Modular power distribution system

• US 5,336,097 A
• Filed: 10/29/1993
• Issued: 08/09/1994
• Est. Priority Date: 06/05/1992
• Status: Expired due to Fees

• Current Assignee: RHC/Spacemaster Corporation
• Original Assignee: RHC/Spacemaster Corporation
• Inventors: Smith, Donald C., Snyder, Charles R., Williamson, Lawrence J. Jr.
• Primary Examiner(s): Paumen, Gary F.
• Application Number:
  US08/146,426
• Time in Patent Office: 284 Days
• Field of Search: 439/110-122, 439/207-212, 439/215, 439/94, 439/100, 439/351, 439/352, 439/358
• US Class Current: 439/94
• CPC Class Codes: H02G 3/288 in modular walls, e.g. wall panels

Abstract

An electrical power distribution system is provided with an elongate track and a plurality of power tap assemblies that are engageable with the track. The power tap assemblies may be moved to any desired location along the track. Power may be fed into the track through one of the assemblies and taken out of the track through another of the assemblies. Receptacles may be mounted to one or more of the power tap assemblies. A latch system can hold the power tap assemblies in (1) a fully inserted, electrically engaging orientation and (2) an electrically disconnected orientation wherein the components are still supported on the track. The components employ spring terminals which establish electrical contact through a surface-to-surface butt engagement with a conducting member. Mechanical key systems are provided for preventing improper mounting of the components on the track and for preventing the connection of more than one power in-feed to the track.

Claims

1. An elongate electrical conducting system with which a multi-terminal power tap assembly can be engaged to conduct electricity into or out of said system, said system comprising:

an elongate, electrically conductive support frame suitable for mounting to a structure along which electrical power distribution is desired, said frame defining an elongate receiving main channel therein with a bottom and an opening opposite said bottom, said frame having an elongate electrical contact ground surface unitary with said frame and located within said main channel adjacent said main channel bottom opposite said opening to face out of said main channel opening for being engaged by a terminal of said power tap assembly;

at least one insulating carrier disposed in said main channel permitting access to said ground surface from outside of said main channel, said carrier having a plurality of spaced-apart walls defining a recess between each pair of adjacent walls; and

a plurality of elongate conducting elements each disposed within one of said insulting carrier recesses, each said element defining a planar contact surface facing outwardly of said main channel for being engaged by a terminal of said power tap assembly, and all said contact surface lying generally in a common plane.

2. The system in accordance with claim 1 in which said frame defines a second channel parallel to, and in communication with said main channel, said frame having a pair of flanges defining an intermediate opening between said main and second channels which is narrower than said second channel, said insulating carrier having (1) a bus bar holder portion in said frame main channel, (2) a neck portion in said intermediate opening, and (3) a retention head wider than said intermediate opening disposed in said frame second channel to mount said carrier in said frame.

3. An elongate electrical conducting system with which a multi-terminal power tap assembly can be engaged to conduct electricity into or out of said system, said system comprising:

an elongate, electrically conductive support frame suitable for being mounted to a structure along which electrical power distribution is desired, said frame defining an elongate receiving main channel therein and having an elongate electrical contact ground surface located within said main channel to face outwardly of said channel for being engaged by a terminal of said power tap assembly;

insulating carriers disposed in said main channel permitting access to said ground surface from outside said main channel, each said carrier having a plurality of spaced-apart walls defining a recess between each pair of adjacent walls;

three of said insulating carriers are disposed in said frame main channel with one of said three carriers being located on one side of said elongate electrical contact ground surface and with another of said three carriers being located on the other side of said elongate electrical contact ground surface; and

a plurality of elongate conducting elements each disposed within one of said insulating carrier recesses and each defining a contact surface facing outwardly of said main channel for being engaged by a terminal of said power tap assembly.

4. A system suitable for distributing electrical power at selected locations along a structure, said system comprising:

a conductor assembly having elongate, electrically conducting elements suitable for being disposed along said structure, said conductor assembly further including a pair of spaced-apart, elongate walls that are electrically insulated from said conducting elements and that are disposed to project outwardly along said conducting elements to define a channel opening to said conducting elements; and

a power tap assembly for being disposed at least partly within said channel at selected locations along said conductor assembly and having a plurality of terminals for each engaging one of said conductor elements, said power tap assembly and said conductor assembly cooperatively defining an insertion depth-positioning structure for releasably retaining said power tap assembly in (1) a fully inserted position with said terminals engaged with said conducting elements and (2) a partially inserted position with said terminals disengaged from said conducting elements to accommodate relocation of said power tap assembly along the length of said conductor assembly.

5. The system in accordance with claim 4 in which each said insertion depth-positioning structure includes lips on said conductor assembly walls, a bottom surface of said power tap assembly, and a latching tab having a generally inverted, U-shaped member having one longer leg extending downwardly below said bottom surface of the power tap assembly.

6. The system in accordance with claim 5 in which said power tap assembly includes four of said latching tabs arranged in two pairs, one pair being located at one end of said power tap assembly and the other pair being located at the other end of said power tap assembly.

7. A system suitable for distributing electrical power at selected locations along a structure, said system comprising:

a conductor assembly having elongate, electrically conducting elements suitable for being disposed along said structure, said conductor assembly further including a pair of spaced-apart, elongate walls that are electrically insulated from said conducting elements and that are disposed to project outwardly along said conducting elements to define a channel opening to said conducting elements, each said wall including a lip projecting toward the other wall; and

a power tap assembly for being disposed at least partly within said channel at selected locations along said conductor assembly and having a plurality of terminals for each engaging one of said conductor elements, said power tap assembly including at least one pair of spaced-apart latching tabs, each tab being deflectable inwardly toward the other from an unstressed configuration, each said tab including an outwardly facing camming surface terminating in a latch surface whereby said camming surfaces are engaged by said wall lips and deflected inwardly as said power tap assembly is inserted into said channel until said camming surfaces have moved past said lips and said tabs are free to return to the unstressed configuration where said latch surfaces releasably engage said lip to retain said power tap assembly on said walls in a fully inserted position with said terminals engaged with said conducting elements. said latch surface being a first latch surface and each said power tap assembly including a bottom surface spaced above said first latch surface, and lateral margins of said bottom surface defining a second latch surface for engaging one of said lips to hold said power tap assembly on said walls in a partially inserted position with said terminals disengaged from said conducting elements.

8. The system in accordance with claim 7 in which each said terminal has an upwardly angled, deflectable, contact arm having a length that is insufficient to contact an associated conducting element when said power tap assembly is in said partially inserted position with said terminals disengaged from said conducting elements.

9. A system suitable for distributing electrical power at selected locations along a structure, said system comprising:

a conductor assembly having elongate, electrically conducting elements suitable for being disposed along said structure, said conductor assembly further including a pair of spaced-apart, elongate walls that are electrically insulated from said conducting elements and that are disposed to project outwardly along said conducting elements to define a channel opening to said conducting elements, each said wall including a lip projecting toward the other wall; and

a power tap assembly for being disposed at least partly within said channel at selected locations along said conductor assembly and having a plurality of terminals for each engaging one of said conducting elements, said power tap assembly including at least one pair of spaced-apart latching tabs, each tab being deflectable inwardly toward the other from an unstressed configuration, each tab including an outwardly facing camming surface terminating in a latch surface whereby said camming surfaces are engaged by said wall lips and deflected inwardly as said power tap assembly is inserted into said channel until said camming surfaces have moved past lips and said tabs are free to return to the unstressed configuration where said latch surfaces releasably engage said lips to retain said power tap assembly on said wall in a fully inserted position with said terminals engaged with said conducting elements, some of said terminals each having (1) a base and a cantilevered contact arm extending from said base at an angle relative to said conducting elements when the arm is in an unstressed, release position and (2) a distal end extending downwardly toward said base, and said arm being deflectable from said unstressed position whereby, when said power tap assembly is in said fully inserted position, said terminals are deflected by, and are in contact with, said conducting elements and said arm distal end engages said base.

10. An electrical power distribution system comprising:

an elongate support frame suitable for being mounted to a structure along which electrical power distribution is desired, said support frame defining a first elongate channel and a second elongate channel which is narrower than said first channel, which is parallel to said first channel, and which is in communication with said first channel, said frame having a pair of flanges defining an intermediate opening between said first and second channels which is narrower than said second channel;

at least two insulating carriers each received in said frame, said carrier having (1) a bus bar holder portion in said frame first channel outwardly of said intermediate opening, (2) a neck portion in said intermediate opening, and (3) a retention head which is wider than said intermediate opening, which is narrower than said bus bar holder portion, and which is disposed inwardly of said intermediate opening in said frame second channel to mount said carrier in said frame, said carrier bus bar holder portion having a plurality of spaced-apart walls defining a recess between each pair of adjacent walls and a reduced width opening thereto;

a plurality of bus bars each disposed within one of said insulating carrier recesses, each said bar defining a planar elongate electrical contact surface facing outwardly toward said reduced width opening and out of the opening of said first elongate channel for engagement by an electrical terminal, and all of said contact surfaces lying generally in a common plane.

11. An electrical power distribution system comprising:

an elongate support frame suitable for being mounted to a structure along which electrical power distribution is desired, said support frame defining a first elongate channel and three second elongate channels parallel to, and in communication with, said first channel, said frame having a pair of flanges associated with each said second channel defining an intermediate opening between said first channel and each said second channel which is narrower than said second channel;

three insulating carriers received in said frame, each said carrier having (1) a bus holder portion in said frame first channel, (2) a neck portion in one of said intermediate openings, and (3) a retention head wider than said one intermediate opening disposed in one of said frame second channels to mount said carrier in said frame, each said carrier bus bar holder portion having a plurality of spaced-apart walls defining a recess between each pair of adjacent walls and a reduced width opening thereto; and

a plurality of bus bars, one of which bars is disposed within each of said insulating carrier recesses to present an elongate electrical contact surface facing outwardly toward said reduced width opening for engagement by an electrical terminal.

12. An electrical power distribution system comprising:

an elongated support frame suitable for being mounted to a structure along which electrical power distribution is desired, said support frame defining at least one elongate channel therein;

a plurality of elongated conducting elements each disposed within said frame channel to present an outwardly facing elongate electrical contact surface;

a power tap assembly for being selectively positioned longitudinally along said frame channel to conduct electricity into or out of said conducting elements;

abutment means projecting from said power tap assembly and being laterally offset relative to the longitudinal centerline of said channel; and

said frame having an end portion at each end of said frame, each said end portion defining a clearance passage means that is laterally offset relative to the longitudinal centerline of said channel for being in registration with said abutment means only when said power tap assembly and frame are aligned for proper insertion of said power tap assembly into said frame channel whereby said power tap assembly can be longitudinally positioned into and out of said track in only one of two 180 degree end-for-end rotation orientations, said frame and power tap assembly preventing removal of said power tap assembly in a direction perpendicular to the length of said frame.

13. An electrical power distribution system comprising:

an elongated support frame suitable for being mounted to a structure along which electrical power distribution is desired, and support frame defining at least one elongate channel therein having an opening therein;

a plurality of elongate conducting elements each disposed within said frame channel to present an outwardly facing elongate electrical contact surface facing out of said opening;

a power tap assembly for being selectively positioned longitudinally along said frame channel and retained therein to conduct electricity into or out of said conducting elements;

an engagement structure at least adjacent each end of said power tap assembly projecting upwardly therefrom and extending only partially across the width of said power tap assembly;

an abutment means on each end of said frame for being engaged by said engagement structure to prevent longitudinal displacement of said power tap assembly beyond either end of said frame channel; and

said frame and power tap assembly cooperatively defining a retention structure for preventing removal of said power tap assembly by pulling it generally perpendicular to the length of said frame.

14. An elongate electrical conducting system with which a multi-thermal power tap assembly can be engaged to conduct electricity into or out of said system, said system comprising:

an elongate, electrically conductive support frame suitable for being mounted to a structure along which electrical power distribution is desired, said frame defining an elongate receiving main channel therein with a bottom and an opening opposite said bottom, said frame having an elongate electrical contact ground surface located within said main channel to face out of said main channel opening for being engaged by a terminal of said power tap assembly;

insulating carriers disposed in said main channel permitting access to said ground surface from outside said main channel, each said carrier having a plurality of spaced-apart walls defining a recess between each pair of adjacent walls, at least two of said insulating carriers being disposed in said frame main channel with one of said carriers being located on one side of said elongate electrical contact ground surface and with another of said carriers being located on the other side of said elongate electrical contact ground surface; and

a plurality of elongate conducting elements each disposed within one of said insulating carrier recesses and each defining a contact surface facing out of said main channel opening for being engaged by a terminal of said power tap assembly.

15. A system suitable for distributing electrical power at selected locations along a structure, said system comprising:

a conductor assembly having elongate, electrically conducting elements suitable for being disposed along said structure, said conductor assembly further including a pair of spaced-apart, elongate walls that are electrically insulated from said conducting elements and that are disposed to project outwardly along said conducting elements to define a channel opening to said conducting elements, each said wall including ga lip projecting toward the other wall; and

a power tap assembly for being disposed at least partly within said channel at selected locations along said conductor assembly and having a plurality of terminals for each engaging one of said conducting elements, said power tap assembly inculding at least one pair of spaced-apart latching tabs, each tab being deflectable inwardly toward the other from an unstressed configuration, each said tab including a outwardly facing camming surface and a tab latch surface whereby said camming surfaces are engaged by said wall lips and deflected inwardly as said power tap assembly is inserted into said channel until said camming surfaces have moved past said lips and said tabs are free to return to the unstressed configuration where said latch surfaces releasably engage said lips to retain said power tap assembly on said walls in a fully inserted position with said terminals engaged with said conducting elements, each said power tap assembly including a bottom surface spaced above said tab latch surface, said lateral margins of said bottom surface functioning to engage one of said lips to hold said power tap assembly on said walls in a partially inserted position with said terminals disengaged from said conducting elements.

16. An electrical power distribution system comprising:

an elongate support frame suitable for being mounted to a structure along which electrical power distribution is desired, said support frame defining a main elongate channel and at least two secondary elongate channels parallel to, and in communication with, said channel, said frame having pairs of flanges with each pair defining an intermediate opening between said main channel and one of said secondary channels which is narrower than said secondary channel;

at least two insulating carriers received in said frame, each said carrier having (1) a bus bar holder portion in said frame main channel, (2) a neck portion in said intermediate opening, and (3) a retention head wider than said intermediate opening disposed in one of said frame secondary channels to mount said carrier in said frame, said carrier bus bar holder portion having a plurality of spaced-apart walls defining a recess between each pair of adjacent walls and a reduced width opening thereto;

a plurality of bus bars, each disposed within one of said insulating carrier recesses to present an elongate electrical contact surface facing outwardly toward said reduced width opening and also outwardly toward the opening to said first channel for engagement by an electrical terminal.