Plug tail lighting switch and control system

• US 7,780,470 B2
• Filed: 05/20/2008
• Issued: 08/24/2010
• 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: Weeks, Richard, Savicki, Gerald R. Jr., Benoit, John
• Primary Examiner(s): TA, THO DAC
• Application Number:
  US12/123,866
• Publication Number:
  US 20090197461A1
• Time in Patent Office: 826 Days
• Field of Search: 439/535, 439/536, 439/650, 174/48, 174/66, 174/67, 174/50, 174/53, 174/68, 220/241
• US Class Current: 439/535
• CPC Class Codes: H01H 1/5866 characterised by the use of a plug and socket connector
• CPC Class Codes: H01H 23/168 using cams
• CPC Class Codes: H01H 23/205 using a compression spring between tumbler and an articulated contact plate
• CPC Class Codes: H01R 13/70 with built-in switch
• CPC Class Codes: H01R 13/7177 filament or neon bulb
• CPC Class Codes: H01R 25/00 Coupling parts adapted for simultaneous co-operation with two or more identical counterparts, e.g. for distributing energy to two or more circuits supported only by co-operation with a counterpart H01R31/00; with a holder adapted for supporting apparatus to which its counterpart is attached H01R33/88
• CPC Class Codes: H02H 1/0061 concerning transmission of signals transmission of measured quantities or switching orders; sectionalised protection involving signal transmission between at least two stations H02H7/261; comparison of the voltage or current values at two spaced portions of a single system H02H3/28; transferring the output of a sensing member to another variable G01D5/00; electrical measuring arrangements using modulation of electromagnetic waves, e.g. light beams G01R15/24, G01R15/26
• CPC Class Codes: H02H 3/162 for ac systems
• CPC Class Codes: H04L 69/40 for recovering from a failure of a protocol instance or entity, e.g. service redundancy protocols, protocol state redundancy or protocol service redirection management of faults, events, alarms or notifications in data switching networks H04L41/06
• CPC Class Codes: H05K 3/30 Assembling printed circuits with electric components, e.g. with resistor
• CPC Class Codes: Y10T 29/4913 Assembling to base an electrical component, e.g., capacitor, etc.

Abstract

The present invention is directed to an electrical wiring system for use in an AC electrical power distribution circuit including at least one first AC power conductor disposed between an upstream AC power element and a device box and at least one second AC power conductor disposed between the device box and a downstream AC power element. The at least one first AC power conductor and the at least one second AC power conductor are routed into an interior portion of the device box and accessible via a front open face of the device box. The system includes a connector device including a connector housing having a plurality of connector contacts disposed therein.

The plurality of connector contacts are coupled to termination structures configured to couple the at least one first AC power conductor and the at least one second AC power conductor to corresponding contacts of the plurality of connector contacts. An electrical wiring device includes a device housing having a front portion and a rear portion. The front portion includes at least one user-accessible control element disposed thereon. The at least one user-accessible control element is coupled to an electrical switch mechanism disposed in the device housing and coupled to a plurality of device contacts. The plurality of device contacts are accessible by way of a device connection arrangement formed in the rear portion of the device housing. The plurality of device contacts are configured to mate with the plurality of connector contacts when the connector device is coupled to the device connection arrangement.

Claims

1. An electrical wiring system for use in an AC electrical power distribution circuit including at least one first AC power conductor disposed between an upstream AC power element and a device box and at least one second AC power conductor disposed between the device box and a downstream AC power element, the at least one first AC power conductor and the at least one second AC power conductor being routed into an interior portion of the device box and accessible via a front open face of the device box, the system comprising:

a connector device including a connector housing having a plurality of connector contacts disposed therein, the plurality of connector contacts being coupled to termination structures configured to couple the at least one first AC power conductor and the at least one second AC power conductor to corresponding contacts of the plurality of connector contacts; and

an electrical wiring device including a device housing having a front portion and a rear portion, the front portion including at least one user-accessible control element disposed thereon, the at least one user-accessible control element being coupled to an electrical switch mechanism disposed in the device housing and coupled to a plurality of device contacts, the plurality of device contacts being accessible by way of a device connection arrangement formed in the rear portion of the device housing, the plurality of device contacts being configured to mate with the plurality of connector contacts when the connector device is coupled to the device connection arrangement.

2. The system of claim 1, wherein a first contact of the plurality of connector contacts is configured to be coupled to a hot AC conductor, a second contact of the plurality of connector contacts is configured to be coupled to a first traveler conductor, and a third contact of the plurality of connector contacts is configured to be coupled to a second traveler conductor.

3. The system of claim 2, wherein a fourth contact of the plurality of connector contacts is configured to be coupled to a ground conductor.

4. The system of claim 1, wherein the upstream AC power element includes an AC power distribution point in an AC branch electrical circuit.

5. The system of claim 4, wherein the upstream AC power element includes a circuit breaker in a load center panel.

6. The system of claim 1, wherein the upstream AC power element includes an electrical wiring device.

7. The system of claim 1, wherein the downstream AC power element includes an electrical load.

8. The system of claim 1, wherein the downstream AC power element includes an electrical wiring device.

9. The system of claim 1, wherein the plurality of connector contacts includes at least four connector contacts.

10. The system of claim 1, wherein the at least one user-accessible control element includes a toggle switch.

11. The system of claim 1, wherein the at least one user-accessible control element includes a paddle switch.

12. The system of claim 1, wherein the at least one user-accessible control element includes a dimmer control mechanism.

13. The system of claim 1, wherein the electrical switch mechanism includes a single pole single throw switch mechanism.

14. The system of claim 1, wherein the electrical switch mechanism includes a single pole double throw switch mechanism.

15. The system of claim 1, wherein the device connection arrangement includes a power connection receptacle formed in the rear portion, the plurality of device contacts being recessed within the power connection receptacle.

16. The system of claim 15, wherein the connector housing is at least partially disposed within the power connection receptacle when the plurality of device contacts are mated with the plurality of connector contacts.

17. The system of claim 1, wherein the electrical switch mechanism includes a stationary common member having at least one fixed contact disposed thereon and a common device contact of the plurality of device contacts, the electrical switch mechanism further including at least one movable switch member having a flex arm portion coupled to a stationary portion, the flex arm including a movable contact disposed at an end portion thereof, the stationary portion including a traveler device contact of the plurality of device contacts, the movable contact and the at least one fixed contact being opened or closed in accordance with a position of the at least one user-accessible control element.

18. The system of claim 17, wherein the stationary portion includes a side-rail connected to the flex arm at a first end thereof, the side-rail being characterized by a rail length greater than a length of the flex arm, the side-rail including the traveler device contact disposed at a second end thereof.

19. The system of claim 17, wherein the stationary common member includes a first fixed contact and a second fixed contact, the common device contact extending therebetween, the at least one movable switch member comprising a first movable switch member including a first stationary portion coupled to a first flex arm portion, the first flex arm portion including a first movable contact disposed at an end portion thereof, the at least one movable switch member further comprising a second movable switch member including a second stationary portion coupled to a second flex arm portion, the second flex arm portion including a second movable contact disposed at an end portion thereof, the first movable contact corresponding to the first fixed contact and the second movable contact corresponding to the second fixed contact.

20. The system of claim 19, wherein the first stationary portion includes a first side-rail connected to the first flex arm at one end thereof, the first side-rail being characterized by a rail length greater than a length of the first flex arm, the first side-rail including a first traveler device contact disposed at an end opposite the one end thereof, the second stationary portion including a second side-rail connected to the second flex arm at one end thereof, the second side-rail being characterized by a rail length greater than a length of the second flex arm, the second side-rail including a second traveler device contact disposed at an end opposite the one end thereof.

21. The system of claim 20, wherein the common device contact is disposed between the first traveler device contact and the second traveler device contact within the device connection arrangement.

22. The system of claim 20, further comprising a ground device contact disposed between the first traveler device contact and the second traveler device contact.

23. The system of claim 1, wherein the electrical switch mechanism is coupled to an electric circuit assembly disposed within the device housing, the electric circuit assembly being selected from a group of electric circuit assemblies including a GFCI, a dimmer control, or a user-accessible receptacle accessible via the front portion.

24. The system of claim 1, wherein the device connection arrangement includes a power connection receptacle formed in the rear portion at an end portion thereof, the plurality of device contacts being recessed within the power connection receptacle, the power connection receptacle being separated from the electric switch mechanism by a non-conductive isolating member.

25. The system of claim 1, further comprising a latching mechanism configured to latch the connector assembly to the device connection arrangement when the plurality of connector contacts are mated with the plurality of device contacts.

26. The system of claim 25, wherein the latching mechanism includes a flexible latch member configured to mate with a stationary latch member.

27. The system of claim 1, further comprising a pull switch mechanism configured to mate with the connector assembly when the connector assembly is not connected to the device connection arrangement, the pull switch mechanism including a plurality of pull switch contacts disposed within a pull switch housing, the plurality of pull switch contacts being shorted together, the plurality of pull switch contacts being configured to mate with predetermined ones of the plurality of connector contacts, the plurality of pull switch contacts and the plurality of connector contacts being inaccessible to a user when the pull switch mechanism is mated with the connector device.

28. The system of claim 27, wherein the pull switch mechanism is configured to provide a hot connection between the upstream AC power element and the downstream AC power element when the AC electrical power distribution circuit is energized.

29. The system of claim 27, wherein the pull switch and the connector device further comprise a latch mechanism configured to latch the pull switch and the connector device when the pull switch mechanism is mated with the connector device.

30. The system of claim 1, wherein the at least one first AC power conductor includes a hot line conductor configured to be coupled to a hot line connector contact of the plurality of connector contacts and a neutral line conductor configured to be coupled to a neutral line connector contact of the plurality of connector contacts, and the at least one second AC power conductor includes a load hot conductor configured to be coupled to a load hot connector contact of the plurality of connector contacts and a load neutral conductor configured to be coupled to a load neutral connector contact of the plurality of connector contacts.

31. The system of claim 30, wherein the electrical switch mechanism includes a circuit interrupting mechanism configured to couple the hot line conductor with the load hot conductor and couple the neutral line conductor with the load neutral conductor in a reset state, and decouple the hot line conductor from the load hot conductor and decouple the neutral line conductor from the load neutral conductor in a tripped state.

32. The system of claim 1, wherein the termination structures include twist-on wire connectors.

33. The system of claim 1, wherein the electrical switch mechanism comprises a common member including a cradle portion formed therein and a common device contact of the plurality of device contacts, a movable pivot contact being disposed within the cradle portion, the electrical switch mechanism further including at least one stationary contact structure including a fixed contact and a traveler device contact of the plurality of device contacts, the movable pivot contact being configured to switchably engage the fixed contact in accordance with a position of the at least one user-accessible control element.

34. The system of claim 33, wherein the at least one user-accessible control element includes a paddle switch coupled to the movable pivot contact.

35. The system of claim 33, wherein the at least one stationary contact structure includes a first stationary contact structure having a first stationary contact and a first traveler device contact and a second stationary contact structure having a second stationary contact and a second traveler device contact, the movable pivot contact being configured to switchably engage the first fixed contact or the second fixed contact in accordance with a position of the at least one user-accessible control element.

36. The system of claim 1, wherein the electrical switch mechanism comprises a common member including a base portion connected to a common device contact of the plurality of device contacts, a first common flex arm and a second common flex arm extending from the base portion, the first common flex arm and the second common flex arm including at end portions thereof a first movable common contact and a second movable common contact, respectively, the electrical switch mechanism including a first stationary traveler contact structure having a first stationary contact and a first traveler device contact of the plurality of device contacts, the electrical switch mechanism further including a second stationary traveler contact structure having a second stationary contact and a second traveler device contact of the plurality of device contacts.

37. The system of claim 1, wherein the electrical switch mechanism comprises a first switch structure including a fixed first contact and a first device contact of the plurality of device contacts, the electrical switch mechanism further including a second switch structure including a movable second contact and a second device contact of the plurality of device contacts, the moveable second contact being and the fixed contact being closed or open in accordance with a position of the at least one user-accessible control element.

38. An electrical wiring system for use in an AC electrical power distribution circuit including a first plurality of AC power conductors disposed between an upstream AC power element and a device box and a second plurality of AC power conductors disposed between the device box and a downstream AC power element, the first plurality of AC power conductors and the second plurality of AC power conductors being routed into an interior portion of the device box and accessible via a front open face of the device box, the system comprising:

a connector device including a connector housing having a plurality of connector contacts disposed therein, the plurality of connector contacts being coupled to termination structures configured to couple the first plurality of AC power conductors and the second plurality of AC power conductors to corresponding contacts of the plurality of connector contacts; and

an electrical wiring device including a device housing having a front portion and a rear portion, the front portion including at least one user-accessible control element disposed thereon, the at least one user-accessible control element being coupled to an electrical circuit mechanism disposed in the device housing and coupled to a plurality of device contacts, the electrical circuit mechanism being configured to be switched between a first circuit state and a second circuit state, the plurality of device contacts being accessible by way of a device connection arrangement formed in the rear portion of the device housing, the plurality of device contacts being configured to mate with the plurality of connector contacts when the connector device is coupled to the device connection arrangement.

39. The system of claim 38, wherein the electrical circuit mechanism is configured to switchably control a light fixture.

40. The system of claim 38, wherein the plurality of device contacts include a line hot contact, a line neutral contact, a load hot contact and a load neutral contact.

41. The system of claim 38, wherein the electrical circuit mechanism includes a circuit interrupter, and the first circuit state includes a reset state and the second circuit state includes a tripped state.

42. The system of claim 38, wherein the device connection arrangement includes a power connection receptacle formed in the rear portion at an end portion thereof, the plurality of device contacts being recessed within the power connection receptacle, the power connection receptacle being separated from the electrical circuit mechanism by a non-conductive isolating member.