Modular wiring system with locking elements

• US 8,096,818 B2
• Filed: 01/18/2010
• Issued: 01/17/2012
• Est. Priority Date: 10/27/2006
• Status: Active Grant

• Current Assignee: Leviton Manufacturing Company Incorporated
• Original Assignee: Leviton Manufacturing Company Incorporated
• Inventors: Arenas, Alfredo, Lindenstraus, Leslie, Tufano, Anthony, Oddsen, Dennis, Eder, John, Rafferty, Christopher
• Primary Examiner(s): Patel, Tulsidas C
• Assistant Examiner(s): Imas, Vladimir
• Application Number:
  US12/689,163
• Publication Number:
  US 20100120274A1
• Time in Patent Office: 729 Days
• Field of Search: 439/107, 439/337, 439/135, 439/332, 439/535, 439/673, 439/674
• US Class Current: 439/107
• CPC Class Codes: H01R 13/514 composed as a modular blocks or assembly, i.e. composed of co-operating parts provided with contact members or holding contact members between them
• CPC Class Codes: H01R 13/652 with earth pin, blade or socket
• CPC Class Codes: H01R 2103/00 Two poles
• CPC Class Codes: H01R 24/78 with additional earth or shield contacts
• CPC Class Codes: H01R 25/006 the coupling part being secured to apparatus or structure, e.g. duplex wall receptacle
• CPC Class Codes: H01R 9/2491 Terminal blocks structurally associated with plugs or sockets
• CPC Class Codes: Y10T 29/49826 Assembling or joining

Abstract

A wiring system includes a wiring module and a functional module. The wiring module in at least one embodiment includes elongated holes or openings which are configured to engage or lock with prongs on a functional module to create a lockable connection. The wiring module and the functional module form both a physical and an electrical connection. In another embodiment, there is an adapter which is configured to connect the wiring module and the functional module or unit together.

Claims

1. A wiring system comprising:

a) a functional unit configured to engage a wall box, said functional unit comprising a housing having a plurality of conductive elements extending therefrom;

b) a wiring unit configured to be located in said wall box, the wiring unit comprising;

i) a housing having a front face configured to contact said functional unit, a back face opposite said front face, a perimeter region extending between said front face and said back face and a plurality of conductive elements located therein and a plurality of openings formed in the front face thereof so that the plurality of conductive elements extending from the functional unit housing can be inserted into said wiring unit housing and into contact with the plurality of conductive elements located in said wiring unit housing when said wiring unit is coupled to said functional unit;

ii) plurality of wires extending from said wiring unit housing, each of the wires being connectable to one of the conductive elements in said wiring unit housing and to a power distribution network; and

iii) at least one flange coupled to said wiring unit housing and extending out from said perimeter region to an exterior region of said wiring unit housing, said at least one flange being adapted to inhibit the disconnection of the wiring unit from said functional unit after the wiring unit is rotated into a connected position.

2. The system as in claim 1, wherein at least one of said plurality of openings has at least one receiving region and at least one locking region, wherein said functional unit comprises a front face and a back face, wherein said wiring unit is configured to connect to said back face of said functional unit.

3. The system as in claim 1, further comprising at least one removable cover coupled to said front face of said wiring unit.

4. The system as in claim 3, wherein said removable cover is at least one of a label and a cap.

5. The system as in claim 3, wherein said at least one functional unit comprises a strap.

6. The system as in claim 2, wherein said removable cover has a write-on surface.

12. The system as in claim 1, wherein said wiring unit housing comprises at least two flanges, wherein said at least two flanges comprise a first flange extending out from an exterior region of said wiring unit housing, and a second oppositely spaced flange extending out from an exterior region of said wiring unit housing, wherein said functional unit comprises at least two flanges, wherein when said wiring unit is coupled to said functional unit and rotated, said at least two flanges of said wiring unit are coupled to at least two corresponding flanges of said functional unit.

15. The system as in claim 1, further comprising at least one central conductive element disposed in said wiring unit housing and wherein said functional unit further comprises a ground prong, said central conductive element being configured to receive said ground prong from said functional unit.

18. The system as in claim 15, further comprising at least one ground wire, wherein said central conductive element is coupled to said ground wire.

19. The system as in claim 15, further comprising at least one ground wire, wherein said central conductive element is coupled to said ground wire.

7. A wiring system comprising:

a) a functional unit including a strap configured to allow said functional unit to engage a wall box, the functional unit including a housing and at least one prong extending therefrom;

b) a wiring unit configured to be rotatively coupled to the functional unit, the wiring unit comprising;

i) a housing having a front face, a back face, a perimeter region extending between said front and back faces, at least one opening and at least one conductive element, the at least one opening being configured to receive the at least one prong of said functional unit when the wiring unit is coupled to said functional unit;

ii) at least one wire extending from said wiring unit housing, said at least one wire connecting the conductive element to a power distribution network for providing power from the power distribution network; and

iii) at least one connection element comprising a flange disposed on said wiring unit housing, and being adapted to inhibit the disconnection of said wiring unit from said functional unit.

8. The system as in claim 7, wherein said flange comprises a curved leading edge.

9. The system as in claim 8, wherein said curved leading edge of said flange is formed as a rounded corner on said flange, and wherein said functional unit comprises a flange, such that when said flange on the wiring unit contacts said flange on the functional unit during rotation, said curved leading edge allows said wiring unit to continue to rotate.

13. The system as in claim 7, wherein said wiring unit housing comprises at least two flanges, wherein said at least two flanges comprise a first flange extending out from an exterior region of said wiring unit housing, and a second oppositely spaced flange extending out from an exterior region of said wiring unit housing, and wherein said functional unit comprises at least two flanges, wherein when the wiring unit is coupled to said functional unit and rotated, said at least two flanges of said wiring unit are coupled to at least two corresponding flanges of said functional unit.

16. The system as in claim 7, at least one central conductive element disposed in said wiring unit housing and wherein said functional unit further comprises a ground prong, said central conductive element being configured to receive said ground prong from said functional unit.

10. A method for connecting a functional electrical module to a power distribution network comprising the steps of:

a) electrically coupling a wiring unit to the power distribution network;

b) positioning a plurality of electrical contacts of a functional unit into contact with a wiring unit having a housing having a plurality of openings, a plurality of electrical contacts, and a flange, wherein said plurality of openings on said wiring unit housing is configured to receive said plurality of electrical contacts of said functional unit, the functional unit including a flange;

c) rotating said wiring unit from a first position to a second position;

d) coupling said wiring unit flange extending out from an exterior surface of a perimeter region of said wiring unit housing, to said functional unit flange, to secure said wiring unit to said functional unit and to inhibit the disconnection of the wiring unit from said functional unit wherein said perimeter region of said wiring unit extends along a substantial portion of said wiring unit housing; and

e) installing said functional unit into a wall box.

11. The method as in claim 10, wherein said functional unit has a functional element that is selected from the group consisting of:

a switch, a receptacle, a ground fault circuit interrupter, a dimmer, an occupancy sensor, a remote control, a home security control, and a surge protector.

14. The method as in claim 10, wherein said wiring unit housing comprises at least two flanges, wherein said at least two flanges comprise a first flange extending out from an exterior region of said wiring unit housing, and a second oppositely spaced flange extending out from an exterior region of said wiring unit housing, and wherein said functional unit comprises at least two flanges, wherein when the wiring unit is coupled to said functional unit and rotated, said at least two flanges of said wiring unit are coupled to at least two corresponding flanges of said functional unit.

17. The method as in claim 10, further comprising at least one central shaft disposed in said wiring unit housing, and wherein said functional unit further comprises a ground prong, said central conductive element being configured to receive said ground prong from said functional unit.

20. The method as in claim 17, further comprising at least one ground wire, wherein said central conductive element is coupled to said ground wire.