Modular electrical distribution system for a building

• US 8,172,588 B2
• Filed: 04/09/2010
• Issued: 05/08/2012
• Est. Priority Date: 08/09/2007
• Status: Active Grant

• Current Assignee: Haworth Incorporated
• Original Assignee: Haworth Incorporated
• Inventors: Johnson, Ross, Wilson, Harold R., Gingrich, Bryan
• Primary Examiner(s): Le, Thanh Tam
• Application Number:
  US12/798,746
• Publication Number:
  US 20100328852A1
• Time in Patent Office: 760 Days
• Field of Search: 439/215, 439/535, 439/538, 439/654, 174/60, 174/62, 174/64, 174/65
• US Class Current: 439/215
• CPC Class Codes: H01R 25/006 the coupling part being secured to apparatus or structure, e.g. duplex wall receptacle
• CPC Class Codes: H01R 25/16 Rails or bus-bars provided with a plurality of discrete connecting locations for counterparts
• 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
• CPC Class Codes: H02G 3/38 the cables or lines being installed in preestablished conduits or ducts

Abstract

A universal power distribution system is provided for routing electrical circuits within a building structure to comprehensively provide electrical power to the building in ceiling configurations, wall-mounted configurations, raised floor configurations and in office furniture configurations. The system components for all of these configurations have common plug connectors that are engagable with each other so as to be readily usable in a wide variety of applications. The system is readily adaptable to form virtually any conventional circuit configuration found within conventional hard-wired systems yet is formed simply through the routing of the cables through the building cavities and interconnection is accomplished merely by plugging components together rather than through labor-intensive manual wiring.

Claims

1. A building power wiring system comprising:

elongate cables having opposite A-ends and B-ends, wherein each of said cables includes a single A-end connector on said A-end of each of said cables and at least two B-end connectors on the opposite B-end thereof, said cables having mating structures to allow said A-end connectors to connect to any said B-end connector but said mating structures do not allow said A-end connector to connect with any other said A-end connector or said B-end connector to connect to any other said B-end connector of another one of said cables, a plurality of said cables being serially connectable together by serial interconnection of the A-end connector of one of said cables to said B-end connector of said another one of said cables;

a box fixture having one of said A-end connector and said B-end connector; and

at least one fixture box, each of said at least one fixture box being provided with connector mounts which allow for interconnection of one or more of said cables thereto, said connector mounts permitting at least one of said A-end connectors or said B-end connectors to be fixedly attached to said at least one fixture box for routing of electrical power to said at least one fixture box so that either of said A-end or B-end connectors are accessible in said at least one fixture box for connection of said box fixture thereto.

2. The system according to claim 1, wherein said at least one fixture box comprises a first fixture box and a first one of said cables has the B-end connector fixedly attached to said first fixture box so that a plurality of connection access points providing access to the. B-end connections are defined within said first fixture box.

3. The system according to claim 2, wherein said box fixture comprises first outlet receptacle which includes an integral plug connection defining said A-end connector that is plug-connected to a first one of the B-end connectors of said first one of said cables supported on said first fixture box.

4. The system according to claim 3, wherein a second one of said cables has said A-end connector thereof connected to a second one of said B-end connectors of said first one of said cables within said first fixture box and exits therefrom to route power away from said first fixture box.

5. The system according to claim 4, wherein said at least one fixture box further includes a second fixture box, and the B-end of said second one of said cables is fixedly attached to said second fixture box and a second outlet receptacle is plug-connected to one of the B-end connectors of said second one of said cables on said second fixture box.

6. The system according to claim 2, which includes a pigtail device including an integral plug connection and pigtail wires being plug-connected to one of the B-end connectors of said first one of said cables and the pigtail wires are connected to a standard direct-wired receptacle.

7. The system according to claim 1, wherein said at least one fixture box comprises a first fixture box and a first one of said cables has the A-end fixedly attached to said first fixture box so that a connection access point providing access to the A-end connector is defined within said first fixture box.

8. The system according to claim 7, wherein said box fixture comprises a switch device having an integral B-end connector attached to said A-end of said first one of said cables within said first fixture box.

9. The system according to claim 7, including a first switch pigtail device having a first integral B-end connector and pigtail wires wherein said B-end connector is attached to the A-end of said first one of said cables and the pigtail wires are attached to a standard direct-wired switch defining a first standard switch.

10. The system according to claim 9, wherein the A-end of a second one of said cables is fixedly attached to said first fixture box and including a second switch pigtail device having a second integral B-end connector and pigtail wires wherein said second integral B-end connector is attached to the A-end of said second one of said cables and the pigtail wires of said second switch pigtail device are attached to a second standard switch wherein said first and second standard switches are spaced side to side in a same increment as industry standard spacing.

11. The system according to claim 2, including a second one of said cables having said A-end thereof fixedly connected to said first fixture box so that a connection access point to the A-end connector is located within said first fixture box and wherein a switch device having an integral B-end connector is attached to said A-end of said second one of said cables within said first fixture box.

12. A building power wiring system comprising:

elongate cables having opposite A-ends and B-ends, wherein each of said cables includes one or both of an A-end connector on said A-end of each of said cables and a multi-connector configuration of at least two B-end connectors on the opposite B-end thereof, said cables having mating structures to allow any said A-end connector to connect to any said B-end connector but said mating structures do not allow said A-end connector to connect with any other said A-end connector or said B-end connector to connect to any other said B-end connector of another one of said cables;

a box fixture having said A-end connector; and

at least one fixture box, each of said at least one fixture box being provided with at least one connector mount which allows for interconnection of one or more of said cables thereto, said at least one connector mount at least permitting said B-end connectors in said multi-connector configuration of a first one of said cables to be fixedly attached to said at least one fixture box for routing of electrical power to said at least one fixture box so that said B-end connectors are accessible in said at least one fixture box for connection of said box fixture to a first one of said B-end connectors of said first one of said cables, a second one of said B-end connectors of said first one of said cables being accessible next to said box fixture for connection of an additional A-end connector thereto.

13. The system according to claim 12, wherein said at least one fixture box comprises a first fixture box, and said first one of said cables is connected to said first fixture box, said A-end connector of a second one of said cables defining said additional A-end connector, which said additional A-end connector is connected to the second one of said B-end connectors of said first one of said cables within said first fixture box, said second one of said cables exiting said first fixture box to route power away from said first fixture box.

14. The system according to claim 13, wherein said box fixture comprises a first outlet receptacle which includes said A-end connector which defines an integral plug connection that is plug-connected to said first one of the B-end connectors of said first one of said cables supported on said first fixture box.

15. The system according to claim 13, where said at least one fixture box further includes a second fixture box, and wherein each of said cables includes a single one of said A-end connectors on said A-end of each of said cables and at least two of said B-end connectors on the opposite B-end thereof, a plurality of said cables being serially connectable together by serial interconnection of the A-end connector of one of said cables to said B-end connector of another one of said cables, said B-end of said first one of said cables being connected to said first fixture box, said A-end of said second one of said cables being connected to said B-end of said first one of said cables in said first fixture box, and said B-end of said second one of said cables being connected to said second fixture box to permit simultaneous connection of said box fixture and a further one of said cables to said second one of said cables within said second fixture box.

16. The system according to claim 12, wherein said at least one fixture box comprises a first fixture box, and wherein said first one of said cables has the B-end connector thereof fixedly attached to said first fixture box so that a plurality of connection access points providing access to the B-end connections are defined within said first fixture box, said box fixture comprising a first outlet receptacle which includes an integral plug connection defining said A-end connector that is plug-connected to one of the B-end connectors of said first one of said cables supported on said first fixture box, a second one of said cables having said A-end connector thereof defining said additional A-end connector which is connected to the second one of said B-end connectors of said first one of said cables within said first fixture box and exits therefrom to route power away from said first fixture box.

17. The system according to claim 16, wherein said at least one fixture box further comprises a second fixture box, and the B-end of said second one of said cables is fixedly attached to said second fixture box and a second outlet receptacle is plug-connected to one of the B-end connectors of said second one of said cables on said second fixture box.

18. In a system of plug connectors for interconnecting system components of a modular power distribution system for distributing power to a building structure wherein each of said plug connectors is engagable with another one of said plug connectors of other system components which carry electrical power throughout said building structure, comprising the improvement wherein said plug connectors of said system components have a common plug section with common electrical contacts respectively therein for completing an electrical connection between a mated pair of said plug sections by mating engagement of said plug sections and said electrical contacts together when said plug sections are in oppositely opposed orientations forming a mated pair of said plug connectors, said plug connectors and said contacts thereof being configured to carry a plurality of voltage levels of line power;

said plug connectors including a settable keying structure which sets said mated pair of said plug connectors in one of a plurality of keying conditions to structurally limit connection of one of said plug connectors of said pair of said plug connectors to only a further one of said plug connectors which is set to a matable one of said keying conditions, said plurality of keying conditions corresponding to a respective plurality of said voltage levels wherein setting of said keying structure to a selected one of said one of said plurality of keying conditions limits the voltage level intended for use through said plug connector to the voltage level corresponding thereto;

said keying structure comprising movable key segments which include first connector parts engaged with said plug section which permit relocation of said key segments while preventing removal of said key segments from said plug section and include alignment parts which prevent relocation of said key segments upon displacement of said key segments relative to said plug section from an adjustable position to a fixed position, said alignment parts defining a plurality of key segment positions which define said plurality of keying conditions corresponding to said voltage levels.

19. A plug connector of claim 18, wherein a first one of said plug connectors of said pair of plug connectors includes at least two of said key segments that are displacable side to side through at least two optional keyed first positions, and wherein a second one of said pair of plug connectors includes at least one of said key segments that can be displaced side to side through at least two optional keyed second positions, wherein said key segments of said pair of plug connectors, when set to indicate the same voltage level, are positioned so that said key segments will not occupy the same keyed locations, thereby allowing said pair of said plug connectors to fully mate and wherein said key segments of said pair of plug connectors, when set to indicate a different voltage level, are positioned so that said key segments would occupy the same keyed locations, thereby interfering with each other and not permitting said pair of said plug connectors to fully mate together.

20. A plug connector of claim 19, wherein a portion of each of said key segments projects from one said plug connector into the other said plug connector of said mated pair and wherein said key segment portions occupy space adjacent said key segments of said plug connector into which each said key segment projects.

21. A plug connector of claim 18, wherein said key segments include side to side locking structures, and a removable barrier plate is provided adjacent said locking structures which said removable barrier plate prevents said key segments from engaging said side to side locking structures, and wherein said key segments lock into selected said fixed positions when said barrier plate has been removed.

22. A plug connector of claim 20, wherein each said plug connector includes a movable guide plate having guide channels that control positioning of said key segments wherein said movable guide plate has front and rear operative positions, wherein, in said rear position, said channels allow side to side movement of said key segments and wherein, in said front position, said channels prevent said key segments from side to side movement.

23. A plug connector of claim 22, wherein said guide plate includes an exposed handle portion that serves as a handle for movement of the plate initially from said rear position to said front locking position.

24. A plug connector of claim 23, wherein said key segments include a locking pawl that engages a slot edge in said guide plate when said guide plate is moved from said rear position to said front position, thereby preventing said guide plate from being returned to said rear position.

25. A plug connector of claim 24, wherein said exposed handle portion of said guide plate has frangible formations that allow manual break-off of said exposed handle portion from a remaining portion of said guide plate.

26. A plug connector of claim 25, wherein a portion of said break-off handle is formed as a barrier to prevent mating of a plug connector pair when said break-off portion is present, and wherein the barrier portion of said break-off handle includes extended edge portions wherein said barrier portion is substantially wider than said plug connector plugging face width so that said break-off barrier portion prevents installation of said plug connector into a substantially close fitting knockout opening in a junction box when said break-off portion is present.

27. A building power wiring system comprising:

elongate cables having opposite A-ends and B-ends, wherein each of said cables includes an A-end connector on said A-end thereof and a B-end connector on the opposite B-end thereof, said cables having plug sections that define mating plug structures to allow said A-end connectors to connect to any said B-end connector but said mating plug structures do not allow said A-end connector to connect with any other A-end connector or said B-end connector to connect to any other B-end connector of another one of said cables, a plurality of said cables being serially connectable together by serial interconnection of the A-end connector of a first one of said cables to said B-end connector of a second one of said cables; and

at least one junction box, each said at least one junction box being provided with A-end and/or B-end box connectors which allow for interconnection of a plurality of said cables thereto, said box connectors permitting said A-end connectors and/or said B-end connectors to be fixedly attached to said at least one junction box for routing of electrical power through said at least one junction box and between said at least one junction box and each of said cables attached thereto;

each one of said A-end box connectors and/or said B-end box connectors including a settable keying feature which sets each one of said A-end box connectors and/or said B-end box connectors in one of a plurality of keying conditions to structurally limit connection of said each one of said A-end box connectors and/or said B-end box connectors to only a further one of said A-end box connectors or B-end box connectors which is keyed to a matable one of said keying conditions, said plurality of keying conditions corresponding to a respective plurality of voltage levels wherein setting of said keying feature to a selected one of said keying conditions limits the voltage level intended for use with said end connectors to the voltage level corresponding thereto;

said keying feature comprising movable key segments which include first connector parts engaged to said plug sections to permit relocation of said key segments while preventing removal thereof from said plug sections, and alignment parts which prevent relocation of said key segments upon displacement of said key segments relative to said plug sections from an adjustable position to a fixed position, said alignment parts defining a plurality of key segment positions which define said plurality of keying conditions corresponding to said voltage levels.

28. A building power wiring system of claim 27, wherein said at least one junction box includes a plurality of said box connectors having said keying features and wherein said keying features of at least two of said box connectors of said at least one junction box are interlinked so that a keyed voltage configuration of at least two of said box connectors are simultaneously selected to the same voltage indication.

29. A building power wiring system of claim 27, wherein at least some of said box connectors are substantially aligned so that respective plug face openings each have substantially the same orientation so that a respective plug-mating motion that engages one of said plug sections with one of said box connectors is substantially in the same direction for all said box connectors.

30. A building power wiring system of claim 29, wherein said key segments include side to side locking structures, and a removable barrier plate is provided adjacent said locking structures which said removable barrier plate prevents said key segments from engaging said side to side locking structures, and wherein said key segments lock into selected ones of said fixed positions when said barrier plate has been removed.

31. A building power wiring system of claim 30, wherein said barrier plate is a single plate with projecting portions that provide said barrier portions within each one of the box connectors of said at least one junction box that are substantially aligned.

32. A building power wiring system comprising:

elongate cables having opposite A-ends and B-ends, wherein each of said cables includes a single A-end connector on said A-end of each of said cables and at least one B-end connector on the opposite B-end thereof, said cables having mating structures to allow said A-end connectors to connect to any of said B-end connectors at a mating connection but said mating structures do not allow said A-end connector to connect with any other said A-end connector or said B-end connector to connect to any other said B-end connector of another one of said cables, a plurality of said cables being serially connectable together by serial interconnection of the A-end connector of a first one of said cables to said B-end connector of a second one of said cables;

wherein said A-end and B-end connectors have housings with matingly telescoping end portions and wherein said telescoping end portion of said B-end connector overlaps said telescoping end portion of said A-end connector when one of said A-end connectors is mated with one of said B-end connectors, and wherein said mating connection includes a substantially “

C”

shaped spring retaining latch having opposed inwardly projecting portions that engage aligned openings in walls of both the housings of said B-end connectors and said A-end connectors thereby locking said matingly telescoping end portions together by penetration of said inwardly projecting portions into the aligned openings of the walls of the housings of the end connectors.

33. A building power wiring system of claim 32, wherein said telescoping end portion of said B-end connector outwardly overlaps said telescoping end portion of said A-end connector.

34. A building power wiring system of claim 33, wherein said spring retaining latch is formed from spring steel wire, a perimeter of a cross section of said spring steel wire being substantially rounded.

35. A building power wiring system of claim 34, wherein said system includes metallic junction boxes to which said connectors can be fixedly mounted, and wherein said housings are of metallic material and wherein said housings include at least one attachment opening for attachment of said connectors to the junction boxes.

36. A building power wiring system of claim 35, wherein said junction boxes attached to said connectors include at least one metallic projection that engages said at least one attachment opening in said housings.

37. A building power wiring system of claim 36, wherein said at least one metallic projection of said junction boxes are configured to provide a snap-action latching engagement with said at least one attachment opening in said housings.

38. A building power wiring system of claim 37, wherein said engagement of said at least one projection with said at least one attachment opening provides an electrical grounding path between said junction boxes and said housings.

39. A building power wiring system of claim 38, wherein said junction boxes include knock-out wall portions that are removable and when removed, provide a substantially closely fitting insertion opening for insertion of the telescoping end portions of said A-end connectors or said B-end connectors.

40. A building power wiring system of claim 39, wherein said junction boxes include interior portions into which the telescoping end portions of said connectors project and thereby allow said mating connection of one of said A-end connectors to said B-end connectors to be accomplished from within said junction boxes.

41. A building power wiring system of claim 40, wherein engagement of said projections of said junction boxes to the at least one attachment opening in said housings further establishes a depth or location into which said mating connection projects into said interior portions of said junction boxes.

42. A building power wiring system of claim 40, wherein said spring retaining latch engages said aligned openings in said walls of said mating connection mounted to said junction boxes, wherein said aligned openings are engaged from within said interior portions of said junction boxes, thereby locking said mating connection within said junction boxes.

43. A building power wiring system of claim 40, wherein said cables have double B-end connectors on the B-end that will allow connection of two A-end connectors.

44. A building power wiring system of claim 43, wherein said substantially “

C”

shaped spring retaining latch has a double set of opposed inward projections to engage and latch two A-end connectors into mating connection with one of said double B-end connectors.

45. A building power distribution system defined by a plurality of system components which are selectively connectable to define a comprehensive power supply system within partitions of a building, some of said partitions having substantially rigid outer wall coverings separated by and secured to internal frame structures, wherein some of said coverings have an outer substantially exposed surface, said system components comprising:

a plurality of distribution cables having a first connector end and a second connector end with respective connector plugs thereon wherein said first connector end can mate with said second connector end but said first connector end cannot mate with another one of the first connector ends and said second connector ends cannot mate with another one of said second one connector ends of another one of said cables;

at least one metallic junction box configured to have said connector plugs connect thereto, said at least one junction box being fixedly mounted to be substantially hidden within one of said partitions and said at least one junction box having an interior space in which component connections are made;

wherein said connector plugs have metallic housings including telescopingly mating end portions for said first connector end to mate with said second connector end and wherein said housings have structures for attachment of one of said connector plugs to said at least one metallic junction box to which said connector plugs can be fixedly mounted;

a connector plug attachment of said at least one junction box includes at least one metallic structure that engages a mating metallic structure of the metallic housings of a connected one of said connector plugs and wherein engagement of said one of said at least one junction box with one of said connector plugs provides an electrical grounding path between said one of said at least one junction box and said one of said connector plugs.

46. A building power distribution system of claim 45, wherein said at least one junction box includes at least one metallic projection that engages a mating opening in the metallic housings of a connected one of said connector plugs.

47. A building power distribution system of claim 46, wherein said at least one metallic projection of said at least one junction box is configured to provide a snap-action latching engagement with said mating opening in said one of said connector plugs.

48. A building power distribution system of claim 47, wherein said connector ends are separated by and connected to a standard MC cable or armored cable portion having metallic outer coverings that are electrically grounded to said metallic housings of said connector plugs.

49. A building power distribution system of claim 48, wherein said MC cable or armored cable portion of one of said distribution cables is connected to one of said connector plugs that is connected to said one of said at least one metallic junction box to which said one of said connector plugs is fixedly mounted, said cable portion being secured directly to said one of said at least one junction box by securing means.

50. A building power distribution system of claim 49, wherein said securing means is one of a plastic wire-tie, a screw attached U-bracket, and a U-clamp.

51. A building power distribution system of claim 50, wherein some of said distribution cables include multiple conductors that provide multiple electrical circuits and wherein others of said distribution cables have conductors only sufficient for a single electrical circuit and wherein said first connector ends of said cables with multiple conductors can mate with said second connector ends of said cables with conductors only sufficient for the single electrical circuit and wherein said second connector ends of said cables with multiple conductors can mate with said first connector ends of said cables with conductors only sufficient for the single electrical circuit and wherein said first connector ends of some of said cables with conductors only sufficient for the single electrical circuit include structures that allow one of said cables with conductors only sufficient for the single electrical circuit to selectively receive power from one optionally selected circuit of said multiple circuits of one of the cables with multiple conductors to which said one of said cables with conductors only sufficient for the single electrical circuit is matingly connected.

52. A building power distribution system of claim 51, wherein said connector ends are separated by and connected to a standard MC cable or armored cable portion having metallic outer coverings that are electrically grounded to said metallic housings of said connector plugs.

53. A building power distribution system of claim 52, wherein said MC or armored cable portion of one of said distribution cables is connected to one of said connector plugs that is connected to one of said at least one metallic junction box to which said one of said connector plugs is fixedly mounted, said cable portion being secured directly to said one of said at least one junction box by securing means.

54. A building power distribution system of claim 53, wherein said securing means is one of a plastic wire-tie, a screw attached U-bracket, and a U-clamp.

55. A building power distribution system of claim 51, wherein said cables with only sufficient conductors for the single electrical circuit includes a movable plug portion to which a single line conductor terminal is attached and wherein said movable plug portion can be selectively moved between at least two possible plugging locations.

56. A building power distribution system of claim 55, wherein said movable plug portion must be positioned to access power from a desired one of the circuits prior to connection of said first connector end of said single circuit to said second connector end.