Modular wiring system with locking elements

• US 7,357,652 B1
• Filed: 10/27/2006
• Issued: 04/15/2008
• Est. Priority Date: 10/27/2006
• Status: Active Grant

• Current Assignee: Leviton Manufacturing Company Incorporated
• Original Assignee: Leviton Manufacturing Company Incorporated
• Inventors: Tufano, Anthony, Arenas, Alfredo, Lindenstraus, Leslie, Oddsen, Dennis
• Primary Examiner(s): Patel; Tulsidas C.
• Assistant Examiner(s): Imas; Vladimir
• Application Number:
  US11/553,793
• Publication Number:
  US 20080102661A1
• Time in Patent Office: 536 Days
• Field of Search: 439/107, 439/535, 439/337, 439/135
• US Class Current: 439/107
• CPC Class Codes: H01R 13/514 composed as a modular blocks or assembly, i.e. composed of co-operating parts provided with contact members or holding contact members between them
• CPC Class Codes: H01R 13/652 with earth pin, blade or socket
• 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

Abstract

A modular wiring system comprising a functional unit and a wiring unit. There is also a system for coupling the functional unit to the wiring unit in a rotational manner. This system can be formed from at least one locking prong comprised of electrically conductive material. When the functional unit is coupled to the wiring unit, the locking prong is both electrically and physically coupled to the functional unit at a first end and to the wiring unit at a second end. Alternatively, or in addition, the system for coupling the functional unit to the wiring unit in a rotational manner can include at least one flange coupled to the functional unit and at least one flange coupled to the wiring unit. These flanges operate such that when the functional unit and the wiring unit are coupled together, they are rotated to form a locking connection between the flange on the functional unit and the flange on the wiring unit.

Claims

1. A modular wiring system comprising:

a) a functional unit comprising;

i) a housing;

ii) at least one functional interface disposed within said housing;

iii) at least one connection element extending out from said housing, said at least one connection element having a first section and a second section wherein said second section forms a locking section;

b) a wiring unit comprising;

i) a housing having at least one opening; and

ii) at least one front face forming a connection interface for said locking section of said at least one connection element wherein said wiring unit housing is smaller than said functional unit housing.

2. The modular wiring system as in claim 1, wherein said at least one connection element is in the form of a substantially cylindrically shaped prong made from electrically conductive material.

3. The modular wiring system as in claim 1, wherein said at least one connection element is in the form of a plate made from electrically conductive material.

4. The modular wiring system as in claim 1, wherein said first section of said at least one connection element is smaller in area than said locking section.

5. The modular wiring system as in claim 1, wherein said locking section is in the form of a locking overhang which can be used to interact with said front face of said housing on said wiring unit to lock said functional unit to said wiring unit.

6. The modular wiring system as in claim 1, wherein said wiring unit further comprises at least one locking flange.

7. The modular wiring system as in claim 6, wherein said wiring unit having at least one locking flange includes at least two locking flanges.

8. The modular wiring system as in claim 1, wherein said functional unit further comprises at least one locking flange.

9. The modular wiring system as in claim 6, wherein said functional unit further comprises at least one locking flange which is used to couple to said at least one locking flange on said wiring unit.

10. The modular wiring system as in claim 9, wherein said at least one locking flange on said functional unit is in the form of a fixed latch tab.

11. The modular wiring system as in claim 9, wherein said at least one locking flange on said functional unit is in the form of a latch release tab.

12. The modular wiring system as in claim 1, wherein said functional unit further comprises at least one raised surface disposed on a back face for allowing said wiring unit to couple to said at least one prong and then rotate on said at least one raised surface.

13. The modular wiring system as in claim 12, wherein said at least one raised surface has a perimeter which indicates to a user a proper orientation of said wiring unit with respect to said functional unit.

14. The modular wiring system as in claim 13, wherein said functional unit, further comprises a rejection element, such that said wiring unit cannot be coupled to said functional unit unless said wiring unit is in said proper orientation with respect to said functional unit.

15. The modular wiring system as in claim 13, wherein said wiring unit further comprises a rejection element, which is adapted so that said wiring unit cannot be coupled to said functional unit unless said wiring unit is in a proper orientation with respect to said functional unit.

16. The modular wiring system as in claim 14, wherein said rejection element comprises a post on said functional unit and said wiring unit has a perimeter, wherein said perimeter of said wiring unit is asymmetrical such that during a connection rotation, said post will interfere with said perimeter of said wiring unit if said wiring unit is not in said proper orientation with respect to said functional unit.

17. The modular wiring system as in claim 1, wherein said wiring unit further comprises at least one removable cover.

18. The modular wiring system as in claim 1, wherein said at least one opening in said housing of said wiring unit comprises a first wider receiving region and a second narrower locking region.

19. The modular wiring system as in claim 14, wherein said at least one connection element on said functional unit is in the form of a locking prong having a narrower base and a wider end portion, and wherein at least one first wider receiving region on said wiring unit is adapted to receive said wider end portion of said locking prong, such that when said wiring unit is coupled to said functional unit, said wider end portion inserts into said at least one first wider receiving region, said wiring unit is rotated relative to said functional unit such that said wider end portion on said locking prong rotates into said second narrower locking region on said wiring unit to lock said functional unit to said wiring unit.

20. The modular wiring system as in claim 15, wherein said wiring unit further comprises at least one cover.

21. The modular wiring system as in claim 20, wherein said cover on said wiring unit, is removable and includes an area for labeling for identification purposes.

24. The modular wiring system as in claim 1, wherein said housing of said wiring unit comprises a body section and wherein said front face is coupled to said body section, and wherein said wiring unit further comprises a plurality of wiring connectors, disposed inside of said wiring housing and behind said at least one front face.

25. The modular wiring system as in claim 1, wherein said wiring unit further comprises at least one removable cover.

26. The modular wiring system as in claim 1, wherein said housing of said functional unit further comprises a front face and a back face, wherein said at least one connection element extends out from said back face of said housing of said functional unit.

22. A modular wiring system comprising:

a) a functional unit;

b) a wiring unit;

c) a system for coupling said functional unit to said wiring unit in a rotational manner, said system comprising at least one flange coupled to said functional unit and at least one flange coupled to said wiring unit such that when said functional unit and said wiring unit are coupled together, they are rotated to form a locking connection between said at least one flange on said functional unit and said at least one flange on said wiring unit.

27. The modular wiring system as in claim 22, wherein said functional unit comprises:

a housing and at least one functional interface disposed within said housing;

wherein said at least one flange coupled to said functional unit extends out from said housing, said at least one flange comprises a first section and a second section wherein said second section forms a locking section.

28. The modular wiring system as in claim 27, wherein said first section of said at least one flange extends out from a back face of said housing, and said second section comprises an overhang which extends substantially perpendicular to said first section.

23. A modular wiring system comprising:

a) a functional unit;

b) a wiring unit;

c) a system for coupling said functional unit to said wiring unit in a rotational manner, said system comprising at least one locking prong comprised of electrically conductive material, wherein when said functional unit is coupled to said wiring unit, said at least one locking prong is both electrically and physically coupled to said functional unit at a first end and to said wiring unit at a second end.

29. The modular wiring system as in claim 23, wherein said functional unit comprises a housing and at least one functional interface disposed within said housing;

and wherein said at least one locking prong is coupled to and extends out from a back face of said functional unit housing and comprises a first section and a second section forming a locking section having a larger cross sectional area than said first section.