Electrical wiring system with slide-in connector

• US 7,510,429 B1
• Filed: 02/23/2007
• Issued: 03/31/2009
• Est. Priority Date: 10/07/2003
• Status: Active Grant

• Current Assignee: Pass & Seymour Incorporated (Legrand SA)
• Original Assignee: Pass & Seymour Incorporated (Legrand SA)
• Inventors: Baldwin, Ralph, Savicki, Gerald R. Jr.
• Primary Examiner(s): TA, THO DAC
• Application Number:
  US11/678,283
• Time in Patent Office: 767 Days
• Field of Search: 439/535, 439/536, 439/650, 439/352, 174/48, 174/66, 174/67, 174/50, 174/53, 174/58, 174/68
• US Class Current: 439/535
• CPC Class Codes: H01R 25/003 the coupling part being secured only to wires or cables
• CPC Class Codes: H01R 27/02 for simultaneous co-operation with two or more dissimilar counterparts
• CPC Class Codes: H01R 31/02 Intermediate parts for distributing energy to two or more circuits in parallel, e.g. splitter with a holder adapted for supporting apparatus to which its counterpart is attached H01R33/92
• CPC Class Codes: H01R 4/48185 adapted for axial insertion of a wire end
• CPC Class Codes: H01R 43/26 for engaging or disengaging the two parts of a coupling device structural association with two-part coupling device H01R13/629
• CPC Class Codes: H02G 3/18 providing line outlets

Abstract

The present invention is directed to an electrical wiring system for use in an electrical distribution system including at least one electric circuit. The at least one electric circuit includes a plurality of electric power transmitting wires disposed between an electric power source interface and at least one electrical device location. The system includes an electrical wiring device disposed at the at least one electrical device location. The electrical wiring device includes a predefined coupling area having a plurality of electrical wiring device contacts disposed therein. A connector assembly includes a plurality of electrical connector contacts disposed therein. The connector assembly is configured to be directly connected to the plurality of electrical power transmitting wires such that electrical continuity is established between the plurality of electrical power transmitting wires and the plurality of electrical connector contacts. The connector assembly is also configured to be disposed in a contacting relationship with the predefined coupling area of the electrical wiring device such that electrical continuity is established between the plurality of electrical connector contacts and the plurality of electrical wiring device contacts.

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 source interface and at least one electrical device location, the system comprising:

an electrical wiring device disposed at the at least one electrical device location, the electrical wiring device including a predefined coupling area having a plurality of electrical wiring device contacts disposed therein; and

a connector assembly including a plurality of electrical connector contacts disposed therein, the connector assembly being configured to be directly connected to the plurality of electrical power transmitting wires such that electrical continuity is established between the plurality of electrical power transmitting wires and the plurality of electrical 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 such that electrical continuity is established between the plurality of electrical connector contacts and the plurality of electrical wiring device contacts.

2. The system of claim 1, wherein the predefined coupling area is an exterior substantially planar region disposed on a rear surface of the electrical wiring device.

3. The system of claim 2, wherein the plurality of electrical wiring device contacts are disposed in the exterior substantially planar region.

4. The system of claim 3, wherein the electrical wiring device includes a neutral contact structure and a hot contact structure disposed within the electrical wiring device, the plurality of electrical wiring device contacts including a neutral wiring device contact coupled to the neutral contact structure and a hot wiring device contact coupled to the hot contact structure.

5. The system of claim 4, wherein the rear surface accommodates a ground strap structure, and the plurality of electrical wiring device contacts includes at least one ground contact formed in the ground strap structure.

6. The system of claim 2, wherein the connector assembly is configured to cover at least one of the wiring device contacts if there is electrical continuity between the wiring device contact and the corresponding electrical connector contact.

7. The system of claim 2, wherein the connector assembly includes a covering element that is configured to prevent human contact of at least one of the electrical connector contacts.

8. The system of claim 2, wherein the connector assembly, in the contacting relationship, is configured to slide along the exterior substantially planar region from an initial predefined coupling area position to a second predefined coupling area position whereby the plurality of electrical connector contacts are mated with the plurality of electrical wiring device contacts.

9. The system of claim 8, wherein the connector assembly further comprises a registration member configured to position and align the connector assembly in the initial predefined coupling area position when the connector assembly is disposed in the contacting relationship with the electrical wiring device.

10. The system of claim 9, wherein the registration member and/or the connector assembly is configured to cover the plurality of electrical wiring device contacts when the connector assembly is disposed in the second predefined coupling area position.

11. The system of claim 8, wherein the connector assembly further comprises a latch configured to mate with a keeper mechanism disposed on the electrical wiring device when the connector assembly is disposed in the second predefined coupling area position.

12. The system of claim 1, wherein the predefined coupling area is a receptacle having the plurality of electrical wiring device contacts disposed therein, the receptacle being configured to receive the connector assembly in the contacting relationship such that electrical continuity is established between the plurality of electrical connector contacts and the plurality of electrical wiring device contacts.

13. The system of claim 12, wherein the plurality of electrical wiring device contacts comprise female receptacle contacts.

14. The system of claim 13, wherein the plurality of electrical connector contacts comprises male contact elements.

15. The system of claim 12, wherein the plurality of electrical wiring device contacts comprise male receptacle contacts.

16. The system of claim 15, wherein the plurality of electrical connector contacts comprises female contact elements.

17. The system of claim 1, further comprising a latching apparatus configured to prevent the connector assembly from being removed from the electrical wiring device to thereby ensure that electrical continuity is maintained between the plurality of electrical connector contacts and the plurality of electrical wiring device contacts.

18. The system of claim 17, wherein the latching apparatus includes a latching mechanism disposed on the connector assembly and a keeper structure disposed on the electrical wiring device, the latching mechanism being configured to mate with the keeper structure when the plurality of electrical connector contacts mate with the plurality of electrical wiring device contacts.

19. The system of claim 18, wherein the keeper structure is formed from a portion of a ground strap structure disposed on the rear major surface of the electrical wiring device.

20. The system of claim 18, wherein the latching mechanism is manually moveable to permit removal of the connector assembly from the electrical wiring device.

21. The system of claim 18, wherein the latching mechanism provides an indication that the connector assembly is in a locked position within the electrical wiring device.

22. The system of claim 21, wherein the indication includes an audible indication.

23. The system of claim 21, wherein the indication includes a visual indication.

24. The system of claim 1, wherein the predefined coupling area is a relatively planar area disposed on a rear major surface of the electrical wiring device.

25. The system of claim 1, wherein the connector assembly further comprises a registration member configured to position and align the connector assembly in the predefined coupling area.

26. The system of claim 1, wherein the connector assembly further comprises a plurality of feed-through terminal ports in electrical communication with the plurality of electrical connector contacts, each of the plurality of feed-through terminal ports being configured to accommodate one of a plurality of feed-through wires, the plurality of feed-through wires being disposed in the electrical distribution system down stream from the at least one electrical device location.

27. The system of claim 1, wherein the electrical wiring device includes at least one electrical wiring device apparatus selected from a group of electrical wiring device apparatuses comprising an electrical face receptacle configured to accept a power plug coupled to an electrical load, an electrical switch, a GFCI, an AFCI, a lighting device, a sensor device, a transient voltage surge suppressor, an environmental regulation device, and/or a timer device.

28. A method for installing 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 source interface and at least one electrical device location, the method comprising:

disposing an electrical wiring device at the at least one electrical device location, the electrical wiring device including a predefined coupling area having a plurality of electrical wiring device contacts disposed therein;

providing a connector assembly including a plurality of electrical connector contacts disposed therein;

directly connecting the connector assembly to the plurality of electrical power transmitting wires such that electrical continuity is established between the plurality of electrical power transmitting wires and the plurality of electrical connector contacts; and

positioning the connector assembly in a contacting relationship with the predefined coupling area of the electrical wiring device to thereby establish electrical continuity between the plurality of electrical connector contacts and the plurality of electrical wiring device contacts.

29. The method of claim 28, wherein the predefined coupling area is an exterior substantially planar region disposed on a surface of the electrical wiring device, and wherein the plurality of electrical wiring device contacts are disposed in the exterior substantially planar region.

30. The method of claim 29, wherein the electrical wiring device includes a neutral contact structure and a hot contact structure disposed within the electrical wiring device, the plurality of electrical wiring device contacts including a neutral wiring device contact coupled to the neutral contact structure and a hot wiring device contact coupled to the hot contact structure.

31. The method of claim 29, wherein the surface accommodates a ground strap structure, and the plurality of electrical wiring device contacts includes at least one ground contact formed in the ground strap structure.

32. The method of claim 28, wherein the step of positioning further comprises:

positioning the connector assembly in an initial position within the predefined coupling area; and

sliding the connector assembly from the initial position to a second position in the predefined coupling area, whereby the plurality of electrical connector contacts are mated with the plurality of electrical wiring device contacts.

33. The method of claim 32, wherein the connector assembly further comprises a registration member and the step of positioning the connector assembly in an initial position within the predefined coupling area further comprises:

aligning the registration member with the initial position; and

positioning the connector assembly in the predefined coupling area to establish the contacting relationship with the electrical wiring device.

34. The method of claim 33, wherein the registration member and/or the connector assembly cover the plurality of electrical wiring device contacts when the connector assembly is disposed in the second predefined coupling area position.

35. The method of claim 28, further comprising the step of latching the connector assembly to the electrical wiring device to thereby prevent the connector assembly from being removed from the electrical wiring device after electrical continuity is established between the plurality of electrical connector contacts and the plurality of electrical wiring device contacts.

36. The method of claim 35, wherein the step of latching is effected by a latching apparatus that includes a latching mechanism disposed on the connector assembly and a keeper structure disposed on the electrical wiring device, the latching mechanism being configured to mate with the keeper structure when the plurality of electrical connector contacts mate with the plurality of electrical wiring device contacts.

37. The method of claim 36, wherein the latching mechanism provides an indication that the connector assembly is locked within the electrical wiring device.

38. The method of claim 37, wherein the indication includes an audible indication.

39. The method of claim 37, wherein the indication includes a visual indication.

40. The method of claim 35, further comprising the step of manipulating manually and/or with the aid of a tool the latching mechanism to permit removal of the connector assembly from the electrical wiring device.

41. The method of claim 28, wherein the step of positioning the connector assembly in a contacting relationship with the predefined coupling area of the electrical wiring device includes the step of inserting the connector assembly into a receptacle stricture disposed in the predefined coupling area, the receptacle being configured to receive the connector assembly in the contacting relationship such that electrical continuity is established between the plurality of electrical connector contacts and the plurality of electrical wiring device contacts.

42. The method of claim 41 wherein the plurality of electrical wiring device contacts comprise female receptacle contacts and the plurality of electrical connector contacts comprises male contact elements.

43. The method of claim 41, wherein the plurality of electrical wiring device contacts comprise male receptacle contacts and the plurality of electrical connector contacts comprises female contact elements.

44. The method of claim 28, wherein the connector assembly further comprises a plurality of feed-through terminal ports in electrical communication with the plurality of electrical connector contacts.

45. The method of claim 44, further comprising the step of inserting one of a plurality of feed-through wires into a corresponding one of the plurality of feed-through terminal ports, the plurality of feed-through wires being disposed in the electrical distribution system down stream from the at least one electrical device location.

46. 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 having a first end portion connected to an electric power source interface and a second end portion disposed at least one electrical device location, a device box having a wiring egress aperture and an interior volume being disposed at the at least one electrical device location, the system comprising:

an electrical wiring device configured to be mounted on the device box, the electrical wiring device including a predefined coupling area having a plurality of electrical wiring device contacts disposed therein; and

a connector assembly including a plurality of electrical connector contacts disposed therein, the connector assembly being configured to be connected to the second end portion of the plurality of electrical power transmitting wires such that electrical continuity is established between the plurality of electrical power transmitting wires and the plurality of electrical 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 such that electrical continuity is established between the plurality of electrical connector contacts and the plurality of electrical wiring device contacts, the second end portion extending through the wiring egress aperture into the interior volume and not connected to the device box.

47. The system of claim 46, wherein the plurality of electrical connector contacts include a plurality of stripped wire leads extending therefrom, the plurality of stripped wire leads being configured to be connected to the second end portion by way of connectors configured to be stowed in the interior volume after the plurality of stripped wire leads are connected to the second end portion.

48. The system of claim 46, wherein the second end portion of the plurality of electrical power transmitting wires are directly terminated to corresponding ones of the plurality of electrical connector contacts.

49. 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 premise wires disposed between an electric power source interface and at least one electrical device location, the system comprising:

an electrical wiring device disposed at the at least one electrical device location, the electrical wiring device including a predefined coupling area having a plurality of electrical wiring device contacts disposed therein; and

a connector assembly including a plurality of electrical connector contacts disposed therein, the connector assembly being configured to be directly connected to each of the plurality of premise wires at corresponding connection points such that electrical continuity is established between the plurality of premise wires and the plurality of electrical 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 such that electrical continuity is established between the plurality of electrical connector contacts and the plurality of electrical wiring device contacts.

50. The system of claim 49, wherein the electrical wiring device is configured to be mounted to a device box at an open faced portion thereof, the device box further including a wiring egress aperture disposed in at least one wall portion of the device box, the at least one wall portion defining an interior volume.

51. The system of claim 50, wherein the plurality of premise wires extend through the wiring egress aperture and the corresponding connection points are disposed in the interior volume of the device box.

52. The system of claim 49, wherein the plurality of electrical connector contacts include a plurality of stripped wire leads extending therefrom, the plurality of stripped wire leads being configured to be connected to the plurality of premise wires via connector elements not fixed relative to the at least one electrical device location.

53. The system of claim 49, wherein the plurality of premise wires are directly terminated to corresponding ones of the plurality of electrical connector contacts.

54. 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 having a first end portion connected to an electric power source interface and a second end portion disposed at least one electrical device location, a device box having a wiring egress aperture and an interior volume being disposed at the at least one electrical device location, the system comprising:

an electrical wiring device configured to be mounted on the device box, the electrical wiring device including a predefined coupling area having a plurality of electrical wiring device contacts disposed therein; and

a connector assembly including a plurality of electrical connector contacts disposed therein, the connector assembly being configured to be directly connected to the plurality of electrical power transmitting wires such that electrical continuity is established between the plurality of electrical power transmitting wires and the plurality of electrical connector contacts within the interior volume, the connector assembly also being configured to be disposed in a contacting relationship with the predefined coupling area of the electrical wiring device such that electrical continuity is established between the plurality of electrical connector contacts and the plurality of electrical wiring device contacts.

55. The system of claim 54, wherein the plurality of electrical connector contacts include a plurality of stripped wire leads extending therefrom, the plurality of stripped wire leads being configured to be connected to the second end portion by way of connectors configured to be stowed in the interior volume after the plurality of stripped wire leads are connected to the second end portion.

56. The system of claim 54, wherein the second end portion of the plurality of electrical power transmitting wires are directly terminated to corresponding ones of the plurality of electrical connector contacts.

57. 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 source interface and at least one electrical device location, the system comprising:

an electrical wiring device disposed at the at least one electrical device location, the electrical wiring device including a predefined coupling area having a plurality of electrical wiring device contacts disposed therein; and

a connector assembly including a plurality of electrical connector contacts disposed in an interior portion of the assembly and a plurality of wire leads connected to the plurality of electrical connector contacts and extending to an exterior portion of the connector assembly, the plurality of wire leads disposed at the exterior portion being configured to be connected to corresponding wires of the plurality of electrical power transmitting wires at corresponding connection points such that electrical continuity is established between the plurality of electrical power transmitting wires and the plurality of electrical 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 such that electrical continuity is established between the plurality of electrical connector contacts and the plurality of electrical wiring device contacts.

58. The system of claim 57, wherein the electrical wiring device is configured to be mounted to a device box at an open faced portion thereof, the device box further including a wiring egress aperture disposed in at least one wall portion of the device box, the at least one wall portion defining an interior volume.

59. The system of claim 58, wherein the plurality of electrical power transmitting wires extend through the wiring egress aperture and the corresponding connection points are disposed in the interior volume of the device box and not mechanically fixed to the device box.

60. 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 source interface and at least one electrical device location, the system comprising:

an electrical wiring device disposed at the at least one electrical device location, the electrical wiring device including a predefined coupling area having a plurality of electrical wiring device contacts disposed therein being disposed on a major rear surface of the electrical wiring device; and

a connector assembly including a plurality of electrical connector contacts disposed therein, the connector assembly being configured to be directly connected to the plurality of electrical power transmitting wires such that electrical continuity is established between the plurality of electrical power transmitting wires and the plurality of electrical 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 such that electrical continuity is established between the plurality of electrical connector contacts and the plurality of electrical wiring device contacts.