Modular electrical distribution system for a building

• US 8,172,589 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:
  US12/798,747
• Publication Number:
  US 20100328853A1
• Time in Patent Office: 760 Days
• Field of Search: 439/215, 439/535, 439/538, 439/650, 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: H01R 25/162 Electrical connections between or with rails or bus-bars rails having primarily a non electrical function H01R4/64
• 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 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 a substantially rigid outer wall covering separated by and secured to internal frame structures, wherein said covering has an outer substantially exposed surface, said system components comprising:

a plurality of distribution cables each 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 said first connector end and said second connector end cannot mate with said second connector end of another identical one of said cables;

at least one 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;

at least one ring bracket which includes at least one pair of outwardly extending flange segments and is configured to have at least one wiring device comprising one or more of receptacles and switching devices fixedly mounted thereto; and

a first wiring device fixedly mounted to a first one of said at least one ring bracket to define a first bracket-wiring device assembly, wherein said first wiring device has a plug connector for providing power to said first wiring device by plug connection to said first connector end of a first one of said distribution cables connected to said at least one junction box;

least one fastener engaging said first bracket-wiring device assembly and said at least one junction box so that a portion of said covering is clamped between said at least one junction box and the flange segments.

2. A system of claim 1 wherein the plug connector of said first bracket-wiring device assembly is flexibly secured to said first wiring device to allow for variation in thickness of the portion of the covering being clamped between said first one of said at least one junction box and the flange segments.

3. A system of claim 2 wherein portions of said flange segments of said at least one ring bracket contact an outer surface of the covering which has the outer substantially exposed surface.

4. A system of claim 3 wherein said at least one junction box has structural wall portions that project into an opening in the covering, wherein said opening provides access to the interior space of said at least one junction box.

5. A system of claim 4 wherein said at least one junction box has substantially hidden structures or rigidly secured mounting accessories that clampingly contact an inner face of the covering which contains the opening through which said structural wall portions project.

6. A system of claim 5 wherein said first one of said at least one ring bracket has inwardly projecting flanges that telescopingly engage the structural wall portions of said at least one junction box.

7. A system of claim 6 wherein said first wiring device of said first bracket-wiring device assembly is a first switching device.

8. A system of claim 6 wherein said first wiring device of said first bracket-wiring device assembly is a first receptacle.

9. A system of claim 6 wherein said first one of said at least one junction box has a second one of said distribution cables having one said connector plugs thereof connected to said first one of said at least one junction box.

10. A system of claim 9 wherein said first bracket-wiring device assembly includes both a first switching device and a first receptacle and wherein a first one of the plug connectors associated with said first switching device is connected to a second one of the connector plugs of said first one of said distribution cables and each of the plug connectors associated with said first receptacle is connected to one of the connector plugs of a second one of said cables.

11. A system of claim 10 wherein said inwardly projecting flanges of said first one of said at least one ring bracket are located inwardly from the structural wall portions of said at least one junction box.

12. A system of claim 11 wherein said at least one fastener is a screw.

13. A system of claim 10 wherein said first switching device and said first receptacle of said first bracket-wiring device assembly are spaced apart side-by-side equal to standard industry spacing.

14. A system of claim 7 wherein said first bracket-wiring device assembly also includes a second receptacle, wherein one of the plug connectors associated with said first receptacle is Y connected to said second receptacle so that both receptacles are plug connected to said first one of said distribution cables by one plug connection.

15. A system of claim 8 wherein said first bracket-wiring device assembly also includes a second receptacle, wherein the plug connector associated with said second receptacle is plug connected to said second one of said distribution cables.

16. A system of claim 8 wherein said first connector end of said first one of said distribution cables has a side by side first duplicate plug connector and a second duplicate plug connector.

17. A system of claim 16 wherein said first wiring device assembly also includes a second receptacle, wherein the plug connector associated with said first receptacle is plug connected to said first duplicate plug connectors of said first one of said distribution cables and said second receptacle is plug connected to said second duplicate plug connector.

18. A system of claim 16 wherein the plug connector associated with said first receptacle is plug connected to said first duplicate plug connector of said first end connectors of said first one of said distribution cables.

19. A system of claim 18 wherein a second one of said distribution cables has the second connector end thereof connected to said second duplicate plug connector of said first end connectors of said first one of said distribution cables and wherein said second one of said distribution cables exits therefrom to route power away from said at least one junction box.

20. A system of claim 10 wherein the first one of the connector plugs of said first switching device is configured so the first one of the connector plugs can not connect to the same plug connector end of said distribution cables to which the connector plug of said first receptacle can connect and the second one of the connector plugs of said first receptacle is configured so the second one of the connector plugs can not connect to the same plug connector end of said distribution cables to which the first one of the connector plugs of said first switching device can connect.

21. A system of claim 20 wherein the plug connector associated with said first switching device is connected to the connector plug of said second connector end of said second one of said distribution cables and the plug connector associated with said first receptacle is connected to the connector plug of said first connector end of said first one of the distribution cables.

22. A system of claim 7 wherein said first switching device has first and second flexibly secured plug connectors, said first flexibly secured plug connector being plug-connected to said first one of said distribution cables for receiving power to an input pole of said first switching device;

a second one of said distribution cables being plug-connected to said second plug connector of said first switching device for conducting switch controlled power away from said at least one junction box.

23. A system of claim 22 wherein said first switching device is a double pole double throw switch.

24. A system of claim 22 wherein said first switching device is a ground fault interrupting receptacle.

25. 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 a substantially rigid outer wall covering separated by and secured to internal frame structures, wherein said covering has an outer substantially exposed surface, said system components comprising:

a plurality of distribution cables each 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 said first connector end and said second connector end cannot mate with said second connector end of another identical one of said cables;

at least one 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;

at least one ring bracket which includes at least one pair of outwardly extending flange segments and is configured to have one or more wiring devices fixedly mounted thereto; and

at least one fastener engaging said at least one ring bracket and said at least one junction box so that a portion of said covering is clamped between said at least one junction box and the flange segments of said at least one ring bracket, wherein portions of said flange segments contact the outer substantially exposed surface of the covering and wherein said at least one junction box has structural wall portions that project into an opening in the covering, said opening providing access to the interior space of said at least one junction box, wherein said at least one junction box has substantially hidden structures or rigidly secured mounting accessories that clampingly contact an inner face of the covering which contains the opening through which said structural wall portions project; and

said at least one ring bracket has inwardly projecting flanges that telescopingly engage the structural wall portions of said at least one junction box.

26. A system of claim 25 wherein a first one of said distribution cables has the first connector end thereof connected to said at least one junction box and a second one of said cables has the second connector end thereof connected to said at least one junction box, wherein said connector ends are spaced apart and connected together via a pigtail connector assembly having a first pigtail connector end and a second pigtail connector end, wherein said second pigtail connector end is connected to said first connector end of said first one of said cables and said first pigtail connector end is connected to said second connector end of said second one of said cables.

27. A system of claim 26 wherein said opening in said covering is at least partially covered by a cover that is secured to said at least one ring bracket.

28. An electrical power accessible wall partition assembly comprising:

a substantially rigid outer wall covering separated by and secured to internal frame structures, wherein said covering has an outer substantially exposed surface;

at least one junction box configured to have at least one connector plug end of a distribution cable connected thereto, said at least one junction box being fixedly mounted to be substantially hidden within one of said covering and said at least one junction box having an interior space in which component connections are made;

at least one ring bracket which includes at least one pair of outwardly extending flange segments and is configured to have one or more wiring devices fixedly mounted thereto;

a first wiring device fixedly mounted to a first one of said at least one ring bracket forming a first bracket-wiring device assembly, wherein said first wiring device has a plug connector for providing power to said first wiring device by plug connection to the connector end plug of a first one of said distribution cables connected to a said at least one junction box; and

at least one fastener engaging said first bracket-wiring device assembly and said at least one junction box, so that a portion of said covering is clamped between a portion of said at least one junction box and the flange segments.

29. An assembly of claim 28 wherein the plug connector of said first bracket-wiring device assembly is flexibly secured to said first wiring device to allow for variation in thickness of the portion of the covering clamped between the portion of said at least one junction box and the flange segments.

30. An assembly of claim 29 wherein portions of said flange segments contact the outer substantially exposed surface of the covering.

31. An assembly of claim 30 wherein said at least one junction box has structural wall portions that project into an opening in the covering, wherein said opening provides access to the interior space of said at least one junction box.

32. An assembly of claim 31 wherein said at least one junction box has substantially hidden structural portions or rigidly secured mounting accessories that clampingly contact an inner face of the covering in which contains the opening through which said structural wall portions project.

33. An assembly of claim 32 wherein said at least one ring bracket has inwardly projecting flanges that telescopingly engage the structural wall portions of said at least one junction box.

34. An assembly of claim 33 wherein said first wiring device of said first bracket-wiring device assembly is a first switching device.

35. An assembly of claim 34 wherein said first wiring device of said first bracket-wiring device assembly is a first receptacle.

36. An assembly of claim 35 wherein said at least one junction box has a second one of said distribution cables having the at least one connector plug end thereof connected thereto.

37. An assembly of claim 36 wherein said first bracket-wiring device assembly includes both the first switching device and the first receptacle and wherein the plug connector associated with said first switching device is connected to the at least one connector plug end of said first one of the cables and the plug connector associated with said first receptacle is connected to the at least one connector plug end of said second one of the cables.

38. An assembly of claim 33 wherein said inwardly projecting flanges of said first ring bracket are located inwardly from the structural wall portions of said at least one junction box.

39. An assembly of claim 38 wherein said at least one fastener is a screw.

40. An assembly of claim 37 wherein said first switching device and said first receptacle of said first bracket-wiring device assembly are spaced apart side-by-side equal to standard industry spacing.

41. An assembly of claim 35 wherein said first bracket-wiring device assembly also includes a second receptacle, wherein the plug connector associated with said first receptacle is Y connected to said second receptacle so that both receptacles are plug connected to said first one of the cables by one plug connection.

42. An assembly of claim 36 wherein said first bracket-wiring device assembly also includes a second receptacle, wherein the plug connector associated with said second receptacle is plug connected to said second one of the cables.

43. An assembly of claim 33 wherein said distribution cables each comprise a metal jacketed MC or armored flexible cable construction between connector ends thereof.

44. An assembly of claim 43 wherein said MC or armored cable construction is secured directly to said at least one junction box by securing means.

45. An assembly of claim 44 wherein said securing means is one of a plastic wire-tie, a screw attached U-bracket, and a U-clamp.

46. An assembly of claim 29 wherein said at least one junction box includes a pair of sidewalls, a top wall, a bottom wall and a back wall forming a box with a front opening facing outward through a covering opening in said covering and wherein said covering opening provides access to the interior space of said at least one junction box and wherein said sidewalls include attached sidewardly extending flanges that are substantially parallel to the exposed surface of said covering and each contain mounting openings for fixedly mounting said at least one junction box to said internal frame structures so that when said sidewardly extending flanges are used for mounting to said interior frame structures, said sidewardly extending flanges are located between the outer surface of said frame structures and an inner face of an adjacent one of said covering.

47. An assembly of claim 46 wherein said sidewardly extending flanges are offset rearward from a front edge of said at least one junction box so that, when mounted, a front portion of said at least one junction box projects into said covering opening in said covering.

48. An assembly of claim 47 wherein said sidewalls of said at least one junction box include aligned pairs of rearwardly extending parallel slots with an edge between said slots offset rearwardly to provide a substantially form-fitting mounting position for a U-shaped mounting channel to extend across said at least one junction box through said sidewalls, wherein said slots position said mounting channel so that legs thereof extend rearwardly and a bottom face of a U-portion of the mounting channel contacts the inner face of said covering and wherein said U-shaped mounting channel extends substantially horizontally from one of said internal frame structures to another of the internal frame structures with said at least one junction box mounted to said U-shaped mounting channel suspended somewhere between said frame structures with front edges of said at least one junction box projecting into said covering a distance substantially equal to a distance achieved when side flange mounting is employed.

49. An assembly of claim 48 wherein said bottom face of said U-portion includes a plurality of elongated slots thereby providing multiple mounting locations for said at least one junction box on said U-portion and wherein said legs of said mounting channel are interrupted near each end to form a tab for mounting to said internal frame structures so that said tabs are located between said frame structures and the inner face of said covering.

50. An assembly of claim 49 wherein said mounting channel is a first mounting channel, and said at least one junction box is also mounted to a second U-shaped mounting channel and wherein said first mounting channel is mounted above said front opening and the second U-shaped mounting is mounted below said front opening.

51. An assembly of claim 50 wherein a second one of said at least one junction box is mounted to said mounting channels and wherein said second junction box includes walls that project into a second opening in said covering.