Quick connect electrical box

• US 5,785,551 A
• Filed: 03/28/1995
• Issued: 07/28/1998
• Est. Priority Date: 03/28/1995
• Status: Expired due to Term

• Current Assignee: Ashland Industries Corporation, Aslan Industries Corporation
• Original Assignee: Robert A. Libby
• Inventors: Libby, Robert A.
• Primary Examiner(s): Paumen, Gary F.
• Application Number:
  US08/411,950
• Time in Patent Office: 1,218 Days
• Field of Search: 439/535, 439/676, 439/418, 439/425, 174/53
• US Class Current: 439/535
• CPC Class Codes: H01R 13/743 integral with the housing
• CPC Class Codes: H01R 2103/00 Two poles
• CPC Class Codes: H01R 24/76 with sockets, clips or analogous contacts and secured to apparatus or structure, e.g. to a wall
• CPC Class Codes: H01R 4/188 having an uneven wire-receiving surface to improve the contact

Abstract

An electrical box is pre-wired with a duplex receptacle, a light switch, a junction or the like. The box has a number of connectors, each having electrical contacts. The connectors receive complementary plugs having terminals which make an electrical connection between the pre-wired box and the conductors of the electrical cable. The plug is attached to an unstripped end of an electrical cable, preferably by crimping to engage through the sheathing and conductor insulation. The connectors are pre-wired for a range of functions and are labeled with indica symbolizing the function assigned to the connector. During construction, preferably prior to installation of a wall panel, electrical cables are run from a power source to locations designated to receive an electrical box. A hole is made in the wall and the previously installed cable is located and pulled out through the hole. The plugs are installed on the ends of cables to be coupled to the box and the plugs are inserted into the appropriate connector on the box. The box has a retaining means which is operable to retain the box within the hole cut into the wall. The box is inserted into the hole and the retaining means is engaged with the wall panel to fix the box in the wall.

Claims

1. A means for wiring a branch circuit comprising:

an electrical box which is pre-wired with a terminal element forming at least one of a junction, an outlet operable to receive a standard AC line plug and a switch, the electrical box having an outer surface with at least one connector having at least one of a male or female contact, wherein the contact and at least one of the outlet, switch and junction are electrically coupled,

an insulated electrical cable having at least one end and at least two individually insulated conductors which are encased in an outer sheath, the at least one end being unstripped, the insulated conductors and the outer sheath fully extending to the end of the electrical cable,

a female or male plug complementary to said at least one of a male or female contact, the plug being connectable to the unstripped end of the electrical cable, wherein the plug has at least one terminal that is electrically coupled to the conductor, the plug being operable to mate with the connector, the terminal making an electrical connection with the contact, thereby electrically connecting the conductor to at least one of the junction, the outlet and the switch.

2. The means for wiring a branch circuit of claim 1 wherein the box further comprises a retaining means for coupling the electrical box to at least one of a wall and a framing member.

3. The means for wiring a branch circuit of claim 2 wherein the retaining means couples the electrical box to the wall.

4. The means for wiring a branch circuit of claim 1 wherein the terminal element is pre-wired for grounded 110-120 volt AC service.

5. The means for wiring a branch circuit of claim 1 wherein the terminal element is pre-wired for grounded 220-240 volt AC service.

6. The means for wiring a branch circuit of claim 1 wherein the box has a front surface which is substantially aligned with the terminal element.

7. The means for wiring a branch circuit of claim 1 wherein the connector has a hot contact, a neutral contact and a ground contact.

8. The means for wiring a branch circuit of claim 7 wherein the terminal element has a hot terminal, a neutral terminal and a ground terminal.

9. The means for wiring a branch circuit of claim 8 wherein the hot contact, the neutral contact and the ground contact of the connector are electrically coupled to the hot terminal, the neutral terminal and the ground terminal, respectively, of at least one of the junction, the receptacle and the switch.

10. The means for wiring a branch circuit of claim 1 comprising a first said connector having a hot contact, a neutral contact and a ground contact and a second said connector having a first hot contact, a second hot contact, a neutral contact and a ground contact.

11. The means for wiring a branch circuit of claim 10 wherein the terminal element comprises a three way switch having a first hot terminal, a second hot terminal, a neutral terminal and a ground terminal.

12. The means for wiring a branch circuit of claim 11 wherein the hot contact of the first said connector is electrically coupled to the neutral terminal of the switch, the neutral contact of said first connector is electrically coupled to the neutral contact of the second said connector, the ground contact of said first connector is electrically coupled to the ground terminal of the switch and to the ground contact of said second connector, the first hot terminal is electrically coupled to the first hot contact of said second connector and the second hot terminal is electrically coupled to the second hot contact of said second connector.

13. The means for wiring a branch circuit of claim 1 wherein the plug further comprises a first retaining means which means which mechanically couples the plug to at least one of the conductors, the insulation and the sheathing of the electrical cable.

14. The means for wiring a branch circuit of claim 1 wherein the plug further comprises a second retaining means which cooperates with the connector such that when the plug is mated with the connector, the plug and the electrical cable are mechanically attached to the electrical box.

15. The means for wiring a branch circuit of claim 1 wherein the plug further comprises indicia symbolizing the orientation of the plug with respect to at least one of the conductors of the electrical cable.

16. The means for wiring a branch circuit of claim 1 wherein the electrical box is labeled with indicia associated with the connector for indicating particular connections to be made with the electrical box.

17. The means for wiring a branch circuit of claim 16 wherein the indicia symbolizes the wiring connections made between the contact and at least one of the outlet, switch and junction.

18. A means for wiring a branch circuit comprising:

an electrical box which is pre-wired with a terminal element forming at least one of a junction, an outlet operable to receive a standard AC line plug and a switch, the electrical box having an outer surface with at least one connector having at least one of a male or female contact, wherein the contact and at least one of the outlet, switch and junction are electrically coupled,

an insulated electrical cable having at least two individually insulated conductors which are encased in an outer sheath, the insulated electrical cable having at least one end formed by a substantially transverse cut, the insulated conductors and the outer sheath fully extending to the end of the cable to form an unstripped end of the electrical cable,

a female or male plug complementary to said at least one of a male or female contact, the plug being connectable to the unstripped end of the electrical cable, wherein the plug has at least one terminal that is electrically coupled to the conductor, the plug being operable to mate with the connector, the terminal making an electrical connection with the contact, thereby electrically connecting the conductor to at least one of the junction, the outlet and the switch.