Note: Descriptions are shown in the official language in which they were submitted.
~L23~
_IRING SYSrEM WITH QUICK CONNECT WIRE TERMINALS
Background Of The Invention
1. Field Of The Invention
The presen~. invention is related to plug-in type
electrical wiring apparatus for use in constructing the
wiring system of a house or other building.
2. D scripti_n Of Ihe Prior_rt
When a new building is being wired or an older building
is being rewired, considerable time rnust be spent in making
electrical connections within conventional junction, switch
and receptacle boxes, and considerable time must also be
spent in mounting such boxes. Accordingly, a need exists
or an electrical connection box with which various two and
three-wire conductors may be quickly electrically connected
in order to provide the electrical circuitry, and which may
be quickly mounted fro~ joists and studs.
The prior art does include wiring systems having plug-in
type connections, such as seen, for es~ample, in 11. S. Patent
No. 4,165,443 to Figart et al.
Also, the prior art has included outlet boxes having
ofEset flanges Eor mounting of the box on studs with the
face of the box extending rom the stud a distance equal to
the thickness o wallboard to be used with the device, as
seen in U. S. Patent No. 3,863,037 to Schindler et al.
Other examples of various forms of electrical connection
apparatus, including plug-in type connectors, and in some
instances some of the other general structural and opera-
tional features oE the present invention, include 1~ S.
Patents Nos. 3,885,852; 3,339,170; 3,393,397; 3,451,037;
3,569,911; 3,717,840; 3,828,113; 4,012,100; and 4,106,835.
--1--
'`~
i ~
'~:
ln spite of the numerous attempts which have been made
to develop a practical alternative to conventional junction,
switch and receptacle boxes, some of which attempts are
shown by the above cited reEerences, none of these attempts
have succeeded in providing a system which has found
widespread acceptance in the marketplace. There is still
the need for much improvement in plug-in type syste,ns.
Summary _f rhe Invention
The present invention provides a number of improvements
in plug-in type wiring systems.
An improved design is provided for an electrical contact
strip disposed in an insulated housing. The strip includes
a middle web portion having a wire receiving opening
disposed therethrough in registry with a wire receiving
housing opening oE the housing. The web portion includes
retaining means for engaging a wire when the wire is
inserted through the housing opening and the web opening,
and for resisting withdrawal ~of the wire from the web
~0 opening. rhe olectrical contact strip further includes
first and second leg portions extending from tho web portion
away from a wall of the housing through which the housing
opening is disposed. The first and second leg portions are
arranged to engagingly receive the wire therebetween when
2S the wire is inserted through the housing opening and the web
opening.
Also provided is a cable receiving external socket in
the housing. The socket is defined by a bottom wall and a
tapered side wall extending outward ~rom the bottom wall.
The side wall is convergingly tapered toward the bottom wall
~3~
so that when a conventional wiring cable is inserted ~ithin
the socket, the cable will wedge withill the tapered side
wall oE the socket.
Numerous objects, features and advantages of the present
invention will be readily apparent to those skilled in the
art upon a reading of the following disclosure when taken in
conjunction with the accompanying drawings.
Brief Descript n Of The D win~s
FIG. 1 is a ~ragmentary perspective view of a ceiling
joist illustrating the manr~er in which the electrical con-
nection box of the instant invention may be operatively sup-
ported from the joist and further illustrating the manner in
which an electrical connection between a ceiling light and
the connection box may be accomplished, a wall switch for
controlling the light being also electrically connected to
the connection box.
FIG. 2 is a further perspective view of the assemblage
illustrated in FIG. 1 wherein the wall switch is broken away
and illustrating the manner in which a wall mounted recep-
tacle may be also electrically connected to the connection
box.
FIG. 3 is an enlarged ~ragmentary vertical sectional
view of the connection box with an associated joist being
illustrated in phantom lines.
FIG. 4 is a horizontal sectional view taken substan-
tially upon the plane indicated by the section line 4-a of
FIG. 3.
FIG. 5 is a vertical sectional view taken substantially
upon the plane indicated by the section line 5-5 of FIG. 3.
~L2~
FIG. 6 is a fragmentary sectional view taken along line
6-6 of FIG. 4 illustrating the manner in which the ceiling
light Serminal may be electrically connected to the power
bar of the connection box.
SF~IG. 7 is an enlarged perspective view of a portion of
one of the three bars of the connection box.
FIG. 8 is a fragmentary enlarged sectional view
illustrating the manner in which a wlre end connected to one
of the bars of the connection box may be released from enga-
gement therewith.
FIG. 9 is a schematic illustration of a complete wiring
system utili~ing an alternative embodiment of an electrical
wiring apparatus such as the one shown in FIG. 10.
FLG. 10 is a plan view of an alternative embodiment of
an electrical wiring apparatus.
FIG. 11 is a section elevation view of the apparatus of
FIG. 10 taken along line 11-11 of FIG. 10.
FIG. 12 is a plan view of the bottom housing section of
the apparatus of FIG. 1l, showing the olectricaL contact
strips in place within the bottom houslng section.
FIG. 13 is an isometric view of one of the electrical
contact strips such as seen in FIGS. 11 and 12.
FIG. 14 is a bottom view of the bottom housing section
of the apparatus of FIGS. 10-12.
25FIG. 15 is a section elevation view of a fixture wiring
stud and associated knob as taken along line 15-15 of FIG.
14.
FIG. 16 is a view similar to FIG. 11, showing an alter-
native design for the electrical contact strips.
30FIG. 17 is a section view along line 17-17 of FIG. 11
showing a cross section of a typical cable.
. I
-4-
~3~
FIG. 18 is a 6ide elevation view oE a lo~er portion of
an electric cable constructed for use with the present
invention.
Detailed Description Of The Invention
The _b ~_me nt Of FIGS. 1-8
Referring now more speciEically to the drawings, the
numeral 10 yenerally designates a joist Erorn which an
electrical connection box constructed in accordance with the
present invention is mounted. The electrical connection box
is reEerred to in general by the reference numeral 12 and
includes a housing 14 constructed of dielectric material,
including a first side wall portion 16 and a second side
wall portion 18 remote Erom the first side wall portion 16.
Although the housing 14 is illustrated as a one-piece
construction, it is to be noted that the housing 14 is
constructed of upper and lower halves 14' and 14" fusion
welded or otherwise joined together as at 1!3 (see FIG. 5).
The housing 14 is constructed of a dielectric material such
as plastic.
Mounted within cavities 15 of the housing half 14" are
f irst, second and third power, ground and common elongated
conductor means or bars 20, 22 and 24, respectively, and
each oE the bars 20, 22 and 24 comprises a channel member
including opposite side flanges, or leg portions, 26 inter-
connected by a bight, or web, portion 28 and wherein the
planar midportions 30 of the flanges 26 are laterally offset
toward each other by oppositely inclined portions 32 and 34
of the flanges 26 (see FIG. 7), the lower ends of the
f langes 26 being spaced from the lower extremities of the
~3~
cavities 15 in order to enable the ends oE associated ~ires
to force apart and be received between the Elange midpor-
tions 30 (see FIG. 3).
~ars 20, 22 and 24 may also be referred to as electrical
contact strips.
Each of the bars 20, 22 and 24 includes laterally struck
and angled tongue portions, or resilient tabs, 36 cut frorn
the bight portion 20 and spaced along the corresponding bar,
the tongue portions including free end notches 36'. The
cutting of the tongue portions 36 Erom the bight portion 20
deEines openings 38 registered with the space between the
contact flanges 32. Eurther, the bars 20, 22 and 24 are
insulatably mounted relative to each other within the
housing 14 and the housing 14 further includes a pair of
terminal clips 40 and 42 relatively insulatably mountecl
therein. Each of the clips 40 and 42 may be in the Eorm of
short bars otherwise similar in construction to the bars 20,
22 and 24. The terminal clip 40 ls electrically connected
to the bar 20 by a connecting strap 44 and the other ter-
minal clip 42 has a terminal 46 electrically connected
thereto which projects outwardly of the side wall portion
18. In addition, a second terminal 48 is provided and pro-
jects outwardly of the side wall portion 18 and is electri-
cally connected with bar 24 by a connecting strap 49.
2S The side wall portion 16 has a plurality of sets oE
housing openings 50, 52 and 54 formed therein registered
with the bars 20, 22 and 24 and with the sets of openings
spaced along the bars. Further, the side wall portion 16
also has a pair of housing openings 56 and 58 formed
therethrough registered with the terminal clips 40 and 42.
2~
The openings 5~, 52, 54, 56 and 58 are formed through
raised portions 59 of the side wall portion 16 and are
adapted to receive wire ends 6~ therethrough. The openings
are not only of sufficient size to receive the wire ends
therethrough but also the insulatec] coatings 62 disposed
about those wire ends. The wire ends may be received
through correspondillg openings and forced into openings 38.
The forcing of the wire ends 60 through the openings 38 suf-
ficiently deflects the free ends of the tongues 36 to enable
the wire ends 60 to be received through the openings 38 and
the tongues 36 prevent withdrawal of the wire ends through
the operlings 38. However, a slender tool shank 66 may be
inserted through an opening formed in the side wall portion
16 and inwardly toward engagement with the associated
lS tongues 36 in order to deflect the latter to the phantom
line position thereof illustrated in FIG. 8 in order to
enable the associated wire ends 60 to be withdrawn from the
opening 38.
The housing 14 defines an open-ended notch 70 formed
tilerein which opens laterally outwardly of the side wall
portion 16 and which may receive the opposing marginal edge
of the joist 10. The notch 70 of the housing 14 defines a
mounting flange 74 through which a pair of bores 76 are
formed and suitable fasteners 77 may be secured through the
bores 76 in order to mount the flange 74 to the joist 10,
The thickness of the flange 74 is substantially the same
thickness as a ceiling panel 78 supported from the joist 10
and in this manner the outer surface of the side wall por-
tion 18 may be flush with the under surface of the ceiling
panel 78. Of course, housing 14 may also be mounted Erom a
~326~L
stud in substantially the same manner and thus have the
outer surace of its side wall portion 18 flush with the
surface oE an associated wall panel corresponding to the
ceiling panel 78. Further, the thickness of the flange 74
may vary, according to the thickness of the ceiling or wall
panel to be used.
It will also be noted from FIG. 1 of the drawings that
the side wall portion 18 includes a plurality of threaded
L~ores 82 formed therein in which mounting screws may be
threadedly engaged for supporting a ceiling light fixture
from the housing 14. In addition, the conductor wires 84
from a ceiling light bulb socket 86 may be connected to the
terminals 46 and 48 and the wire ends of a pair of conduc-
tors 87 and 88 extending from a wall-mounted switch 90 may
be inserted through the openings 56 and S8 for electrical
connection with the terminal clips 40 and 42. In this
manner, the wall switch 90 may be utilized to actuate and
deactuate the associated ceiling light including the bulb
socket 86.
FIG. 2 of the drawings illu.strates the manner in which a
three-conductor cable 92 extending froln a source may have
its wire ends electrically connected with the bars 20, 22
and 24 through a corresponding set of openings 50, 52 and 54
and also the manner in which a three-conductor cable 94
extending to a remote wall-mounted receptacle 96 may have
its three wire ends electrically connected with the bars 20,
22 and 24 through another set of the openings 50, 52 and 54.
Of course, additional three-wire conductors extending to
further remote wall-mounted receptacles or the like may also
be operatively associated with the electrical connection box
12.
~:3~
From the foregoing, it may be seen that three- or two-
wire conductors may be readily electrically connectsd to the
bars 20, 22 and 24 and the terminal clips 40 and 42 merely
by inserting the bare wire ends through the openings S0, 52
and 54 and also the openLngs 56 and 58. Further, the ter-
minals 46 and 48 projecting outwardly of the side wall por-
tion 18 of the housing 14 greatly facilitate the electrical
connection of the conductors 84 of a ceiling light with the
electrical connection box 12. Further, all wiring to remote
areas may be readily made to the connection box 12 and the
notch 70 greatly facilitates the mounting of the box 12 from
a joist or stud flush with the exposed surface of an asso-
ciated ceiling or wall panel. Of course, all oE tllese
features greatly facilitate putting in the wiring of an
lS associated bullding or rewiring a building and the construc-
tion of the box 12 is such that it may be readily mass-
produced at a low cost.
Since all of the exposed ends of the wires electrica}ly
connected to the box 12 internally oE the latter are Eully
enclosed within the box, electricLans may not only rough-
wire a new house, but complete and make hot all wiringbefore dry wall or other wall and ceiling panels are to be
put up. Thus, an electrician need not return to a new house
after the wall and ceiling panels have been put up in order
to accornplish final wiring. Further, the full wiring of a
new house with the instant invention may be accomplished in
less time than only rough wiring by present methods.
~3~6~L~
The Embodiment Of FIGS. 9-18
In FIGS. 9-18, an alternative embodiment of the present
invention is shown. With particular reference to FIGS. 10
and 11, a plug-in electrical wiring apparatus is thereshown
and generally designated by the numeral 100.
The apparatus lOO is particularly constructed for
attachrnent to the lower surface of one or more ceiling beams
such as 102 and 104, and replaces a conventional electrical
junction box.
The apparatus 100 includes an insulating housing 106
constructed from a dielectric material such as plastic.
The housing 106 includes an upper first housing section
108 which is received within a rectangular groove llO of a
bottom second housing section 112.
Received within the housing 106 are five electrical con-
tact strips 114, 116, 118, 120 and 122, as best seen in FIG.
12 which is a top plan view of bottom second housing section
112 with the upper first housing section 108 removed.
Strip 114 is reEerred to as a cormnon contact strip.
20 Strlp 116 is referred to as a ground contact strip 116.
Strip 118 is referred to as a power contact strip 118.
Strip 120 is referred to as a ground extension contact strip
120. Strip 122 is referred to as a switched power strip
122,
The construction of the strips 114-122 may best be
understood with re~erence to FIGS. 11 and 13. In FIG. 11,
the strips 114, 116 and 118 are each seen in cross-section
view, and in FIG. 13, the strip 122 is shown in an oblique
perspective view.
Each of the strips 114-122 are similarly constructed in
that their cross sections are identical, and the manner oE
--10--
~3~
construction oE the openings in the top portion thereo~ are
identical. The lengths and placement of the strips, of
course, are different as showrl in FIG. 12.
Referring now to FIG. 13, the general construction of
any one oE the strips 114-12Z will be described with par-
ticular reference to the strip 122 thereshown.
The contact strip 122 includes a middle elongated web
portion 124 having wire-receiving web openings 126 disposed
therethrough.
The web opening 126 is formed by punching a resilient
tab 128 from web 12~. The tab 12B may further be described
as a retaining means 128 for engaging and retaining a wire
inserted through the web opening 126 and for resisting
withdrawal of such a wire from the web opening 126 as is
further described below.
Each of the resilient tabs 128 has a fixed end 130
integrally attached to web portion 124, and has a free end
132. As seen in FIG. 13, the free ends 132 are deElected
downwardly from the web portion 124.
The free ends 132 of the resilient tabs 128 have V-
notches 134 disposed therein for engaging a wire.
The strip 122 further includes first and second
elongated leg portions 136 and 138 extending downwardly Erom
the web portion 124. The leg portions 136 and 138 are
arranged to engagingly receive a wire therebetween a5 best
seen in FIG. 11.
As seen in FIG. 13, the second leg portion 138 has a
split 140 oriented transversely to a length of the elongated
strip 122, between adjacent web openings 126. The split 140
permits different size wires to be received through adjacent
~L~23~
web openings 126. Due to the split 140, the second leg l38
on either side of the split can flex differently so that
different size wires can both be snugly engaged between the
legs 136 and 13a.
5Referring now to FIG. 11, it is seen that each of the
strips 114-122 is disposed in a groove of the housing 106.
With particular reference to the strip 114, the strip 114 is
disposed in a groove deEined by an upper first wall l42, a
Iower second wall 144 opposed to Eirst wall 142, and opposed
10~hird and fourth walls 146 and 148 extending at least par-
tially between the first and second walls 142 and 144.
The first and second walls 142 and 144 are deEined on
the first and second housing sections 108 and 112, respec-
tively.
15The third wall 146 has first and second separate por-
tions 150 and 152, respectively, integrally formed on first
and second housing sections 108 and 112, respectively.
Similarly, fourth wall 148 has first and second separate
portions 154 and 156 integrally formed on Eirst and second
housing sections 108 and lL2, respectively.
The web portion 12q oE common contact strip 114 engages
upper first wall 142, and the lower end of first leg portion
136 of common contact strip 114 engages lower second wall
144.
The second leg portion 138 of common contact strip 114,
however, has a lower free end 158 which engages lower second
portion 156 of fourth wall 148 and which is spaced above
lower second wall 144.
The second leg portion 138 is a flexible leg portion and
is constructed so that it is Elexed upon insertion of a wire
-12-
~26~
between first and second leg portions 136 and 138. As the
second leg portion 138 is flexed upon insertion of the wire
between leg portions 136 and 138, the lower free end 158
thereof slides downwardly along lower second portion 156 of
fourth wall 148 towards the lower second wall 144.
A lower portion 160 of second leg portion 138 is arcuate
in cross section and has a convex side 162 Eacing first leg
portion 136.
The first leg portion 136 has a planar part 164 which is
adjacent and offset toward the arcuate part 160 of second
leg portion 138.
When a wire is inserted between the first and second leg
portions 136 and 138, it is engagingly gripped between the
convex side 162 of arcuate portion 160 of second leg portion
138 and the planar part 164 of first leg portion 136.
As the wire is inserted between the Eirst and second leg
portions 136 and 138, the first leg portion 136 remains
relatively Eixed, since its lower end engages the lower
second wall 144, and the arcuate cross-section portion 160
c~f second leg portion 136 flexes by flattening the arc
thereof. I'his causes the second leg portion 138 to be resi-
liently biased against the wire so that it pushes against
the wire and accordingly pushes the wire against the planar
part 164 of first leg portion 136.
Due to the large flat area of planar part 164, a large
area of electrical contact is provided between the wire and
the Eirst leg portion 136.
The first leg portion 136 includes sloped portions 166
and 168 joining the oEEset planar part 164 with the
remainder of first leg portion 136.
~26~
Referring brieEly now to FIG. 16, an alternative design
is thereshown for the electrical contact strips, in which
alternative design both the eirst and second leg portions
136A and 138A are constructed to resiliently flex away from
each other when a wire is received therebetween.
Fach oE the leg portions 136A and 138A are constructed
somewhat silni]ar to the Eirst leg portion 136 of FIG. lL,
except, however, most importantly, the free lower ends 158A
thereof engage the lower portions 152 and 156 of third and
fourth walls 146 and 148, respectively, and are spaced above
the second wall 144. When a wire is inserted between the
leg portions 136A and 138A of strip 114A oi FIG. 16, both
the first and second leg portions 136A and 138A are flexed
away from each other, and the lower free ends 158A thereof
both move closer to the second wall 144.
Each oE the first and second leg portions 136A and 138A
are constructed with offset planar portions 164A, which are
substantially paralleL to each other and are arranged so
that a wire inserted between the first and second leg por-
tions 136A and 138A is engagingly gripped between the ofEset
planar portions 164~.
Referring now to FIG. 10, the upper ~irst housing sec-
tion 108 has six cable-receiving external sockets 170, 172,
174, 176, 178 and 180 disposed therein.
As will be further explained below, socket 170 is a
power inlet socket. Sockets 172, 174 and 176 are plug-in
receptacle sockets. Socket 178 is a wall switch connecting
socket. Socket 180 is a light fixture connecting socket.
~ach of the sockets 170-180 is identical in construc-
tion. Socket l76 is shown in cross section in FIG. 11, and
-14-
~232~
the Eollowing de.scription thereoE is applicable to each of
the sockets 170-188.
Fach oE the sockets 170-180 is constructed Eor use with
a cable 182.
The construction of the cable 182 is best seen in FIG.
ll wherein the end oE the cable is seen in elevation, and in
FIG. l7 which is a cross-sectional view of the typical
cable~
The cable l82 includes ~irst, second and third suhstan-
tially coplanar, substantially parallel wires 184, 186 and
188. As will be understood by those skilled in the art,
wire 184 is a comrnon wire 184, wire 186 is a ground wire
186, and wire 188 is a power wire 188.
The common and power wires 184 and 188 are insulated
wires and have first and second substantially circular
cross-section resilient tubular insulating sheaths 190 and
lq2, respectively, disposed thereabout. rhe insulating
sheaths 190 and 192 ar~ typically a rubber-like plastic
material. I
Located between the insulated common wire 184 and the
insulated power wire 188 is the ground wire 186 which
generally iB not covered with an insulating sheath.
The three wires 184, 186 and 188 are all received within
a substantially oval cross-section resilient tubular insu-
25 lating casing 194. Typically, the three wires 184, 186 and
; 188 are wrapped with a plurality of wraps of paper wrapping
196 which separates them from each other and from the casing
194.
For use with the present invention, the cable 132 must
have its three ends constructed in a particular manner as
best seen in FIG. 18.
-15-
~2~6~
Ln FIG. 18, the cable 182 is shown in side elevation
view analogous to the view seen in FIG. 11. There, it is
seen that Eree end portions 198, 200 and 202 of Eirst,
second and third wires 184, 186 and 188, respectively,
extend beyond a free end 204 of casing 194, and at least a
part oE the Eree end portions 198, 200 and 202 extending
beyond free end 204 of casing 194 is bare.
The first and second insulatLng sheaths 190 and 192
disposed about common wire 184 and power wire 188, respec-
tively, extend a distance 206 beyond the free end 204 of
casing 194.
Referring again to FIG. 11, the following detailed
description of the socket 176 thereshown in cross section
can best be understood relative to the description just
given of the cable 182.
The socket 176 is de~ined by a bottom wall 208 and a
tapered side wall 210 extending outward from bottom wall
208.
The side wall 210 is convergingly tapered downward
toward the bottom wall 208. The tapered side wall 210 iB
illustrated as having a somewhat inverted cone shape with a
substantially oval cross section, which is the preEerred
shape. Tapered side wall 210 could, however, be differently
shaped, for example with a rectangular cross section, or
with one tapered wall and one opposed vertical wall, so long
as at least one tapered surface oE substantial si~e is pro-
vided to wedgingly engage the casing 194 of cable 182.
The bottom wall 208 has Eirst, second and third aligned
housing openings 212, 214 and 216 (see FIG. 10), respec-
tively, disposed therethrough.
~3~
The housiog openings 212, 214 and 216 are in registry
with V notches 134A, 1348, and 134C, Gf common strip 114,
ground strip 116, and po~er strip 118, respectively, as seen
in FIG. 12.
Similarly, the pairs of three housirlg openings seen in
each of the other sockets 170, 172, 174, 178 and 178 in FIG.
10 are in registry with the V-notches in the associated con-
tact ~strips located ti-erebelow, which can readily be deter-
mined by comparison of FIGS. 10 and 12, and by the dashed
ovals seen in FIG. 9.
When the cable 182 is inserted within the cable
receiving socket 176, the bare free end portions 198, 200
and 202 of first, second and third wires 184, 186 and 188
are disposed through the first, second and third housing
15 openings 212, 214 and 216, respectively. Also, the substan-
tially oval cross-section casing 194 of cable 182 is
wedgingly engaged with the tapered side wall 210 of socket
176 as best seen in FIG. 11.
rhs socket 176 further includes first and second tapered
20 midwalls 218 and 220, respectively.
The eirst housing opening 212 is located betweell tapered
side wall 210 of socket 176 and the eirst tapered midwall
218, so that the eirst insulating sheath 190 is wedgingly
engaged with the first tapered midwall 218 and the tapered
side wall 210.
The third housing opening 216 is located between the
tapered side wall 210 and the second tapered midwall 220, so
that the second insulating sheath 192 is wedgingly engaged
with the tapered side wall 210 and the second tapered mid-
30 wall 220.
The first, second and third wires 184, 186 and 188 which
are disposed through the ~irst, second and third hou.sing
openings 212, 214 and 216 are received through the
corresponding web openings 126 oE common strip 114, ground
5 strip 116, and power strip 118, respectively.
The wires 184, 186 and lfl8 are each forced between the
f irst and second leg portions 136 and 138 of common strip
114, ground strip 116, and powor strip 118, respectively, as
is best seen in FIG. 11.
When the wires 184, 186 and 188 are inserted into the
strips 114, 116 and 118, the arcuate cross section second
leg portion 138 of each of the strips 114, 116 and 118
f lexes to allow the corresponding wire to be received bet-
ween the legs of the strip and to f irmly engage the wire due
to the resilient biasing action of the arcuate second leg
portion 138 of the respective strip.
As best seen in FIG. 10, the cable receiving socket 176
is oval in cross section, and the f irst, second and third
housing openings 212, 214 and 216 are aligned parallel to a
longest cross sectional axis 222 of the socket 176.
When the cable 182 is inserted within the socket 176, it
is very snugly held therein through a combination of the
resilient gripping action of the strips 114, 116 and 118 on
the wires 184, 186 and 188, in combination with the wedging
action of the casing 194 within the tapered side wall 210~
and the sheaths 190 and 192 between the tapered side wall
210 and the first and second tapered midwalls 218 and 220,
respectively .
r~eferring now to the schernatic illustration of FIG. 9,
an overall system utilizing the plug-in electrical wiring
--18--
~3Z~
apparatus 100 i5 thereshown. The circuitry of the apparatus
100 is represented by the schernatic illustration of the
electrical colltact strips 114, 116, 118, 120 and 122
thereshown. The strips 114-122 are oriented in a manner
corresponding to that seen in F~G. 12. The contact between
wires such as 184, 136 and 188 with the common strip 114,
ground strip 116 and power strip 118 are represented in FIG.
9 by small circies.
The particular contacts corresponding to the sockets
170, 172, 174, l76, 178 and 180 are designated by dashed
oval lines generally corresponding to the outer circum~
ference Oe each of the sockets, which dashed lines are
designated by the numerals 172-180 corresponding to the
sockets 172-180.
IS An electrical power source 224 is schematically shown
near the bottom of FIG. 9. A power lead-in cable 226, which
is a typical cable like the cable 182 shown in FIGS. 17 and
18, connects the power source 224 to the power inlet socket
170,
The power lnlet cable 226 includes a common wire 228, a
ground wire 230, and a power wire 232 which are connected to
the common strip 114, the ground strip 116, and the power
strip 118.
The electrical contacts associated with the plug-in
receptacle sockets 172, 174 and 176 may be connected to
first, second and third electrical outlets 234, 236 and 238,
respectively, by cables 240, 242, and 182, respectively.
Each of the outlets 234, 236 and 238 may be conventional
electrical outlets like the outlet 96 shown in FIG. 2, or
preferably, they may be of a plug-in type design utilizing
--19--
Z6~
plug-in strips similar to the strips 114, 116 and 118 shown
in FIG. 1l.
The electrical contacts associated with switch socket
178, which are readily apparent in FIG. 9, are connected by
a cable 243 to a wall switch 244.
When the wall switch 244 is turned on, the power strip
118 is connected with the switched power strip 122.
The wall switch 244 may be constructed in a conventional
manner like the switch 90 shown in FIG. 1, or preeerably, it
is constructed using plug-in type electrical connections
like those illustrated in FIG. 11.
Switched secondary light fixture socket 180 has its
associated electrical contacts connected by a cable 246 with
a switched secondary light fixture 248. The light fixture
15 248 is controlled by the wall switch 244, so that when wall
switch 244 is turned on to connect power strip 118 with
switched power strip 212, current will then be conducted to
the light fixture 248 to turn on the same.
It will be appreciated in viewir.g FIGS. 9 and 12 that
common strip 116 is always electrically connected to common
ext0nsion strip 120. This is illustrated in FIG. 12 by an
overlapping tab 250 of web portion 124 o~ common strip 116,
which overlays the web portion 124 of common extension strip
120.
Thus, there are actually four electrically independent
strips contained in the apparatus 100. They are the common
strip 114, the ground stries 116 and 120, the power strip
118, and the switched power strip 122.
Each of these electrically independent strips has wiring
attachment studs extending vertically downward through an
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upper wall 2S2 of bottom second housing section 112 for con
nection of wires from a switched ceiling light ixture 254,
and also in some instances, a pull chain switch 256.
A first stud 258 extends downward from common strip 114.
A second stud 260 extends downward from common strips 116
and 120. A third stud 262 extends downward from power strip
118. A fourth stud 264 extends downward from switched power
strip 122.
The electrical connecting studs 258-264 are shown sche-
matically in FIG. 9.
FIG. 15 illustrates the manner in which the second stud
260 is connected to the ground strip 116.
The first leg portion 136 of ground strip 116 has an
underturned horizontal tab 266 to which the stud 260 is
lS welded.
The stud 260 extends downward through an opening 268 in
upper wall 252 of bottom second housing section 112.
, Attached to stud 260 is an olectrical contact plate
270.
The stud 260 is designed to have an electrical wire 272
wound thereabout and held in place thereon ayainst electri-
cal contact plate 270 by a threaded plastic connector knob G
which is threaded onto stud 260 to firmly hold the wire 272
against electrical connecting plate 270.
FIG. 14, which is a bottom view of bottom second housing
section 112 shows in dotted lines the actual locations of
tho studs 258-264.
Returning now to the description of FIG. 9, the switched
ceiling light fixture 254 is typically mounted directly
below the apparatus 100 and has the wire 272 connecting the
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~;32~
ground stud 260 to the fixture 254, along with common and
power ~ires 276 and 278, respectively, connecting the fix-
ture 254 to the common stud 258 and the switched power stud
264.
5The switched ceiling light fixture 254 is controlled by
wall switch 244.
As an alternative to use of the wall switch 244, it is
sometimes desired to provide a pull chain switch 256 which
is directly connected to the apparatus 100 and typically is
associated with the switched ceiling light fixture 254.
IE the pull chain switch 256 is utilized, the wall
switch 244 and associated cable 243 are removed. The pull
chain switch will have a first wire 280 connected to power
stud 262, a ~round wire 282 connected to ground stud 260,
15and a third wire 284 connected to switched power stud 264.
Thus, when the pull chain switch 256 is in an on posi-
tion, it will electrically connect the wires 280 and 284,
and accordingly will e:Lectrically connect the power strip
118 and the switched power strip 122. Thus, the swltched
ceiling light Eixture 254 and/or the switched secondary
light fixture 248 may be controlled by the pull chain switch
256 instead o~ by the wall switch 244.
Referring now to FIGS. 10, 11, 12 and 14, some Eurther
details of the construction of housing 106 will be
described, in addition to some details of the manner in
which the housing 106 is typically mounted to the ceiling
beams such as 102 and 104.
The apparatus 100 is constructed by placing the electri-
cal contact strips 114-122 in place within the bottom second
30housing section 112 as shown in FIG. 12, and by then placing
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~2~2~
the upper first housing section 108 in place within the
groove 110 of bottom second housing section 112 as seen in
FIG. 1l Preferably, the upper and lower housing sections
108 and 112 are connected through the use of cement at the
groove 110.
Each o~ the electrical contact studs 258-264 has a
plastic kllob like tha knob G thereon.
As seen in FIG. 14, the four knobs are designated as s1,
2" W and B2. These designations correspond to the color ot
the knobs. The knobs B1 and B2 are black. The knob G is
green. The knob W is white.
These colors corresoond to the typical colors utilized
on conventional cable. The insulating sheath 190 on the
common wire 184 is always colored white, and accordingly the
1~ knob W is associated with the common strip 114.
The second insulating sheath 192 disposed about the
powor wire 188 is always colored black, and accordinqly the
knobs Bl and s2 which are associated with the power strip
118 and the switched power strip 122 are colored black.
The ground wire 186, if it is insulated, is typically
insulated with green insulation, and accordingly the knob G
on stud 260 associated with ground strips 116 and 120 is
colored green.
To iurther aid in this color coding of the apparatus
100, an upper surface 2~6 o~ upper first llousing section 108
has five colored indicia strips 288, 290, 292, 294 and 296
thereon. The indicia strips 288-296 are represented in FIG.
10 by dashed lines, for ease of illustration, but it wlll be
appreciated that they are in some manner printed or attached
to the upper surface 286 to indicate that the various ope-
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~LZ3~,6~
nings such as openings 212, 214 and 216 covered by the indi-
cia strLps ara associated with a respective one oE the
electrical contact strips 114-122 located within the appara-
tus 100. All of the housing openings associated with a par-
ticular contact strip such as cornmon strip ll4 are aligned
with the corresponding indicia strip such as 288.
The indicia strlp 288 is white, since it corresponds to
the common strip 114 which is to be connected to cormnon
wires such as 184 having a white insulation such as 190
thereon.
Second and fourth indicia strips 290 and 294 are both
colored yreen since they are associated witl~ the ground
strips 116 and 120. 'I'hird and eieth indicia strips 292 and
296 are colored black since they are associated with the
power strip 118 and the switched power strip 122.
The bottom second housing section 112 has Eirst, second
and third attachment holes 298, 300 and 302 disposed
therethrough .
As seen in FIG. 11, the top surEace Oe bottom second
housing section 112, in combination with side walls 304 and
306 of upper eirst housing section 108 deeines two 90
notches which may readily receive ceiling beams such as 102
and 104 thereagainst. By placing the apparatus 100 against
a ceiling beam such as lO2, the apparatus 100 may readily be
attached to the ceiling bea,n 102 through the use oE wood
screws such as 308 shown in phantom lines disposed through
the attachment holes 298 and 300.
In a typical installation, the apparatus 100 will only
be mounted on a single ceiling beam such as 102, through thc
use Oe two wood screws disposed through the attachment holes
298 and 300.
3L~3~
In some instances, however, it is desired to hang a
heavy load Lrom the apparatus 100, such as for example when
mounting a chandelier. In such an instance, a second
ceiling beam such as 104 ~nay be appropriately attached to
the ceiling structure, and then attached to the apparatus
100 with a third wood screw disposed through the attachment
hole 302, rhis gre~t~y increases the physical load which
can be hung from the apparatus 100, since the apparatus 100
is no longer mounted in a cantilevered Eashion.
The upper and lower housing sections 108 and 112
illustrated in FIGS. 10, ll, 12 and 14 are preferably manu-
factured by plastic injection molding.
FIG. 14 is a bottom view of the bottom second housing
section 112 and it shows various reinforcing ribs which sup-
port tll0 upper wall 252 thereof. It is seen that there arecylindrical reinforcing sections 31~, 312, and 314 asso-
ciated with the screw attachment holes 29B, 300 and 302,
respectively.
There is an octagonal-shaped side wall 316 extending
around and downward from the perimeter oE upper wall 252.
There are a plurality of interconnecting ribs 318-342
which extend between the various cylindrical reinforcing
portions 310, 312 and 314 and the octagonal side wall 316
and the upper wall 252.
Additionally, built-up sections 344 and 346 have screw
receiving holes 348 and 350 disposed therein, respectively,
for attaching a metal support plate 352 (see FIG. 11) to the
bottom housing section 112.
The metal support plate 352 is utilized when it is
desired to attach a heavy item such as a chandelier to the
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~L~23~6D~L
apparatus 100. The support plate 352 wil- have suitable
openings (not shown) disposed therein to receive various
wiring from the device being hung, and will provide suitable
means for direct support of the device such as the chan-
delier being hung.
As seen in FIG. 10, each of the housing openings such as212, 214 and 216 has associated therewith a square opening
such as 354, 356, and 358, respectively. The square ope-
nings such as 354, 356 and 358 are access openings for a
tool such as the tool 66 shown in FIG. 8, which engages the
resilient tabs 12a near their eixed ends 130, so that they
may be deflected downward to release the respective wires
received through the openings 212, 214 and 216, in a manner
similar to that previously described with regard to FIG. 8.
Also as seen in FIG. 10, there is lettering indicia
displayed adjacent the sockets 170-180 indicating the item
which should be connected to each of the sockets.
The socket 170 is labeled "POWER IN". The sockets 172,
174 and 176 are collectively labeled "PL~G-I~ RECEPTACLES".
The socket 178 is labeled "SWITC~I". The socket 180 is
labeled "SECOND LIGHT".
Referring now to FIG. 12, further details are there seen
of the bottom housing section 112.
The octagonal-shaped upper wall 252 is surrounded by the
perimeter wall 316 previously described.
The rectangular groove 110 previously described is
disposed in the upper wall 252, and as can be seen in FIG.
11, the upper wall 252 is enlarged as shown as 360 and 362
to provide appropriate strengthening adjacent the groove
110.
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~L~3~
An inner perimeter rib 364 is rectangular in shape and
extends vertically upward from upper wall 252 immediately
within the limits set by rectangular groove 110.
Four parallel long ribs 366, 368, 370 and 372 extend
5 vertieally upward from upper wall 252 for receiving the
lower ends of the electrical contact strips 114, 116 and
l18, respectively.
Sirnilarly, shorter transverse ribs 374, 376, and 378
receive the lower ends of electrical eontact strips 120 and
122. As can be seen in E'IG. 12, the space between ribs 368
and 370 is openly communicated with the space between the
rib 374 and the two short ribs 376 and 378, to allow the
ground strip 116 to contact the ground extension strip 120.
As seen in FIG. 11, the bottorn housing section 112 has a
15 vertical thickness equal to the thickness of wallboard sec-
tions 380 and 382 which are attached to the bottom of the
ceiling beams 102 and 104 in a conventional manner.
For conventional one-hal~ inch thiek wallboard, the bot-
tom housing section 112 will have a thickness of one-hal~
20 inch so that it fits flush vith the bottom surface of the
wallboard sections 380 and 382.
E;aeh of the soekets such as soeket 176 seen in FIG. 11,
of upper housing seetion 108 has four parallel vertieally
downward extending short ribs 384, 336, 388 and 390
25 extending vertieally downward frorn the bottom wall 20-3
thereof for receiving the upper ends of the electrical con-
tact strips such as 114, 116 and 113.
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~;~3~
Summarv of Operation o~ The Present }nvention
A wiring system such as that shown in F~G. 9 based upon
the plug-in type wiring apparatus 100 provides a very much
ilnproved system as compared to conventional present-day
wiring systelns wherein junction boxes, outlet boxes and
switch boxes are hand-wired.
This is particularly true LE the electrical outlets 234,
236 and 23a and the wall switch 244 are also constructed in
a manner silnilar to the apparatus 100 having plug-in type
connectors similar to that illustrated in ~IG. 11 utilizing
electricaL contact strips like strips 114, 116 and ll8 and a
plug-in housing socket such as 176.
With such a systeln, the multi-step wiring process
currently predominantly used, which requires th0 electrical
contractors to visit the construction sites several times to
prewire, and to final-wire a building, is elinninated and is
replaced by a process which only requires the electrical
contractor to make a single visit to the construction site.
For example, to wire the system shown in FIG. 9, the
electrical contractor Eirst connects the power cabla 226 to
the plug-in socket 170.
Assuming that the contractor desires to connect three
electrical outlets 234, 236, 238, the wall switch 244, a
ceiling light fixture 254, and a switch secondary light fix-
ture 248 to the apparatus 100, that is accomplished in the
eollowing manner.
The electrical contractor plugs in cables 240, 242, 182,
243 and 246 into the plug-in sockets 172, 174, 176, 178 and
180, respectively. Those cables 240, 242, 182, 243 and 246
are then placed within the building structure so that they
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run to t~e appropriate locations for the terminal devices
attached to the other ends thereof.
Then, the apparatus 100 is placed against a ceiling beam
such as 102 anù connected thereto by two screws such as 30~.
5~rhrenl the cables 240, 242, 182 and 243 may be connected
to electrical outlets 234, 236 and 23U and wall switch 244,
respectively, preferably by a plug-in type connection sirni-
lar to that previously described with regard to the appara-
tus 100. Those electrical outlets 234, 236 and 23a and wall
switch 244 also are preferably constructed similar to the
apparatus 100 so that they have a flange portion
corresponding to the bottom housing section 112 which can be
directly naiLed on the eront face of a vertical wooden stud
oE a wall.
l5The cable 246 will typically be hand-wired to the
switched secondary light fixture 248, or of course the light
fixture 248 could be constructed for a plug-in type connec-
tion like that previously described with regard to FIG. 11.
The switched ceiling light fixture 254 is hand-wired to
20ths electrical connection studs 258, 260 and 264 as pre-
viously described with regard to FIG. 15.
Then, all that i5 necessary is for the other end oE
power cable 226 to be connected to power source 224 at which
time the entire system shown in PIG. 9 is completed and is
connected to electrical power so that it may be used from
that point forward.
The electrical contractor is then finished with
installation of the system shown in PIG. 9, and there i5 no
need to return to the construction site for any final wiring
procedure.
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~L~3;~6~fl~
An additional benefit provided by a systeln such as that
shown in FIG. 9 is that as soon as the power source 224 is
connected, the electrical outlets 234, 236 and 238 may be
utilized by the electrical contractor to power his tools
S which are utilized in construction of remaining portions of
the electrical system oE t'le particular building involved.
That is not possible with typical preserlt-day wiring prac-
tices where the wirlng system is not ~inal-wired and con-
nected to a power source until the structure is essentially
completed.
Thus it is seen that the apparatus oE the present inven-
tion readily acl,ieves the ends and advantages mentioned as
well as those inherent therein. while certain preEerred
embodiments of the invention have been illustrated for the
purposes oE the present disclosure, numerous changes in the
arrangement and construction oE parts may be made by those
skilled in the art, which changes are encompassed within the
scope and spirit oE the present invention as de~ined by the
appended claims.
~hat is claimed is:
3~
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