Solid wire modular electrical system for office areas

• US 7,614,896 B2
• Filed: 07/01/2005
• Issued: 11/10/2009
• Est. Priority Date: 07/15/2002
• Status: Expired due to Term

• Current Assignee: Haworth Incorporated
• Original Assignee: Haworth Incorporated
• Inventors: Johnson, Ross S., Emery, Dave, Wilson, Harold R., Crow, Derek D., Elushik, Richard D., Borgman, Randy
• Primary Examiner(s): Figueroa; Felix O
• Application Number:
  US11/173,935
• Publication Number:
  US 20060024996A1
• Time in Patent Office: 1,593 Days
• Field of Search: 439119-121, 439/215, 439/731, 439/696, 439/687, 439/214, 439/216
• US Class Current: 439/215
• CPC Class Codes: H02G 3/00 Installations of electric cables or lines or protective tubing therefor in or on buildings, equivalent structures or vehicles installations of bus-bars H02G5/00; overhead installations H02G7/00; installations in or on the ground H02G9/00

Abstract

A modular multi-component power distribution system is provided having a plurality of modular components which are configurable into a bus-bar based system, a flexible cable base system and a hybrid configuration wherein the bus-bar and flexible cable components are interconnected together. The components allow for configuration of the power distribution system into a variety of office systems including wall panel systems, desking or freestanding furniture systems and raised flooring systems either individually or in various combinations. The system components include a bus-bar-like power distribution assembly (PDA), branching connectors, flex connectors, which are useable to join power distribution assemblies together, and receptacles which are pluggable into either the power distribution assembly, the branching connectors or the flex connectors. Additionally, the power distribution assembly includes solid-wire electrical conductors which are accessible through multiple groups of plug openings to which any of the connectors and receptacles may be plugged. Still further, the flexible branching connectors are joinable serially together to distribute power and also may plug into the PDAs. The branching connectors further include at least one group of openings on each end to allow for the connection of additional system components like a branching connector or a receptacle.

Claims

1. A power distribution system for longitudinally elongate raceways comprising:

power distribution modules which are elongate in a longitudinal direction so as to be mountable in and extend longitudinally along raceways, said power distribution modules having a plurality of conductors extending longitudinally therethrough in said longitudinal direction which comprise common, neutral or ground conductors to define a plurality of electrical circuits carried longitudinally through said power distribution module;

a first one of said power distribution modules including a plurality of groups of first openings which are longitudinally spaced apart from each other and open in a sideward direction transverse to said longitudinal direction wherein each group of first openings is arranged in a first opening pattern and provides sideward access to said electrical conductors which extend in said longitudinal direction and are transversely exposed in said sideward direction; and

at least a second one of said power distribution modules including at least one group of second openings on a front module face thereof which faces in said sideward direction wherein said second openings open sidewardly and have a same configuration as said first openings with a same size and shape and are arranged in said first opening pattern to provide access sidewardly to said conductors that are exposed therein, and further including electrical contacts electrically connected to said conductors and each having a projecting contact part projecting sidewardly from a back module face thereof, which said back module face faces sidewardly opposite to said front module face, said projecting contact parts being arranged in a first contact pattern corresponding to said first opening pattern so as to be insertable sidewardly into said first openings and engageable sidewardly with said exposed conductors of said first power distribution module through said group of first openings thereof to electrically connect said conductors of said first and second power distribution modules while said second openings remain exposed in said sideward direction which permit simultaneous connection of another said second power distribution module thereto; and

a receptacle having receptacle contacts projecting sidewardly from a sideward-facing back receptacle face thereof which are arranged in said first contact pattern so as to be alternatively engagable sidewardly with any of said groups of said first and second openings of said first and second power distribution modules, and said second power distribution module being simultaneously engagable with said first power distribution module, by said projecting contact parts thereof, and with said receptacle, by said second openings thereof, said receptacle including plug openings on an exterior receptacle face thereof which open sidewardly and are arranged in a second opening pattern different from said first opening pattern and permit electrical connection of a plug of electrical equipment with said receptacle contacts.

2. The power distribution system according to claim 1, wherein a third one of said power distribution modules serves as an additional power distribution module which is able to be alternately connected to said first and second power distribution modules, said third power distribution module including electrical contacts electrically connected to said conductors thereof and each having a projecting contact part projecting sidewardly from a sideward-facing back module face thereof, wherein said projecting contact parts of said third power distribution module are arranged in said first contact pattern so as to be able to be alternatively engaged sidewardly with said group of first openings of said first power distribution module and said group of second openings of said second power distribution module to electrically connect said conductors of said third power distribution module with said conductors of either alternative one of said first and second power distribution modules.

3. The power distribution system according to claim 2, wherein said third power distribution module includes at least one group of sideward-opening third openings having a same configuration as said first and second openings with a same size and shape and arranged in said first opening pattern to provide access to said conductors therein, said receptacle having said receptacle contacts projecting from said back receptacle face defined by the other said side face thereof which are arranged in said first contact pattern so as to be alternatively engageable with any of said groups of said first, second and third openings of said first, second and third power distribution modules.

4. The power distribution system according to claim 3, wherein said first power distribution module includes said plurality of said groups of said first openings wherein said second power distribution module is engageable with any one of said groups of said first openings and said receptacle is engageable with any one of said groups of said first, second and third openings of said first power distribution module, said second power distribution module and said third power distribution module.

5. The power distribution system according to claim 1, wherein said electrical contacts of said second power distribution module have interior contact parts which are exposed sidewardly through said group of second openings thereof through said front module face.

6. A power distribution system for building raceways comprising:

a main power distribution module having opposite ends and a longitudinal length extending from and between said opposite ends, said main power distribution module comprising an extruded insulative housing extending between and defining said opposite ends which have respective terminal end faces, said housing comprising two longitudinal housing halves which said housing halves each have a one-piece construction having an end-wise constant profile as viewed from one said end face of said housing half and extending continuously along the length thereof from and between said opposite end faces wherein the housing halves are joined together so as to have a uniform end-wise cross-sectional profile along the length thereof, said main distribution module including a plurality of elongate conductor wires which extend between said opposite ends and are confined between said housing halves wherein at least one of said housing halves include groups of first openings which open sidewardly through said housing half to expose portions of said conductor wires wherein each of said groups of first openings is arranged in a first opening pattern; and

a secondary power distribution module having a plurality of electrical conductors therein and a plurality of electrical contacts which project from a back face of said secondary power distribution module and are arranged in a first contact pattern corresponding to said first opening pattern so as to be insertable within a respective one of said groups of first openings of said main power distribution module for engagement with said exposed portions of said conductor wires.

7. The power distribution system according to claim 6, wherein said main power distribution module has opposite side faces defined by said housing halves which are uniformly planar along the longitudinal length of the main power distribution module between said opposite ends and are disposed in parallel planar relation along the length of said main power distribution module from and between said opposite end faces, said first openings being formed in said side faces.

8. The power distribution system according to claim 7, wherein said housing halves are hinged along a longitudinal edge thereof and folded together wherein said conductor wires are confined therebetween.

9. A power distribution system for installation in building raceways comprising:

a first power distribution module having a plurality of electrical conductors extending therethrough that define a plurality of circuits which comprise common, neutral and ground conductors, said first power distribution module including first access parts having a first configuration which define a group of openings arranged in a first pattern providing access to said conductors of said first power distribution module;

a second power distribution module having a plurality of electrical conductors therein, and having second access parts having a second configuration different from said first configuration which permits mating of said first configuration with said second configuration, wherein said first and second configurations are matable together while respectively preventing mating of said first configuration with said first configuration and said second configuration with said second configuration, said second access parts defining openings which are arranged in said first pattern and provide access to said conductors, said second access parts being arranged in said first pattern so as to be adapted for mating engagement with said first access parts to electrically connect said conductors of said first and second distribution modules, said second distribution module further respectively including additional first access parts formed with said first configuration arranged in said first pattern to provide access to said conductors of said second power distribution module; and

a third power distribution module having electrical conductors extending longitudinally therethrough and including additional second access parts which define openings and are formed with said second configuration in said first pattern to permit mating engagement alternatively with either said corresponding first access parts of said second power distribution module or said first power distribution module;

wherein said first configuration is one of a female configuration and a male configuration and said second configuration is the other of said female configuration and said male configuration.

10. The power distribution system according to claim 9, wherein said third power distribution module further includes a group of openings defined by additional first access parts having said first configuration arranged in said first pattern.

11. The power distribution system according to claim 10, wherein said first power distribution module extends longitudinally and has a plurality of said first access parts with said first configuration in said first pattern along the length thereof to permit engagement of said second access parts of said second power distribution module with any of said groups of openings.

12. The power distribution system according to claim 11, wherein said second power distribution module has electrical contacts which includes first and second sections thereof that are exposed respectively through said first and second access parts thereon.

13. The power distribution system according to claim 12, wherein said first and second access parts on said second power distribution module are disposed on opposite side faces thereof which face sidewardly in opposite directions and said electrical contacts extend sidewardly such that opposite ends thereof are exposed through said groups of said openings on said opposite side faces.

14. A power distribution system comprising:

a main power distribution module having a plurality of conductors extending longitudinally therethrough in a longitudinal direction which define a plurality of electrical circuits having common, neutral and ground wires, at least one side face of said main power distribution module facing sidewardly, transverse to said longitudinal direction, and including a group of female openings which open sidewardly and are arranged in a first pattern so as to expose side portions of said conductors; and

a plurality of secondary power distribution modules which are engageable directly with each other and directly with said main power distribution module, each of said secondary power distribution modules including a plurality of conductors extending longitudinally therethrough in said longitudinal direction, which said conductors include electrical contacts disposed within said secondary power distribution module, each said secondary power distribution module further including a plug unit having a group of male projections on one plug face which enclose but permit access to first portions of said electrical contacts and are arranged in said first pattern so as to be insertable sidewardly within said female openings of said main power distribution module to engage said electrical contacts with said conductors of said main power distribution module, each said secondary power distribution module further including a group of female openings on an opposite plug face thereof, which open sidewardly and expose second portions of said electrical contact and are arranged in said first pattern to permit engagement directly with said male projections of another of said secondary power distribution modules, said male projections and said female openings of said secondary power distribution module permitting simultaneous engagement of said secondary power distribution module directly with and intermediately between said main power distribution module and another of said secondary power distribution modules.

15. The power distribution system according to claim 14, wherein a receptacle is provided which includes male projections having exposed electrical contacts therein wherein said male projections are arranged in said first pattern so as to be engageable with said female openings of any of said main and said secondary power distribution modules to complete an electrical connection therebetween, each said secondary power distribution module being simultaneously engagable with said main distribution module and said receptacle.

16. A power distribution system for building raceways comprising:

a main power distribution module having a plurality of parallel electrical conductors extending longitudinally through an insulative housing, said housing including at least one group of openings in a first pattern which provides access to all of said conductors, said openings each have upper and lower edges, and said group of openings being defined by a plurality of vertical rows of openings which are arranged in parallel, side-by-side relation to define said first pattern wherein each adjacent pair of adjacent openings are horizontally aligned with each other with said upper edges being aligned with each other and said lower edges being aligned with each other such that each said pair of adjacent openings provides access to a first said conductor along said upper edges of said pair of said adjacent openings and a second said conductor along said lower edges of said pair of said adjacent openings; and

a secondary power distribution module comprising a plurality of electrical conductors contained within a housing and electrical contacts which project from a back face of said secondary power distribution module in a contact pattern corresponding to said first pattern, said contacts being arranged in two vertical rows corresponding to said vertical rows of said openings of said main distribution module wherein each sidewardly adjacent pair of said contacts have exposed contact portions which face in opposite vertical directions exteriorly of said housing, said contacts being engageable with said openings wherein one of each said pair of said contacts engages said first conductor in one said opening and the other of said pair of contacts engages said second conductor in the sidewardly adjacent one of said pair of said adjacent openings.

17. The power distribution system according to claim 16, wherein said contacts on said secondary power distribution module are enclosed by insulative posts wherein said contacts are exposed on only one side of said posts with said contacts of each sidewardly adjacent pair thereof being exposed in said opposite directions.

18. A power distribution system for longitudinally elongate raceways comprising:

power distribution modules which are elongate in a longitudinal direction so as to define a module length extending lengthwise from end to end and be mountable in and extend longitudinally along raceways, said power distribution modules having opposite lengthwise extending side faces which define a module width, and having a plurality of conductors extending longitudinally therethrough in said longitudinal direction which comprise common, neutral or ground conductors to define a plurality of electrical circuits carried longitudinally through said power distribution module along said module length;

a first one of said power distribution modules including a plurality of groups of first openings which open widthwise from one said side face in a sideward direction transverse to said longitudinal direction wherein said groups of said first openings are longitudinally spaced apart from each other along said module length to define a plurality of connection locations along said one side face, and wherein each group of first openings is arranged in a first opening pattern and provides access to said electrical conductors which extend in said longitudinal direction and are transversely exposed in said sideward direction; and

at least a second one of said power distribution modules including at least one group of second openings on a front module face defined by one said side face thereof which faces in said sideward direction wherein said second openings open sidewardly and have a same configuration as said first openings with a same size and shape and are arranged in said first opening pattern to provide access sidewardly to said conductors that are exposed therein, and further including electrical contacts electrically connected to said conductors and each having a projecting contact part projecting sidewardly from a back module face defined by the other said side face thereof, which said back module face faces sidewardly opposite to said front module face, said projecting contact parts being arranged in a first contact pattern corresponding to said first opening pattern so as to be insertable sidewardly into said first openings and engageable sidewardly with said exposed conductors of said first power distribution module through said group of first openings thereof to electrically connect said conductors of said first and second power distribution modules while said second openings remain exposed in said sideward direction for simultaneous connection of another said second power distribution module thereto; and

a receptacle having receptacle contacts projecting sidewardly from a sideward-facing back receptacle face thereof which are arranged in said first contact pattern so as to be alternatively engagable sidewardly with any of said groups of said first and second openings of said first and second power distribution modules, and said second power distribution module being simultaneously engagable with said first power distribution module, by said projecting contact parts thereof, and with said receptacle, by said second openings thereof, said receptacle including plug openings on an exterior receptacle face thereof which open sidewardly and are arranged in a second opening pattern different from said first opening pattern and which permit electrical connection of a plug of electrical equipment with said receptacle contacts.