Electrical wiring system

• US 7,285,009 B1
• Filed: 11/04/2005
• Issued: 10/23/2007
• Est. Priority Date: 10/07/2003
• Status: Expired due to Term

• Current Assignee: Pass And Seymour Incorporated (Legrand SA)
• Original Assignee: Pass And Seymour Incorporated (Legrand SA)
• Inventors: Savicki, Gerald R. Jr., Benoit, John
• Primary Examiner(s): TA, THO DAC
• Application Number:
  US11/266,795
• Time in Patent Office: 718 Days
• Field of Search: 439/536, 439/535, 439/650, 174/48, 174/66, 174/67, 174/50, 174/53, 174/68, 220/241
• 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. The system includes a plug connector device that is configured to terminate a plurality of wires. A portion of the plurality of wires are configured to transmit electrical power provided by an electrical power distribution system. An electrical wiring device is configured to provide the electrical power to a load. The electrical wiring device includes a receptacle disposed therein. The receptacle is configured to receive the plug device, such that electrical continuity is established between the electrical wiring device and the plurality of wires when the plug device is inserted into the receptacle.

Claims

1. An electrical wiring system for use in an electrical distribution system including at least one electric circuit, the at least one electric circuit including a plurality of electric power transmitting wires disposed between an electric power distribution point and a device box disposed at an electrical device location, the device box having a wiring ingress aperture, an interior device box volume and an open side, the plurality of electric power transmitting wires being routed through the wiring ingress aperture and accessible at the open side after a rough-in phase of installation, the system comprising:

an electrical wiring device including at least one circuit element disposed between a front cover and a rear body member, at least one user interface being disposed on the front cover and operatively coupled to at least one circuit element, the electrical wiring device further including a line receptacle formed in the rear body member, the line receptacle including a plurality of line receptacle contacts disposed therein, the plurality of line receptacle contacts being operatively coupled to the at least one circuit element; and

a plug connector including a plurality of plug connector contacts disposed therein, the plug connector including a termination interface configured to terminate the plurality of electrical power transmitting wires such that electrical continuity is established between the plurality of plug connector contacts and the electric power distribution point, the plug connector also being configured to be inserted into the line receptacle formed in the rear body member to establish electrical continuity between the plurality of line receptacle contacts and the electric power distribution point without any intervening electrical connections between the termination interface and the electric power distribution point.

2. The system of claim 1, wherein the plurality of line receptacle contacts are male contacts and the plurality of plug connector contacts are female contacts.

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

4. The system of claim 1, further comprising a plurality of wire leads connected to the plurality of plug connector contacts and extending into an exterior region of the plug connector, the plurality of wire leads being configured to be connected to the plurality of electrical power transmitting wires to form the termination interface, the plurality of electrical power transmitting wires, the plurality of wire leads, and the termination interface being configured to be stowed in the interior volume without any mechanical or electrical connection to the device box.

5. The system of claim 1, wherein the plurality of electrical power transmitting wires are connected to corresponding contacts of the plurality of electrical connector contacts to form the termination interface.

6. The system of claim 1, wherein the electrical power distribution point is a junction box.

7. The system of claim 1, wherein the electrical power distribution point is an electrical power distribution panel.

8. The system of claim 1, wherein the termination interface includes a connector element selected from a group of connector elements comprising a twist-on connector, an insulation displacement connector, pressure connector, or a push-in spring terminal.

9. The system of claim 1, wherein the at least one user accessible interface includes an electrical receptacle disposed in the front cover and configured to accept a power plug coupled to an electrical load.

10. The system of claim 9, wherein the at least one circuit element includes a set of receptacle contacts in communication with the electrical receptacle disposed in the front cover.

11. The system of claim 1, wherein the at least one circuit element further comprises:

an integrated hot contact structure including a hot line contact of the plurality of line receptacle contacts disposed in the line receptacle, the integrated hot contact structure further comprising at least one hot load receptacle contact accessible via the user interface;

an integrated neutral contact structure including a neutral line contact of the plurality of line receptacle contacts disposed in the line receptacle, the integrated neutral contact structure further comprising at least one neutral receptacle contact in communication with a corresponding receptacle aperture accessible via the at least one user interface; and

an integrated ground contact structure including a ground line contact of the plurality of line receptacle contacts disposed in the line receptacle, the integrated ground contact structure further comprising at least one ground receptacle contact in communication with a corresponding receptacle aperture accessible via the at least one user interface.

12. The system of claim 11, wherein the integrated hot contact structure is a unitary metallic structure.

13. The system of claim 11, wherein the integrated neutral contact structure is a unitary metallic structure.

14. The system of claim 11, wherein the integrated ground contact structure is a unitary metallic structure.

15. The system of claim 11, wherein the integrated ground contact structure includes a ground contact support structure comprising a first material and at least one ground receptacle contact formed of a second material.

16. The system of claim 11, wherein the at least one user interface includes a load receptacle disposed on the front cover.

17. The system of claim 1, further comprising a latching mechanism configured to lock the plug connector into the line receptacle when the plug connector is inserted therein, the latching mechanism being configured to resist a predetermined pulling force.

18. The system of claim 17, wherein the predetermined pulling force is greater than or equal to about twenty (20) pounds.

19. The system of claim 17, wherein the latching mechanism is manually actuatable to permit removal of the plug connector from the line receptacle.

20. The system of claim 19, wherein the latching mechanism provides an indication that the plug connector is locked in the line receptacle.

21. The system of claim 20, wherein the indication is an audible indication and/or a visual indication.

22. An electrical wiring system for use in an electrical distribution system including at least one electric circuit, the at least one electric circuit including a plurality of electric power transmitting wires disposed between an electric power distribution point and a device box disposed at an electrical device location, the device box having a wiring ingress aperture, an interior volume and an open side, the plurality of electric power transmitting wires being routed through the wiring ingress aperture and accessible via the open side after a rough-in phase of installation, the system comprising:

an electrical wiring device including at least one circuit element disposed between a front cover and a rear body member, at least one user interface being disposed on the front cover and operatively coupled to at least one circuit element, the electrical wiring device further including a line receptacle formed in the rear body member, the line receptacle including a plurality of line receptacle contacts disposed therein, the plurality of line receptacle contacts being operatively coupled to the at least one circuit element; and

a plug connector including a plurality of electrical connector contacts disposed therein, the plug connector being configured to be connected to the plurality of electrical power transmitting wires to form a termination interface, the plug connector being configured to be inserted into the line receptacle formed in the rear body member to form an electromechanical connection such that electrical continuity is established between the plurality of line receptacle contacts and the electric power distribution point, the electro-mechanical connection also being configured to resist a predetermined pulling force exerted on the plurality of electric power transmitting wires.

23. The system of claim 22, wherein the plurality of line receptacle contacts are male contacts and the plurality of plug connector contacts are female contacts.

24. The system of claim 22, wherein the plurality of line receptacle contacts are female contacts and the plurality of plug connector contacts are male contacts.

25. The system of claim 22, wherein the plurality of electrical power transmitting wires are connected to corresponding contacts of the plurality of electrical connector contacts to form the termination interface.

26. The system of claim 22, wherein the at least one circuit element further comprises:

an integrated hot contact structure including a hot line contact of the plurality of line receptacle contacts disposed in the line receptacle, the integrated hot contact structure further comprising at least one hot load receptacle contact user-accessible via the front cover;

an integrated neutral contact structure including a neutral line contact of the plurality of line receptacle contacts disposed in the line receptacle, the integrated neutral contact structure further comprising at least one neutral receptacle contact in communication with a corresponding receptacle aperture user-accessible via the front cover; and

an integrated ground contact structure including a ground line contact of the plurality of line receptacle contacts disposed in the line receptacle, the integrated ground contact structure further comprising at least one ground receptacle contact in communication with a corresponding receptacle aperture user-accessible via the front cover.

27. The system of claim 22, wherein the predetermined pulling force is greater than or equal to approximately twenty (20) pounds.

28. The system of claim 22, further comprising a plurality of wire leads connected to the plurality of plug connector contacts and extending into an exterior region of the plug connector, the plurality of wire leads being configured to be connected to the plurality of electrical power transmitting wires to form the termination interface, the plurality of electrical power transmitting wires, the plurality of wire leads, and the termination interface being configured to be stowed in the interior volume without being fixed with respect to the device box.

29. The system of claim 28, wherein the plurality of wire leads includes at least one hot wire lead and a neutral wire lead, and wherein the plurality of electrical power transmitting wires includes at least one hot line wire and a neutral line wire, and wherein the termination interface includes the at least one hot wire lead connected to the at least one hot line wire using a connective element and the neutral wire lead connected to the neutral line wire using another connective element.

30. The system of claim 29, wherein the plurality of wire leads includes a ground lead and the plurality of electric power transmitting wires includes a ground wire, and wherein the termination interface includes the ground lead connected to the ground wire via yet another connective element.

31. The system of claim 22, wherein the electro-mechanical connection includes a latching mechanism configured to lock the plug connector into the line receptacle when the plug connector is inserted therein.

32. The system of claim 31, wherein the latching mechanism is manually actuatable to permit removal of the plug connector from the line receptacle.

33. An electrical wiring system for use in an electrical distribution system including at least one electric circuit, the at least one electric circuit including a plurality of electric power transmitting wires disposed between an electric power distribution point and a device box disposed at an electrical device location, the device box having a wiring ingress aperture, an interior volume and an open side, the plurality of electric power transmitting wires being routed through the wiring ingress aperture and accessible via the open side after a rough-in phase of electric circuit installation, the system comprising:

an electrical wiring device including at least one circuit element disposed between a front cover and a rear body member, the front cover including at least one user accessible electrical interface being disposed on the front cover and operatively coupled to the at least one circuit element, the electrical wiring device further including a predefined coupling area disposed in the rear body member having a plurality of electrical wiring device contacts disposed therein, the plurality of electrical wiring device contacts also being operatively coupled to the at least one circuit element; and

a connector assembly including a plurality of connector contacts disposed therein, the connector assembly being configured to terminate the plurality of electrical power transmitting wires to establish electrical continuity between the electric power distribution point and the plurality of connector contacts, the connector assembly also being configured to be disposed in a contacting relationship with the predefined coupling area of the electrical wiring device to form an electromechanical connection such that electrical continuity is established between the plurality of connector contacts and the plurality of electrical wiring device contacts, the electromechanical connection also being configured to resist a predetermined pulling force exerted on or by the plurality of electric power transmitting wires.

34. The system of claim 33, wherein the plurality of connector contacts include a plurality of wire leads extending from an interior region of the connector assembly to an exterior region, the plurality of wire leads being configured to be connected to the plurality of electrical power transmitting wires at a termination interface, the plurality of wire leads, and the plurality of electrical power transmitting wires and the termination interface being configured to be stowed in the interior volume.

35. The system of claim 33, wherein the plurality of electrical power transmitting wires are directly terminated to corresponding ones of the plurality of connector contacts.

36. The system of claim 33, wherein the predefined coupling area includes a line receptacle disposed in the rear body member, and wherein the connector assembly includes a plug device configured to establish the contacting relationship upon being inserted into the line receptacle.

37. An electrical wiring system for use in an electrical distribution system including at least one electric circuit, the at least one electric circuit including a plurality of electric power transmitting wires disposed between an electric power distribution point and a device box disposed at an electrical device location, the system comprising:

an electrical wiring device including a front cover and a rear body member, at least one load receptacle being disposed on the front cover and a line receptacle being formed in the rear body member, the line receptacle including a plurality of line receptacle contacts disposed therein, the electrical wiring device further including at least one integrated contact structure disposed between the front cover and the rear body, the at least one integrated contact structure including at least one of the plurality of line receptacle contacts and at least one load receptacle contact in operative communication with the at least one load receptacle; and

a plug connector including a plurality of plug connector contacts disposed therein, the plug connector including a termination interface configured to terminate the plurality of electrical power transmitting wires such that electrical continuity is established between the plurality of plug connector contacts and the electric power distribution point, the plug connector also being configured to be inserted into the line receptacle formed in the rear body member to form an electromechanical connection such that electrical continuity is established between the plurality of plug connector contacts and the plurality of line receptacle contacts, the electromechanical connection also being configured to resist a predetermined pulling force exerted on or by the plurality of electric power transmitting wires.

38. The system of claim 37, wherein the at least one integrated contact structure further comprises:

an integrated hot contact structure having a hot line contact of the plurality of line receptacle contacts disposed in the line receptacle, the integrated hot contact structure further comprising at least one hot load receptacle contact in operative communication with a hot load receptacle aperture disposed on the front cover;

an integrated neutral contact structure including a neutral line contact of the plurality of line receptacle contacts disposed in the line receptacle, the integrated neutral contact structure further comprising at least one neutral receptacle contact in operative communication with a neutral load receptacle aperture disposed on the front cover; and

an integrated ground contact structure including a ground line contact of the plurality of line receptacle contacts disposed in the line receptacle, the integrated ground contact structure further comprising at least one ground receptacle contact in operative communication with a ground receptacle aperture disposed on the front cover.

39. The system of claim 37, wherein the plurality of line receptacle contacts are male contacts and the plurality of plug connector contacts are female contacts.

40. The system of claim 37, wherein the plurality of line receptacle contacts are female contacts and the plurality of plug connector contacts are male contacts.

41. The system of claim 37, wherein the plurality of electrical power transmitting wires are connected to corresponding contacts of the plurality of plug connector contacts to form the termination interface.

42. The system of claim 37, wherein the predetermined pulling force is greater than or equal to about twenty (20) pounds.

43. The system of claim 37, further comprising a plurality of wire leads connected to the plurality of plug connector contacts and extending into an exterior region of the plug connector, the plurality of wire leads being configured to be connected to the plurality of electrical power transmitting wires to form the termination interface, the plurality of electrical power transmitting wires, the plurality of wire leads, and the termination interface being configured to be stowed in the device box without any mechanical or electrical connection to the device box.

44. The system of claim 43, wherein the plurality of wire leads includes at least one hot wire lead and a neutral wire lead, and wherein the plurality of electrical power transmitting wires includes at least one hot line wire and a neutral line wire, and wherein the termination interface includes the at least one hot wire lead connected to the at least one hot line wire using a connective element and the neutral wire lead connected to the neutral line wire using another connective element.

45. The system of claim 44, wherein the plurality of wire leads includes a ground lead and the plurality of electric power transmitting wires includes a ground wire, and wherein the termination interface includes the ground lead connected to the ground wire via yet another connective element.

46. The system of claim 37, wherein the electro-mechanical connection includes a latching mechanism configured to lock the plug connector into the line receptacle when the plug connector is inserted therein.

47. The system of claim 46, wherein the latching mechanism is manually actuatable to permit removal of the plug connector from the line receptacle.

48. A method for installing an electric circuit in an electrical distribution system, the method comprising:

placing electric power transmitting wires between an electric power distribution point and a device box disposed at an electrical device location, the electric power transmitting wires being accessible via an open side of the device box;

providing a plug connector including a plurality of plug connector contacts disposed therein;

terminating the electric power transmitting wires to the plug connector at a termination interface such that electrical continuity is established between the plurality of plug connector contacts and the electric power distribution point;

providing an electrical wiring device including at least one circuit element disposed between a front cover and a rear body member, at least one user interface being disposed on the front cover and operatively coupled to at least one circuit element, the electrical wiring device further including a line receptacle formed in the rear body member, the line receptacle including a plurality of line receptacle contacts disposed therein, the plurality of line receptacle contacts being operatively coupled to the at least one circuit element; and

inserting the plug connector into the line receptacle to establish electrical continuity between the plurality of line receptacle contacts and the electric power distribution point without any intervening electrical connections between the termination interface and the electric power distribution point.