include knock-out wall portions that are removable and when removed, provide a substantially closely fitting opening for insertion of the telescoping ends of said A-end connector or said B-end connector.

41. A building power wiring system of claim 40, wherein said junction box includes interior portions into which the telescoping ends of said connectors project and thereby allow said mating connections of A to B connections to be accomplished from within said junction box.

42. A building power wiring system of claim 41, wherein said the engagement of said projections of said junction box to the opening in said connector housings further establishes the depth or location into which said mating connection projects into said junction box interior space.

43. A building power wiring system of claim 41, wherein said spring retaining latch engages said openings in said telescoping walls of said mated A and B connectors mounted to said junction box, wherein said openings are engaged from within said interior space of said junction box, thereby locking said mated connection within said junction box.

44. A building power wiring system of claim 41, wherein said elongated cables have double B-end connectors on the B-end that will allow connection of two A-end connectors.

45. A building power wiring system of claim 44, wherein said substantially “

C”

shaped spring retaining latch has a double set of opposed inward projections to engage and latch two A-end connectors into mating connection with one said double B-end connector.

46. A building power distribution system defined by a plurality of system components which are selectively connectable to define a comprehensive power supply system within partitions of a building, some of said partitions having substantially rigid outer wall coverings separated by and secured to internal frame structures, wherein some of said coverings have an outer substantially exposed surface, said system components comprising;

a plurality of distribution cables having a first connector end and a second connector end with respective connector plugs thereon wherein said first connector end can mate with said second connector end but said first connector end cannot mate with a first connector end and a second connector end cannot mate with a second connector end of another mate-able distribution cable;

one or more metallic junction boxes configured to have said connector plugs connect thereto;

some of said junction boxes fixedly mounted to be substantially hidden within a said partition and said junction boxes having interior spaces in which component connections are made;

wherein said connector plugs have metallic housings including telescopingly mating end portions for a said first connector end to mate with a said second connector end and wherein said housings have structures for attachment of a said connector plug to a said metallic junction box to which said connector plugs can be fixedly mounted;

said junction box configuration for said connector plug attachment, includes at least one metallic structure that engages a mating metallic structure of the metallic housing of a connected said connector plug and wherein said mating engagement of said junction box with said connector plug provides an electrical grounding path between said junction box and said connector plug.

47. A building power distribution system of claim 46, wherein said junction box configuration for said connector plug attachment, includes at least one metallic projection that engages a mating opening in the metallic housing of a connected said connector plug.

48. A building power distribution system of claim 47, wherein said metallic projections of said junction box are configured to provide a snap-action latching engagement with said opening in said connector plug.

49. A building power distribution system of claim 48, wherein said distribution cables having a first said connector end and a second said connector end, said connector ends are separated by and connected to a standard MC Cable or armored cable portion having metallic outer coverings that are electrically grounded to said metallic housings of said connector ends.

50. A building power distribution system of claim 49, wherein said MC or armored cable portion of a said distribution cable is connected to a said connector plug that is connected to a said metallic junction box to which said connector plug is fixedly mounted, said cable portion being secured directly to said junction box structure by securing means.

51. A building power distribution system of claim 50, wherein said securing means of said cable portion is one of a plastic wire-tie, a screw attached U-bracket, and a U-clamp.

52. A building power distribution system of claim 51, wherein some of said distribution cables include multiple conductors that provide multiple electrical circuits and wherein others of said distribution cables have only sufficient conductors for a single electrical circuit and wherein said first connector ends of said multiple circuit distribution cables can mate with said second connector ends of said single circuit distribution cables and wherein said second connector ends of said multiple circuit distribution cables can mate with said first connector ends of said single circuit distribution cables and wherein said first connector ends of some of said single circuit distribution cables include structures that allow said single circuit cable to selectively receive power from one optionally selected circuit of the said multiple circuits of the multiple circuit cable to which it is matingly connected.

53. A building power distribution system of claim 52, wherein said distribution cables having a first said connector end and a second said connector end, said connector ends are separated by and connected to a standard MC Cable or armored cable portion having metallic outer coverings that are electrically grounded to said metallic housings of said connector ends.

54. A building power distribution system of claim 53, wherein said MC or armored cable portion of a said distribution cable is connected to a said connector plug that is connected to a said metallic junction box to which said connector plug is fixedly mounted, said cable portion being secured directly to said junction box structure by securing means.

55. A building power distribution system of claim 54, wherein said securing means of said cable portion is one of a plastic wire-tie, a screw attached U-bracket, and a U-clamp.

56. A building power distribution system of claim 52, wherein said single circuit cable circuit selection structure is a movable plug portion to which a single line conductor terminal is attached and wherein said plug portion can be selectively moved between at least two possible plugging locations.

57. A building power distribution system of claim 56, wherein said movable plug portion must be positioned to connect to access power from the desired circuit prior to connection of said selectable single circuit first connector end to a said second connector end.