Compact electrical wiring system

• US 7,195,517 B1
• Filed: 02/17/2006
• Issued: 03/27/2007
• Est. Priority Date: 10/07/2003
• Status: Expired due to Fees

• Current Assignee: Pass And Seymour Incorporated (Legrand SA)
• Original Assignee: Pass And Seymour Incorporated (Legrand SA)
• Inventors: Savicki, Gerald R. Jr.
• Primary Examiner(s): TA, THO DAC
• Application Number:
  US11/357,563
• Time in Patent Office: 403 Days
• Field of Search: 439/535, 439/536, 439/650, 439/107, 174/58
• US Class Current: 439/535
• CPC Class Codes: H01R 13/6272 comprising a single latching arm
• CPC Class Codes: H01R 13/655 with earth brace
• CPC Class Codes: H01R 2103/00 Two poles
• CPC Class Codes: H01R 24/78 with additional earth or shield contacts

Abstract

The present invention is directed to a electrical wiring system that includes a plug connector having a plurality of plug contacts configured to terminate a plurality of wires. The system also includes an electrical wiring device having a cover member, a body member, a ground strap assembly disposed between the cover member and the body member, and a receptacle formed in a rear portion of the body member, the receptacle being configured to accept the plug connector. The ground strap assembly is configured to conform to at least one body member feature such that a distance from the ground strap assembly to a major rear surface of the body member is less than a predetermined distance. The receptacle includes a plurality of receptacle contacts 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 configured to terminate a plurality of wires; and

an electrical wiring device including a cover member, a body member, a ground strap assembly disposed between the cover member and the body member, and a receptacle formed in a rear portion of the body member, the receptacle being configured to accept the plug connector, the ground strap assembly being configured to conform to at least one body member feature such that a distance from the ground strap assembly to a major rear surface of the body member is less than a predetermined distance, the receptacle including a plurality of receptacle contacts 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 plurality of plug contacts include female contacts and the plurality of receptacle contacts include male contacts.

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

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

5. 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 user-accessible contacts electrically connected with the plurality of receptacle contacts.

6. 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 being electrically connected with the plurality of receptacle contacts.

7. 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 contacts at a first end of the wire segment and electrically 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.

8. The system of claim 1, wherein the ground strap assembly includes an EMI attenuation element.

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

a first mounting yoke;

a ground plate portion coupled to the first mounting yoke and substantially disposed along a central axis of the body member; and

a second mounting yoke coupled to the ground plate, the first mounting yoke, the second mounting yoke, and the ground plate being substantially co-planar.

10. The system of claim 9, wherein the ground strap further comprises:

a first lateral support member rigidly connecting the first mounting yoke and the second mounting yoke along a first lateral portion of the body member; and

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

11. The system of claim 10, wherein the first lateral support member and the second lateral support member are substantially parallel.

12. The system of claim 9, wherein the ground plate portion is electrically isolated from the first mounting yoke and the second mounting yoke.

13. The system of claim 12, wherein the ground plate portion includes a ground contact disposed within the receptacle, the ground contact and the plurality of receptacle contacts forming a tripartite receptacle contact arrangement configured to mate with the plurality of plug contacts when the plug connector is inserted into the receptacle.

14. The system of claim 13, further comprising an insulator member disposed between the ground strap and the ground plate portion to thereby electrically isolate the ground strap from the ground plate portion.

15. The system of claim 1, wherein the ground strap assembly includes a ground plate portion coupled to a ground contact extending within the receptacle.

16. The system of claim 15, wherein the ground contact and the plurality of receptacle contacts form a tripartite receptacle contact arrangement configured to mate with the plurality of plug contacts when the plug connector is inserted into the receptacle.

17. The system of claim 1, wherein the plurality of receptacle contacts includes a hot conductor contact and a neutral conductor contact, the hot conductor contact being an integral portion of a unitary hot conductor assembly disposed in the body member, the neutral conductor contact being an integral portion of a unitary neutral conductor assembly disposed in the body member.

18. The system of claim 17, wherein the ground strap assembly is disposed in the body member in a predetermined spatial relationship with the unitary hot conductor assembly and the unitary neutral conductor assembly, the body member including a plurality of electrically isolating members configured to electrically isolate the ground strap assembly, the unitary hot conductor assembly, and the unitary neutral conductor assembly.

19. An electrical wiring system comprising:

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

an electrical wiring device including a cover member, a body member, a mounting assembly disposed between the cover member and the body member, and a receptacle disposed in a rear portion of the body member and configured to accept the plug connector, the mounting assembly including at least one support structure configured to conform to a least one body member feature such that a distance from the mounting assembly to a major rear surface of the body member is less than a predetermined distance, the mounting assembly also including a ground plate coupled to a ground contact disposed within the receptacle, the receptacle including a plurality of receptacle contacts, the plurality of receptacle contacts and the ground contact being configured to mate with the plurality of plug contacts when the plug connector is inserted into the receptacle.

20. The system of claim 19, wherein the support structure further comprises:

a first mounting yoke disposed at a proximal end of the electrical wiring device; and

a second mounting yoke coupled to the ground plate and disposed at a distal end of the electrical wiring device, the first mounting yoke, the second mounting yoke, and the ground plate being substantially co-planar.

21. The system of claim 19, the ground plate includes an EMI attenuation element.

22. The system of claim 21, wherein the EMI attenuation element electrically isolates a portion of the mounting assembly from the ground contact.

23. The system of claim 22, wherein the EMI attenuation element includes an insulator member disposed between the portion of the mounting assembly and the ground plate, the ground contact being electrically isolated from the at least one support structure by the insulator member.

24. The system of claim 19, wherein the at least one support structure includes a unitary frame member configured to conform to a plurality of external lateral portions of the body member.

25. The system of claim 24, wherein the unitary frame member further comprises:

a first lateral support member disposed along a first lateral portion of the body member; and

a second lateral support member disposed along a second lateral portion of the body member.

26. The system of claim 25, wherein the first lateral support member and the second lateral support member are substantially parallel.

27. 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, the receptacle including a plurality of receptacle contacts 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 being less than 2.0 inches.

28. The system of claim 27, wherein the ground strap includes a unitary frame member and a ground plate, the ground plate including a ground contact disposed within the receptacle.

29. The system of claim 27, wherein the distance is less than 1.225 inches.

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

31. The system of claim 27, wherein the distance is less than 0.7 inches.

32. The system of claim 27, wherein a distance from the back major surface to a distal end of the plug connector when the plug connector is inserted into the receptacle is approximately 0.5 inches or less.

33. The system of claim 32, wherein the distance is approximately 0.436 inches.

34. The system of claim 27, wherein the ground strap further comprises:

a first mounting yoke disposed at a proximal end of the electrical wiring device;

a second mounting yoke coupled to the ground plate and disposed at a distal end of the electrical wiring device, the first mounting yoke, the second mounting yoke, and the ground plate being substantially co-planar;

a first lateral support member rigidly connecting the first mounting yoke and the second mounting yoke along a first lateral portion of the body member; and

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

35. The system of claim 34, wherein the first lateral support member and the second lateral support member are substantially parallel.

36. 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 major rear surface, and a mounting assembly disposed between the cover member and the body member, the mounting assembly including an EMI attenuation element, the body member including a receptacle configured to accept the plug connector, the receptacle including a plurality of receptacle contacts configured to mate with the plurality of plug contacts when the plug connector is inserted into the receptacle.

37. The system of claim 36, wherein the mounting assembly includes at least one mounting yoke and a ground plate coupled to a ground contact, the EMI attenuation element being configured to electrically isolate the at least one mounting yoke from the ground plate and the ground contact.

38. The system of claim 37, wherein the EMI attenuation element includes an insulator member disposed between a portion of the mounting assembly and the ground plate.