Safety electrical outlet and switch system

• US 6,341,981 B1
• Filed: 04/19/2000
• Issued: 01/29/2002
• Est. Priority Date: 01/05/2000
• Status: Expired due to Term

• Current Assignee: Alexandra Block, ANDREW KALANI NIHEU & JAY DEEP CHITNIS, Andrew M. Jenkins, Anne M. Mahoney, Baker Ken, Baum Family Trust, Binkley Family Trust, Bonnie Austin, Brandon Dinoto, Brandon Moore Utma, BRIAN DRISCOLL AND/OR DRISCOLL INVESTMENTS INC., Bruce Johnson, BRUCE & LORENE BOWERS, BRUCE & SANDY BRANDENBURG, CARL A LARSON, TRUSTEE LARSON 1995 REVOCABLE TRUST DTD 11/17/1995, CARL KOBAYASHI & MISHELLE NISHIDA, Chea Chung, CHRISTOPHER MOORE INDIVIDUALLY & AS TRUSTEE MOORE FAMILY TRUST DTD 10/3/2006, Christy L. Hendrickson Trust, CLAUDE KORDUS TRUSTEE KORDUS FAMILY TRUST, CLIFF & MAKOTO MCQUEEN, Court Wilson, Craig Hillegas, Daniel Allen, Daniel C. Serpe, DANIEL & KIMBERLY DOTSON, Daniel White, Dan Way, DAVID & BONNIC AUSTIN INDIVIDUALLY AND AS TRUSTEES AUSTIN FAMILY TRUST DTD 10/1/1999, David Caldwell, David L. Lyon, Dominique Pandolfi, DONALD D. LEARNED, TRUSTEE DONALD LEARNED TRUST C/O SCOTT LEARNED, DONALD & MARY SPENCER, Don Farris Inc Retirement Trust, Doug Cox, Elizabeth Willis, Eric Rawa, Estate Of Gary W. Dixon, GARY & BARBARA A. GENTZKOW AND/OR BARBARA GENTZKOW'S IRA, GARY & LINDSEY BLOCK, George Block, Glenn Frieder, Gloria Marie Gammill, GREG A. JIRAK & LORI HUBBART, GREG BLOCK, TRUSTEE, BLOCK FAMILY TRUST DTD 6/22/1990, Greg MacDonald, Gregory A. Block, Gregory Bernett, HARDEY, JULIE E. AKA JULIE HELLUM FBO BREE DIXON, Hardie David, Howard Brian Malloy, Ian Nausner, IVAN & LORI MENDELSON, James Clifford, James Gammill, JAMES GEVARGES & DOMINIQUE BEITKANOUN, JAMES & KIM WEINBERGER, JAMES & ROBYN CARBAUGH, JANELL SKOMER AKA JANELL SOHMER-BLOCK C/O GREGORY BLOCK, Jeffrey Lubin, Jeffrey Teza, Jeff Schott, Jerry E. Jageman, John Chu, John F. Zolezzi, JOHN & LAUARIE DEWITT AND/OR THIEIR IRAS, JOHN & LYNN BOWEN, TRUSTEES BOWN FAMILY TRUST DTD 11/21/1985, Jon Hillegas, JULIUS & MARRIETTA ZOLEZZI, KASHAN PIRACHA (KPN, LLC), Katherine Williams, KENNETH & JANET SHANER, Ken Rubin, Kevin Thomas Dinoto, Kristopher Dinoto, Laura Lewis, Laurence Balter, LINDA MOORE INDIVIDUALLY & AS TRUSTEE LINDA B. MOORE PERSONAL TRUST, Lisa Odenweller, Lori Shook, MANAGEMENT SYSTEMS LIMITED C/O SMC MULTI-MEDIA, Man-Ling Lai, Marc Cahal, Marc Odenweller, MARION J. BAUER ROSIDUARY TRUST C/O BLOCK, GAUNCE & ASSOCIATES, MARK & DIANA KENNEY, TRUSTEES KENNEY FAMILY TRUST DTD 11/29/1996, Mark McDonald, Marview Holdings, Inc., Maui Preparatory Academy, Megan Molloy, Melody Kitchens, MICHAEL & ANASTASIA FARRELL AND/OR STERLING TRUST CO. FBO MICHAEL FARRELL, Michael Bosworth, Michael Dewitt, MICHAEL MCLOUGHLIN, TRUSTEE MCLOUGHLIN FAMILY TRUST DTD 3/22/1994, Milton F. Damerow, NGUYEN, PETER (KPN, LLC), Nicholas Block, Nicole Cox, Norman M. Estin Trust, Parvis Nabavi, Paul Block, Persis Hataria, PHILIP BURKHARDT, TRUSTEE BURKHARDT 2005 FAMILY TRUST AND/OR THEIR IRAS, Phillip Moore, PHYLLIS ORNDORFF, TRUSTEE PHYLLIS ORNDORFF TRUST DTD 12-30-2010, RANDY & LONA KENT, R/Com Retail Services, LLC, Richard Babcock, RICHARD & DEBRA MYTKO, RICHARD & JACQUELINE SMITH, Robert C. Albrow, Robert M. Skomer, Robert W. Dudley Trust, Ronald S. Chapman, RYAN & SUSAN BOWERS, Ryota Komaru, Samantha Carroll, Scot Hall, Sean Mundy, Shaochong Yan, SMC Multi-Media Products Company Limited (SMC Multi-Media Limited), S Steven Podstreleny, Steve Benshoof, Steve Marlette, Steven Purves, Steven Sreb, STUART & KAREN SHAFER, Sydney Block, TERRENCE E. LEE, TRUSTEE TERRENCE E. LEE TRUST, Terrill Stewart, Terry Davis, THOMAS DINOTO, TRUSTEE DINOTO FAMILY TRUST DTD 1/11/1993, Thomas Goergen, Thomas H. Zolezzi, Timothy Karis Sirak LLC, TIM WALKER, TRUSTEE WALKER FAMILY TRUST DTD 7/21//2009, Valeo Partners LLC, Vincent Guzzetta Vascular Associates Co., WALTER & REBECCA HICKEL C/O CALWEST PROPERTIES, WARREN & ROBIN COHEN, Wendy Frieder, William Orndorff
• Original Assignee: Michael P. Gorman
• Inventors: Gorman, Michael P.
• Primary Examiner(s): Paumen, Gary
• Assistant Examiner(s): Gilman, Alexander
• Application Number:
  US09/553,425
• Time in Patent Office: 650 Days
• Field of Search: 139/535, 174/53, 174/57, 174/60, 220/3.9, 220/3.6, 200/51.R
• US Class Current: 439/535
• CPC Class Codes: H01R 13/652 with earth pin, blade or socket
• CPC Class Codes: H01R 13/70 with built-in switch
• CPC Class Codes: H01R 2103/00 Two poles
• CPC Class Codes: H01R 24/78 with additional earth or shield contacts
• CPC Class Codes: H01R 25/006 the coupling part being secured to apparatus or structure, e.g. duplex wall receptacle
• CPC Class Codes: Y10T 29/49128 Assembling formed circuit to base
• CPC Class Codes: Y10T 29/49169 Assembling electrical component directly to terminal or elongated conductor

Abstract

An electrical outlet and switch system allows snap-in installation and snap-out removal of outlet and switch modules without exposure to high-voltage conductors. The system includes an electrical box, a wiring panel, an outlet or switch module and a corresponding face plate. The wiring panel back side has attachment points for a power cable to be routed through a back portion of the electrical box. The wiring panel front side has a fixture configured to accept an outlet or switch module. The wiring panel physically isolates, yet electrically connects the attached power cable and the module. Module contacts provide electrical connection to the panel contacts. The panel fixture has protective structures that prevent inadvertent exposure to and short circuiting of the panel contacts.

The electrical box is configured for internal placement of the wiring panel, allowing electrical box wiring and verification and electrical system activation prior to wall panel construction. The installed wiring panel has a socket configured to accept a standard AC plug, providing a convenient electrical source prior to outlet module installation. The system also includes a shield configured to fit inside the electrical box and to conform to the wiring panel front side, protecting the electrical box and the installed wiring panel during the makeup phase of construction. After wall panels are installed, the modules can be snapped into the electrical box without the aid of a journeyman electrician. Should a module be damaged at a later date, a homeowner or layman can easily remove and replace the damaged module.

The electrical box has an associated box mount providing installation to studs during rough framing of a residential or commercial building. The box mount has a stud alignment guide for accurate placement of the electrical box on a wall stud. In conjunction with this stud alignment feature, the electrical box slides relative to the box mount and is removably locked in one of several fixed positions in order to locate the electrical box front face flush with the exterior surface of wall panels having various thicknesses.

Claims

1. An electrical wiring assembly comprising:

an electrical box having an open front face and a back face defining a power cable aperture;

a generally planar wiring panel having a front side and a back side, said front side having a panel fixture extending perpendicularly from said front side and a shielded contact surface within said fixture, said back side having a cable connector, said panel having a bus electrically connecting said cable connector to said contact surface, said wiring panel installable within said box so as to create a module compartment in the interior of said box between said front side and said open front face; and

an electrical module comprising a front cover and a back cover, said front cover providing a user accessible electrical function, said back cover having a module fixture and a shielded spring contact within said module fixture, said module fixture configured to engage said panel fixture so as to connect said spring contact with said contact surface;

said module having an installed position inserted into said electrical box within said module compartment and an uninstalled position removed from said electrical box, said module being removably retained by said panel in said installed position so that power cabling routed through said aperture into said electrical box and connected to said cable connector provides power to said module via said bus, said contact surface, and said spring contact.

2. The electrical wiring assembly of claim 1 further comprising a box mount configured to fixedly attach to a wall stud utilizing a stud alignment guide, said electrical box attachable to said box mount and movable between a plurality of latchable positions relative to said alignment guide so as to accommodate various wall panel thicknesses.

3. The electrical wiring assembly of claim 1 wherein said wiring panel has a socket providing access to electrical power when power cabling is attached to said cable connector, said electrical wiring assembly further comprising a protective cover installable over said wiring panel front side and having plug openings so as to allow plug access to said wiring panel socket.

4. The electrical wiring assembly of claim 1 further comprising a face plate having a protruding tab, said module having a corresponding catch so that said face plate removably snaps onto said module front cover when said module is in said installed position.

5. The electrical wiring assembly of claim 1 wherein said module further comprises an extractor handle, said handle having a closed position secured to said electrical box and an open position extending away from said module, said handle in said open position clasping said module and providing a grip to extract said module from said electrical box.

6. The electrical wiring assembly of claim 1 wherein said module further comprises a module keyed portion of said back cover, said module keyed portion corresponding to a wiring panel keyed portion, said module keyed portion and said wiring panel keyed portion insuring the proper orientation of said module in said installed position.

7. An electrical wiring assembly comprising:

an electrical box having an open front face and a back face defining a power cable aperture, said electrical box configured to be installed with said front face generally flush with a wall panel exterior surface;

a wiring panel comprising a generally planar board, said wiring panel fastened within said electrical box so as to partition the interior of said box into a user accessible module compartment proximate said front face and a user inaccessible wiring compartment proximate said back face,

said wiring panel having a fixture within said module compartment and a cable connector within said wiring compartment,

said fixture providing an electrical connection to said cable connector via a bus portion of said wiring panel,

said cable connector configured to terminate a power cable routed through said aperture into said wiring compartment; and

a user replaceable module providing a user operable electrical function, said module installable within said module compartment by snapping said module into said fixture and removable from said module compartment by unsnapping said module from said fixture, said module electrically connected to said cable connector when installed within said module compartment.

8. The electrical wiring assembly of claim 7 wherein said fixture has a first contact and said module has a corresponding second contact, one of said first and second contacts having a latch and an associated contact surface and the other one of said first and second contacts having a spring contact, said spring contact being retained by said latch and electrically connecting to said contact surface when said module is snapped into said fixture.

9. The electrical wiring assembly of claim 8 wherein portions of said fixture shield said first contact on all sides so as to minimize user exposure to said first contact when said module is not installed within said module compartment.

10. The electrical wiring assembly of claim 7 further comprising:

a socket portion of said wiring panel configured to accept a standard AC plug inserted into said module compartment when said module is not installed; and

a corresponding plug contact portion of said wiring panel located within said wiring compartment, said plug contact connected said cable connector via said buss and configured to accept and electrically connect to a prong portion of said plug.

11. The electrical wiring assembly of claim 7 wherein said module has an extractor handle, said handle having a closed position generally flush with said module and an open position extended from said module so as to provide a grip, said module securable to said electrical box with said handle in said closed position and removable from said module compartment with said handle in said open position.

12. An electrical wiring assembly comprising:

an electrical box having an open front face and an internal mounting post located at a recess from said front face;

a wiring panel having a front side and a back side, said wiring panel installed inside said electrical box with said back side abutting said mounting post;

a cable connector located on said wiring panel back side configured to connect to a power cable;

a contact surface electrically connected to said cable connector;

a panel fixture located on said wiring panel front face and housing said contact surface;

a prong connector electrically connected to said cable connector; and

a socket located on said wiring panel front face and housing said prong connector, said cable connector configured to connect to a power cable so that power is transmitted to a plug inserted into said socket via said power cable, said cable connector and said prong connector.

13. The electrical wiring assembly of claim 12 further comprising a protective cover mounted over said wiring panel front side, said protective cover having a plug opening corresponding to said socket so that a plug inserted into said plug opening also is inserted into said socket.

14. The electrical wiring assembly of claim 12 further comprising a box mount attachable to a wall stud along an alignment guide, said box mount having a first catch at a first distance from said alignment guide and a second catch at a second distance from said alignment guide, said electrical box mounted to said box mount and slidable between a first latched position corresponding to said first catch and a second latched position corresponding to said second catch.

15. The electrical wiring assembly of claim 12 wherein said recess is at least about 1.25 inches so as to avoid damage to said wiring panel during wall panel installation.

16. An electrical box assembly comprising:

a box mount attachable to a wall stud in accordance with a stud alignment guide of said box mount;

a plurality of catches located along said box mount;

an electrical box having a front face, said box slidably attached to said box mount;

a latch portion of said box configured to releasably engage any of said catches,

said box having a plurality of fixed positions corresponding to said catches, each of said positions placing said front face at a specific distance from said alignment guide so that said electrical box can be adjusted for various wall panel thicknesses.

17. The electrical box assembly of claim 16 further comprising a plurality of position indicators located on said electrical box associated with said positions, each of said indicators displaying a corresponding distance from said alignment guide to said front face.

18. The electrical box assembly of claim 17 wherein said corresponding distance is in the range of 0.5 inches to 1.75 inches.

19. The electrical box assembly of claim 16 wherein said alignment guide is the leading edge of said box mount and each of said position indicators aligns with said leading edge to indicate the current distance between said front face and said leading edge.

20. The electrical box assembly of claim 16 further comprising a side of said electrical box defining a finger aperture, said aperture providing a grip to move said electrical box between said positions.

21. The electrical box assembly of claim 16 wherein said latch portion has a latch release portion configured to accept a tool to pry said latch from a particular one of said catches.

22. The electrical box assembly of claim 16 wherein said electrical box has a grip configured to accommodate a finger so as to facilitate the moving of said electrical box between said positions.

23. An electrical wiring assembly comprising:

an electrical box means for mounting in a wall;

a wiring panel means for attaching power cables, said wiring panel means installed within said electrical box means;

a module means for providing an electrical function installable within said electrical box means; and

a snapin means for removably attaching and electrically connecting said module means to said wiring panel means with tactile feedback.

24. The electrical wiring assembly of claim 23 further comprising a box mount means for attaching said electrical box to a wall stud.

25. The electrical wiring assembly of claim 23 further comprising a protective cover means for shielding said wiring panel during the makeup phase of building construction.

26. The electrical wiring assembly of claim 23 further comprising a face plate means for trimming said module when installed within said electrical box.

27. An electrical wiring assembly comprising:

an electrical box having an open front face and a back face;

a module compartment defined within said box proximate said front face;

a wiring compartment defined within said box proximate said back face;

a wiring panel separating said module compartment from said wiring compartment;

a plurality of first contacts mounted within said module compartment and configured to electrically connect with a replaceable module; and

a plurality of second contacts mounted within said wiring compartment and configured to electrically connect with a power cable, said first contacts interconnected with corresponding ones of said second contacts.

28. The electrical wiring assembly of claim 27 further comprising a socket portion of said wiring panel having a hot slot, a neutral slot and a ground hole configured to accept a plug inserted into said module compartment when said module is not installed;

and

a plurality of third contacts mounted within said socket portion and interconnected with corresponding ones of said second contacts.

29. The electrical wiring assembly of claim 28 further comprising a removable protective cover configured to install within said module compartment so as to shield said wiring panel.

30. The electrical wiring assembly of claim 27 further comprising a plug opening defined by said protective cover and corresponding to said socket portion so as to allow said plug to be inserted through said protective cover and into said socket.

31. An electrical wiring assembly comprising:

an electrical box having an open front face;

a wiring panel installable within said electrical box;

a cable connector located on a back side of said wiring panel and configured to electrically connect to a power cable;

a panel contact located on a front side of said wiring panel and configured to electrically connect to a removable module having a spring contact; and

a socket contact located on said front side and configured to electrically connect to removable plug having a prong contact.

32. The electrical wiring assembly of claim 31 wherein said panel contact and said spring contact provide tactile feedback when connected.

33. The electrical wiring assembly of claim 31 wherein said wiring panel comprises:

a post attached to and extending perpendicularly, from said front side; and

a clip attached to said post distal said panel, said clip adapted to mount to an edge of said box so as to secure said panel within said box.

34. An electrical wiring assembly comprising:

an electrical box configured to house a power cable;

a wiring panel adapted to install within said box and to electrically connect to said power cable;

a keyed panel fixture located on said wiring panel;

a module adapted to electrically connect to said wiring panel so as to transfer power from said power cable; and

a keyed module fixture located on said module,

said keyed panel fixture and said keyed module configured to engage so as to removably attach said module to said wiring panel only in a proper orientation.

35. The wiring assembly of claim 34 further comprising a ground bar configured to engage a ground connector in said proper orientation.