Wall-mountable wiring installation

• US 4,669,804 A
• Filed: 06/14/1985
• Issued: 06/02/1987
• Est. Priority Date: 06/14/1985
• Status: Expired due to Term

• Current Assignee: Cooper Wiring Devices Incorporated (Eaton Corporation PLC.)
• Original Assignee: Eagle Electric Manufacturing Co., Inc. (Eaton Corporation PLC.)
• Inventors: Munroe, Ronald G.
• Primary Examiner(s): Weidenfeld, Gil
• Assistant Examiner(s): Paumen, Gary F.
• Application Number:
  US06/744,786
• Time in Patent Office: 718 Days
• Field of Search: 339/20, 339/21 R, 339/175 C, 339/191 R, 339/191 A, 339/191 M, 339/192 R, 339/91 R, 339/175 R, 339/147 R, 339/147 P
• US Class Current: 439/398
• CPC Class Codes: H01H 23/00 Tumbler or rocker switches, i.e. switches characterised by being operated by rocking an operating member in the form of a rocker button
• CPC Class Codes: H01R 4/2416 the contact members having insulation-cutting edges, e.g. of tuning fork type
• CPC Class Codes: H02G 3/12 for flush mounting
• CPC Class Codes: H02G 3/18 providing line outlets

Abstract

A boxless wiring installation in which a wall switch or a duplex electrical receptacle may be mounted with snap action within and on a support member which is mounted by means of swing-out wall clamps to a wall.

Claims

1. A wall-mountable wiring installation, comprising:

(I) a discrete electrical device including

(A) a housing of electrically-insulating material and having

(i) a front wall to which direct manual or electrical access is available from the exterior of the housing,

(ii) a rear wall spaced from the front wall and having openings extending through the rear wall, and

(iii) side walls extending between the front and rear walls and bounding therewith an interior compartment, and

(B) electrical device contacts of electrically-conducting material and having

(i) interior contact portions located within the compartment, and

(ii) exterior blade portions integral with and extending from the interior contact portions through the openings in the rear wall and past the rear wall;

(II) a discrete support member including

(A) a recessed support body of electrically-insulating material and having

(i) a generally planar support wall having, as considered in an intended position of use, a forwardly-facing front surface, a rearwardly-facing rear surface, and apertures extending through the front and rear surfaces,

(ii) first body walls extending generally perpendicularly and forwardly of the front surface of the support wall and terminating in an open end, said first body walls and the support wall bounding a pocket in which the electrical device is removably mounted and insertable from a removed position in which the electrical device is remote from the pocket, to a mounted position in which the blade portions extend through the apertures of the support wall and past the same,

(iii) a face plate integral with the first body walls at the open end of the latter and lying in a plane generally parallel to and spaced from the support wall,

(iv) second body walls extending generally perpendicularly and rearwardly of the rear surface of the support wall and terminating in an open end, and

(v) a cover mountable over the open end of the second body walls and bounding therewith a wiring chamber in which an electrical current-carrying cable is received remote from said interior compartment of the housing, and

(B) electrical wire contacts of electrically-conducting material and located within the wiring chamber and having

(i) blade-wiping portions electromechanically engageable with the blade portions in the mounted position, and

(ii) wire-engaging portions integral with the blade-wiping portions and electromechanically engageable with the cable received in the wiring chamber;

(III) clamping means on the support member for fixedly mounting the same behind and on a wall having a forwardly-facing front face and a rearwardly-facing rear face, said clamping means including

(A) at least one wall clamp having a clamping surface movable toward the face plate, and

(B) at least one drive element operative to move the clamping surface into clamping engagement with the rear face of the wall when the face plate is in overlying engagement with the front face of the wall; and

(IV) snap-action co-acting means on the side walls of the housing and on the first body walls of the support body for snapplingly cooperatively engaging and normally lockingly retaining the electrical device within the recessed support body in the mounted position, and for cooperatively disengaging the electrical device from the recessed support body to the removed position, whereby installation and replacement of the electrical device in the wall-mounted support member is easily, rapidly and safely effected without direct access to the current-carrying cable.

2. The wiring installation as recited in claim 1, wherein the electrical device is a duplex electrical receptacle having a pair of adjacent sockets into each of which an electrical plug having prongs is insertable to conduct electrical current from the cable through the electrical wire contacts and the electrical device contacts to the plug.

3. The wiring installation as recited in claim 1, wherein the electrical device is an electrical switch having a manually-movable armature at the front wall of the housing and operative, when the armature is moved, to switch electrical current from the cable through the electrical device contacts of the switch.

4. The wiring installation as recited in claim 1, wherein the housing has a generally parallelepiped shape, and wherein the pocket has a complementary contour for snug reception of the housing.

5. The wiring installation as recited in claim 1, wherein the exterior blade portions of the electrical device and the apertures of the support wall are arranged in the same predetermined pattern;

and further comprising another electrical device having exterior blade portions arranged in a different pattern to prevent insertion of said other electrical device into the apertures of the support wall of the wallmounted support member.

6. The wiring installation as recited in claim 1;

and further comprising means on the cover and the support body for snappingly engaging the cover on the support body, said cover including a generally planar base wall and a plurality of elongated legs extending generally perpendicularly to the base wall and being resiliently yieldable in a direction transverse to their elongation, said legs terminating in shoulders, and said support body having a plurality of recesses into each of which a respective shoulder is received with snap-type inward engagement upon mounting of the cover.

7. The wiring installation as recited in claim 1, wherein the one drive element has an elongated drive shaft extending along and turnable about an axis, and has a drive head located wiithin the pocket.

8. The wiring installation as recited in claim 7, wherein the drive head is located underneath and is concealed by the front wall of the electrical device in the mounted position of the latter.

9. The wiring installation as recited in claim 7, wherein the wall clamp includes a tubular portion in which the drive shaft is received, and an arm portion integral with the tubular portion and extending transversely of the axis, said clamping surface being provided on said arm portion.

10. The wiring installation as recited in claim 9, wherein the support member has an abutment, and wherein the one drive element is initially operative to turn the arm portion from an initial storage position about the axis into engagement with the abutment, and thereupon to draw the clamping surface of the arm portion in an axial direction into engagement with the rear face of the wall.

11. The wiring installation as recited in claim 10, wherein the first body walls have at least one cutout in open communication with the pocket, and wherein the arm portion extends, at least in part, through the cutout into the pocket in the storage position.

12. The wiring installation as recited in claim 11, wherein the support wall has at least one shallow cavity in which at least a portion of the arm portion is accommodated in the storage position.

13. The wiring installation as recited in claim 1, wherein the snap-action co-acting means includes a plurality of legs adjacent the side walls of the housing and resiliently yieldable toward the respectively adjacent side wall during the insertion of the housing into the pocket, each leg having an engaging portion, and wherein the first body walls have recesses into each of which a respective engaging portion is received with snap-type engagement in the mounted position.

14. The wiring installation as recited in claim 13, wherein each leg has a tool-engaging free end extending beyond the face plate in the mounted position, each free end being accessible to a demounting tool.

15. The wiring installation as recited in claim 1;

and further comprising bend-away tabs hingedly connected to the cover and to the second body walls, each tab being yieldable in response to pressure to form an open channel between the wiring chamber and the exterior of the support member.

16. The wiring installation as recited in claim 15, wherein the tabs on the second body walls yield inwardly into the wiring chamber and are located out of the path of movement of the clamping surface of the wall clamp.

17. The wiring installation as recited in claim 1, wherein the first body walls have at least one cutout in open communication with the pocket, and wherein the cutout is located on the support member adjacent the wall clamp and serves as a port through which the wall clamp is visible and accessible.