Compact electrical wiring system

• US 7,189,110 B1
• Filed: 01/10/2005
• Issued: 03/13/2007
• Est. Priority Date: 10/07/2003
• Status: Expired due to Fees

• Current Assignee: Pass & Seymour Incorporated (Legrand SA)
• Original Assignee: Pass & Seymour Incorporated (Legrand SA)
• Inventors: Savicki, Gerald R. Jr.
• Primary Examiner(s): Ta; Tho D.
• Application Number:
  US11/032,420
• Time in Patent Office: 792 Days
• Field of Search: 439/536, 439/535, 439/650, 439/107, 174/58
• US Class Current: 439/535
• CPC Class Codes: H01R 25/003 the coupling part being secured only to wires or cables

Abstract

The present invention is directed to an electrical wiring system that includes a plug connector including a plurality of plug contacts. The plug connector is configured to terminate a plurality of wires. An electrical wiring device includes a cover member, a body member, and a ground strap between the cover member and the body member. The body member including a receptacle configured to accept the plug connector and a plurality of device contacts. The plurality of device contacts are configured to mate with the plurality of plug contacts when the plug connector is inserted into the receptacle.

Claims

1. An electrical wiring system comprising:

a plug connector including a plurality of plug contacts, the plug connector being configured to terminate a plurality of wires; and

an electrical wiring device including a cover member, a body member, and a ground strap disposed between the cover member and the body member, the body member including a receptacle configured to accept the plug connector and a plurality of device contacts, the plurality of device contacts being configured to mate with the plurality of plug contacts when the plug connector is inserted into the receptacle.

2. The system of claim 1, wherein the ground strap is substantially planar.

3. The system of claim 1, wherein the plurality of plug contacts include female contacts and the plurality of device contacts include male contacts.

4. The system of claim 1, wherein the plurality of plug contacts include male contacts and the plurality of device contacts include female contacts.

5. The system of claim 1, wherein the plurality of wires includes an AC phase conductor and an AC neutral conductor.

6. The system of claim 5, wherein the plurality of wires includes a ground conductor.

7. The system of claim 1, wherein the plurality of wires includes at least three wires.

8. The system of claim 1, wherein the plurality of wires includes a first phase conductor, a second phase conductor, a third phase conductor, a neutral conductor, and a ground conductor.

9. The system of claim 1, wherein the electrical wiring device includes at least one user accessible receptacle disposed in the cover member, the at least one user accessible receptacle including a plurality of receptacle contacts having electrical connectivity with the plurality of device contacts.

10. The system of claim 1, wherein the electrical wiring device includes at least one user accessible electrical switch disposed in the cover member, the at least one user accessible electrical switch including a plurality of contacts having electrical connectivity with the plurality of device contacts.

11. The system of claim 1, wherein the electrical wiring device includes a GFCI.

12. The system of claim 1, wherein the electrical wiring device includes an AFCI.

13. The system of claim 1, wherein the electrical wiring device includes a transient voltage surge suppressor (TVSS).

14. The system of claim 1, wherein the plug connector includes a plurality of wire segments, each wire segment being electrically coupled to one of the plurality of plug contact at a first end of the wire segment and electrical coupled to a twist-on connector at a second end of the wire segment, each twist-on connector being configured to terminate one of the plurality of wires.

15. The system of claim 1, wherein the ground strap further comprises:

a first mounting yoke disposed at a proximal end of the ground strap and a second mounting yoke disposed at a distal end of the ground strap; and

at least one lateral support member rigidly connecting the first mounting yoke and the second mounting yoke along a portion of the body member perimeter.

16. The system of claim 15, wherein the at least one lateral support member includes a first lateral support member rigidly connecting the first mounting portion and the second mounting portion along a first side portion of the body member perimeter and a second lateral support member rigidly connecting the first mounting portion and the second mounting portion along a second side portion of the body member perimeter, the first lateral support member and the second lateral support member being substantially parallel.

17. The system of claim 1, wherein electrical wiring device further comprises a ground plate electrically isolated from the ground strap.

18. The system of claim 17, wherein the ground plate includes a ground contact disposed within the body member, the plurality of device contacts and the device ground contact being configured to mate with the plurality of plug contacts when the plug connector is inserted into the receptacle.

19. The system of claim 17, wherein the ground strap further comprises:

a first mounting yoke disposed at a proximal end of the ground strap and a second mounting yoke disposed at a distal end of the ground strap, the first mounting yoke, the second mounting yoke, and the ground plate being substantially coplanar; and

at least one lateral support member rigidly connecting the first mounting yoke and the second mounting yoke along a portion of the body member perimeter.

20. The system of claim 19, further comprising an insulator member disposed between the ground strap and the ground plate to thereby electrically isolate the ground strap from the ground plate.

21. An electrical wiring system comprising:

a plug connector including a plurality of plug contacts, the plug connector being configured to terminate a plurality of wires; and

an electrical wiring device including a cover member, a body member, a ground strap disposed between the cover member and the body member, and a ground plate including a ground contact disposed within the body member and electrically isolated from the ground strap, the body member including a receptacle configured to accept the plug connector and a plurality of device contacts, the plurality of device contacts and the device ground contact being configured to mate with the plurality of plug contacts when the plug connector is inserted into the receptacle.

22. The system of claim 21, wherein the ground strap further comprises:

a first mounting yoke disposed at a proximal end of the ground strap and a second mounting yoke disposed at a distal end of the ground strap, the first mounting yoke, the second mounting yoke, and the ground plate being substantially coplanar; and

at least one lateral support member rigidly connecting the first mounting yoke and the second mounting yoke along a portion of the body member perimeter.

23. The system of claim 22, further comprising an insulator member disposed between the ground strap and the ground plate to thereby electrically isolate the ground strap from the ground plate.

24. The system of claim 22, wherein the at least one lateral support member includes a first lateral support member rigidly connecting the first mounting portion and the second mounting portion along a first side portion of the body member perimeter and a second lateral support member rigidly connecting the first mounting portion and the second mounting portion along a second side portion of the body member perimeter, the first lateral support member and the second lateral support member being substantially parallel.

25. An electrical wiring system comprising:

a plug connector including a plurality of plug contacts, the plug connector being configured to terminate a plurality of wires; and

an electrical wiring device including a cover member, a body member having a back major surface, and a ground strap disposed between the cover member and the body member, the body member including a receptacle configured to accept the plug connector and a plurality of device contacts, the plurality of device contacts being configured to mate with the plurality of plug contacts when the plug connector is inserted into the receptacle, a distance from the ground strap to the back major surface is less than 2.5 inches.

26. The system of claim 25, wherein the distance is less than 1.225 inches.

27. The system of claim 25, wherein the distance is less than 1.0 inches.

28. The system of claim 25, wherein the distance is less than 0.7 inches.

29. The system of claim 25, wherein a distance from a major plug surface to the back major surface is approximately 0.5 inches or less.

30. The system of claim 25, wherein the electrical wiring device includes at least one user accessible receptacle disposed in the cover member, the at least one user accessible receptacle including a plurality of receptacle contacts having electrical connectivity with the plurality of device contacts.

31. The system of claim 25, wherein the electrical wiring device includes at least one user accessible electrical switch disposed in the cover member, the at least one user accessible electrical switch including a plurality of contacts having electrical connectivity with the plurality of device contacts.

32. The system of claim 25, wherein the electrical wiring device includes a GFCI.

33. The system of claim 25, wherein the electrical wiring device includes an AFCI.

34. The system of claim 25, wherein the electrical wiring device includes a transient voltage surge suppressor (TVSS).

35. An electrical wiring system comprising:

a plug connector including a plurality of plug contacts, the plug connector being configured to terminate a plurality of wires; and

an electrical wiring device including a cover member, a body member, and a substantially planar ground strap disposed between the cover member and the body member, the body member including a receptacle configured to accept the plug connector and a plurality of device contacts, the plurality of device contacts being configured to mate with the plurality of plug contacts when the plug connector is inserted into the receptacle.

36. The system of claim 35, wherein the electrical wiring device includes at least one user accessible receptacle disposed in the cover member, the at least one user accessible receptacle including a plurality of receptacle contacts having electrical connectivity with the plurality of device contacts.

37. The system of claim 35, wherein the electrical wiring device includes at least one user accessible electrical switch disposed in the cover member, the at least one user accessible electrical switch including a plurality of contacts having electrical connectivity with the plurality of device contacts.

38. The system of claim 35, wherein the electrical wiring device includes a GFCI.

39. The system of claim 35, wherein the electrical wiring device includes an AFCI.

40. The system of claim 35, wherein the electrical wiring device includes a transient voltage surge suppressor (TVSS).

41. The system of claim 35, wherein the ground strap further comprises:

a first mounting yoke disposed at a proximal end of the ground strap and a second mounting yoke disposed at a distal end of the ground strap; and

at least one lateral support member rigidly connecting the first mounting yoke and the second mounting yoke along a portion of the body member perimeter.

42. The system of claim 41, wherein the at least one lateral support member includes a first lateral support member rigidly connecting the first mounting portion and the second mounting portion along a first side portion of the body member perimeter and a second lateral support member rigidly connecting the first mounting portion and the second mounting portion along a second side portion of the body member perimeter, the first lateral support member and the second lateral support member being substantially parallel.

43. The system of claim 35, wherein electrical wiring device further comprises a ground plate electrically isolated from the ground strap.

44. The system of claim 43, wherein the ground plate includes a ground contact disposed within the body member, the plurality of device contacts and the device ground contact being configured to mate with the plurality of plug contacts when the plug connector is inserted into the receptacle.

45. The system of claim 44, wherein the ground strap further comprises:

a first mounting yoke disposed at a proximal end of the ground strap and a second mounting yoke disposed at a distal end of the ground strap, the first mounting yoke, the second mounting yoke, and the ground plate being substantially coplanar; and

at least one lateral support member rigidly connecting the first mounting yoke and the second mounting yoke along a portion of the body member perimeter.

46. The system of claim 45, further comprising an insulator member disposed between the ground strap and the ground plate to thereby electrically isolate the ground strap from the ground plate.