Note: Descriptions are shown in the official language in which they were submitted.
SWITC~IABLE RECEPTACLE UNIT
FIELD OF THE INVENTION
This invention relates to a wall system Eormed from
a plurality of series-connected electrically prewired
panels having removable power taps and, more
specifically, to an improved switchable power tap.
BACKGROUND OF T~E INVENTION
U. S. Patent No. 4 367 370, owned by the assignee
of this application, discloses a wall system formed from
a plurality of series-connected electrically prewired
panels, and more specifically to a wall system wherein
power-taps such as for light fixtures and conventional
electrical receptacles can be selectively positioned on
the panels and selectively switchably connected, at
their point of use, to any one of a plurality of dif-
ferent electrical circuits. The wall system of the
aforesaid patent is provided with three different
electrical circuits e~tending therealong, and the
switchable power tap is removably connected to a power
block or terminal associated with the respective panel,
and for this purpose a plug-in connection is provided
therebetween. The power tap is provided with five
conductive prongs which project into the power block for
connection to the three different electrical circuits
associated therewith. The power tap, however, has
internal switching structure such that only one of three
different prongs is connected to the output of the power
tap, such as a conventional receptacle, whereby the
output is hence selectively connected to only one of the
three different circuits. The switching structure
permits switching and hence selection between the three
different circuits only when the power tap is discon-
nected from the power block.
The electrified wall system of the aforesaid
patent, and specifically the switchable power tap
associated therewith, has proven highly desirable in its
ability to permit a circuit-selecting function to be
performed at each individual point of use merely by
manually displacing the switch associated with the
respective power tap so as to permit selection of the
desired circuit, following which the power tap is then
plugged into its respective power block. However, in a
continuing effort to improve upon the design, sim-
plicity, function and reliability of the switchable
power tap, specifically when same comprises a receptacle
unit, the improved switchable power tap of this inven-
tion has hence been developed.
More specifically, this invention relates to an
improved switchable power tap, specifically a receptacle
unit, which is removably connectable to a power block or
terminal associated with an electrically prewired wall
system defined by interconnected panels, which improved
power tap permits the output (that is, the receptacle)
thereof to be individually selected at its point of use
so as to be electrically connected to any selected one
of the several electrical circuits which extend along
the prewired wall panels. The improved switchable power
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tap of this invention permits the switching function to
occur only when the power tap is electrically
disconnected, and hence physically disconnected, from
its respective power block. However, with this improved
switchable power tap, the input to -the power tap is
electrically connected to only a single circuit, rather
than to a plurality of circuits as with -the power tap of
the aforesaid patent, so that the improved power tap of
this invention is in its entirety of a single electrical
phase.
In addition, the improved switchable power tap oE
this invention is believed to provide a more reliable
and more efficient switch due to its providing a more
intimate electrical contact, and is believed to be less
sensitive to the accuracy of the switching position.
This improved power tap is also structurally simpler and
less costly to manufacture.
In the improved power tap of this invention, there
is provided a housing mounting therein three
electrically conductive members or plates. These three
plates define the electrical outlet portion of the power
tap, which outlet portion in the preferred embodiment
comprises a conventional electrical receptacle. The
power tap also includes an electrical inlet portion
which is defined by three electrically conductive prongs
adapted to create a plug-like engagement with a power
block. Two of -the prongs are permanently electrically
connected to two of the conductive plates. The third
prong is part of a switch structure and is slidably
supported on but in continuous electrical engagement
with a conductive guide member, the latter being
electrically connected to the third conductive plate.
This slidable, and hence swltchable, prong can be
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selectively positioned in any one of several different
positions, three in the disclosed embodiment, so that
when the power tap is plugged into the power block, the
switchable prong is hence electrically engaged with a
selected one of the three different electrical circuits
provided in the power block, depending upon the pre-
selected position of the switchable prong.
Other objects and purposes of the invention will be
apparent to persons familiar with systems of this type
upon reading the following specification and inspecting
the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 is a perspective view illustrating a wall
system formed from two series-connected panels which are
electrically prewired.
Figure 2 is an enlarged, fragmentary view illus-
trating the prewired raceway, with cover removed, as
associated with the lower edge of the panel.
Figure 3 is an enlarged, fragmentary, partial
sectional view showing one end of the powered raceway on
a single panel.
Figure 4 is a fragmentary sectional view taken
along line IV-IV in Figure 3, but expanded to include a
second panel and the electrical connector between
adjacent panels.
Figures 5-7 are enlarged sectional views as taken
along lines V-V, VI-VI and VII-VII, respectively, in
Figure 3.
Figure 8 is a front view showing the mounting of a
power tap ti.e.~ a receptacle unit) on the power block,
the surrounding raceway being indicated by dot-ted lines.
Figure 9 is a left side view of Figure 8.
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Figure 10 is a sectional view of the power tap as
taken substantially along line X-X in Figures 8 and 11.
Figure 11 is a sectional view of the power tap as
taken substantially along line XI-XI in Figure 10.
Figure 12 is a fragmentary sectional view taken
along line XII-XII in Figure 11.
Certain terminology will be used in the following
description for convenience in reference only, and will
not be limiting. For example, the words "upwardly",
"downwardly", "leftwardly" and "rightwardly" will refer
to directions in the drawings to which reference is
made. The words "inwardly" and "outwardly" will refer
to directions toward and away from, respectively, the
geometric center of the panel and designated components.
Said terminology will include the words specifically
mentioned, derivatives thereof, and words of similar
import.
DETAILED DESCRIPTION
Figure 1 illustrates a wall system 10 formed by a
series of interconnected upright prefabricated wall
panels, only two substantially identical panels 11 and
llA being illustrated. Panels of different lengths can
be serially interconnected.
Each panel, such as panel 11, includes an in-ternal
rigid rectangular frame formed by parallel top and
bottom rails rigidly joined together by parallel side
rails, the bottom rail 12 and side rails 12' being
partially illustrated in Figure 2. These rails are of
channel-shaped configuration and open inwardly of the
panel, whereby the frame confines therein a suitable
core structure, normally a honeycomb layer or similar
conventional structure. The core and frame are normally
sandwiched between thin facing sheets disposed on
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opposite sides of -the frame, which sheets in turn are
normally covered by a suitable fabric, the latter
defining the exterior side faces 13 of the panel. The
structure of panel 11 is well known, and one such
structure is disclosed in U. S. Patent No. 4 060 294,
which patent also discloses the L-shaped plastic hinge
used for hingedly connecting the adjacen-t vertical edges
of two panels together.
The panel 11 ~as well as panel llA) i5 provided
with a prewired electrical system 14 extending longi-
tudinally along the lower edge thereof, which system
includes identical power blocks 16 and 17 disposed
adjacent the opposite lower corners of the panel, as
illustrated in Figure 2. The power blocks 16 and 17
each include a box-like housing 18 constructed of an
electrically insulative material and supporting therein
five electrically conductive plates designated 19-1
through 19-5 (Figures 6 and 7), which plates are
electrically insulated from one another. The five
conductive plates 19 of power blocks 16 and 17 are
individually electrically connected by five wire con-
ductors 21 which extend between the power blocks 16 and
17, which conductors 21 extend through an elongated
closed channel 22. This latter channel 22 extends
between and rigidly joins the housings of the power
blocks 16 and 17 together, and the channel 22 is in turn
fixedly but releasably connected to the underside of the
bottom frame rail 12 by means of quarter turn fasteners
23.
A raceway 26 is defined along the horizontally
extending lower edge of the panel 11 so as to enclose
the power system 14 therein. The raceway 26 is formed
by a pair of substantially identical, elongated L-shaped
covers 27 which cooperate with one another and with the
~2~Lf-~3
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bottom rail 12 to define a closed channel substantially
as illustrated in Figure 5. Each L-shaped cover 27
includes an upper locking tab 28 which permits the cover
to be fixedly but releasably secured to the panel. Each
cover also includes a vertical leg 29 which projects
downwardly and is then bent inwardly to form an integral
bottom leg 31. The two opposed covers 27 cooperate,
when mounted on the panel, to define therein a closed
passage 32 which extends longitudinally along the lower
edge of the panel, which passage 32 is isolated from the
wire-confining channel 22 so as to enable communication
cables or the like to be fed thexethrough.
Each power block 16 and 17 has a pair of identical
connector portions 36 associated therewith, which
portions face outwardly toward opposite sides of the
power block and are identified as 36R and 36L ~Figures 4
and 7) for purposes of identification. Each said
connector portion 36 includes a set of four conductive
blades or prongs 38 which project outwardly from the
power block.
To electrically interconnect adjacent panels such
as 11 and llA, the adjacent power blocks 16 and 17A are
electrically joined by a flexible electrical connector
46 as indicated in Figure 4. This connector 46 includes
a pair of rigid housing parts 47 and 48 which have
arcuate interfitting hinge portions 49 and 51 for
enabling the two housing parts to be horizontally
angularly displaced about an axis which is substantially
aligned with the hinge axis of the hinge structure which
joins the adjacent panels together. The housing parts
47 and 48 are hollow and have therein plural, here five,
wires which extend there-through for transmitting
electrical energy between the identical connector
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portions 54 as disposed on opposite ends of the flexible
connector 46.
The connector portions 54, each of which includes a
set of five electrically conductive prongs, are designed
for creating a plug-type electrical connection with
either of the connector portions 36R or 36L as as-
sociated with the power blocks. The structure of, and
cooperation between, the connector portions 38 and 54 is
explained in said Patent No. 4 367 370.
Each power block 16 and 17 also has a further pair
of connector portions 41R and 41L associated with the
opposite sides thereof, which connector portions are
longitudinally staggered or offset relative to one
another. These connector portions 41R and 41L are
identical and each includes a set of five vertically
spaced slots or openings 42-1 through 42-5, and a set of
four conductive prongs 43-1 through 43-4 projecting
outwardly of the power block housing. The prongs 43
associated with the connector portion 41L are in-
dividually separated from the prongs associated with the
opposite connector portion 41R. Further, each prong 43
is separated from its respectively adjacent conductive
plate 19 by means of the intermediate slot 42.
The structure described above is explained in
greater detail in aforesaid Patent No. 4 367 370.
In the wall system 10, the power blocks 16 and 17
as associated with each panel can have a power-tap unit,
such as a receptacle unit 61, plugged into each or both
sides thereof, whereby the receptacle unit can be
positioned along the wall system at desired locations on
either side thereof. This receptacle unit 61, as
illustrated in Figures 8-9, is positionable within the
raceway passage 32 so that the front face 64 of the
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receptacle unit is disposed substantially flush with -the
outer surface of the cover side wall 29, for which
purpose the cover ls provided with a substantially
rectangular opening 63 in which the receptacle unit is
positioned.
The receptacle unit 61 (Figures 8-12) includes a
hollow block-like housing 62 constructed of a
nonconductive material and having at least one outlet
portion which, in the illustrated embodiment, comprises
two conventional three-hole outlets or sockets 66
associated with the front face of the housing. Each
socket is defined, in a conventional manner, by means of
a pair of vertical slots 67 and 68 and an associated
U-shaped ground slot 69 so as to accommodate any
conventional two-prong or three-prong plug.
The housing 62 mounts therein a first conductive
plate 73 (Figure 11) positioned for defining the
U-shaped ground slot 69, a second conductive plate 72
for defining the conductive slot 68, and a third
conductive plate 71 for defining the other conductive
slot 67~
The rear of receptacle unit 61 also has an input
connector portion 74 associated therewith which, as
illustrated by Figure 10, includes three conductive
prongs 76 through 78. The uppermost prongs 77-78 are
respectively fixedly connected to the conductive plates
72-73. The prong 77 also has a slot or opening 79
formed in the rear housing wall in direct association
with the prong.
The prong 76 is associated with, and forms part of,
a switch structure 81 which permits the prong 76 to be
selectively positioned within one of several different
positions, there being three such positions in the
illustrated embodiment. This switch structure 81
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includes a switching member 82 formed substantially as a
sleeve and slidably supported on an elongated guide rod
83 which is fixedly positioned within the housing 61.
The guide rod 83 is of electrically conductive material
and has the lower end thereof fixedly secured to the
conductive plate 71. The sleeve 82 is also of
electrically conductive material and is snugly slidably
supported on the rod 83~ Sleeve 82, at its upper end,
is joined to an intermediate bridging portion 84, which
in turn is secured to the prong 76 so that the latter
projects outwardly through the rear cover 103 of the
housing in substantially perpendicular relationship to
the dixection of displacement of the prong. This rear
cover has an elongated slot 86 through which the prong
76 projects, which slot 86 enables the prong to be
slidably displaced between the three positions which are
indicated in Figure 10.
The switching means 81 also has circuit indicating
means 91 associated therewith. For this purpose, the
front wall of the receptacle housing 61 has a small
opening or window 92 formed therein directly in front of
the front face of an indicator plate 93. The front face
of this indicator plate 93 has suitable indicia thereon,
specifically the numerals "1", "2'l and "3" so as to
designate the three different electrical circuits as
associated with the prewired panel. One of these lattex
numerals is positionable in direct alignment with the
window 92 depending on the positioning of the prong 76.
This indicator plate 93 is secured to the outer end of
an arm 96 which, at its other end, is joined to a
plastic sleeve 97 which fixedly and snugly surrounds the
conductive sleeve 82. The indicator plate 93 is suit-
ably slidably guided within a pair of guide rails 98
which are fixedly secured to the inner surface of the
front wall of the housing.
OPERATION
After the wall system has been assembled as desired
with the adjacent panels being electrically intercon-
nected by flexible connectors ~6, which connectors can
be disposed on either side of the panels depending on
the angularity between adjacent panels, then the overall
system can be suitably electrified by connecting one of
the power blocks to a suitable power source, whether it
be floor or ceiling mounted. In this manner, electrical
energy is supplied throughout the wall system, whereupon
receptacle units 61 can be positioned on the panels
along the wall system at selected locations. These
receptacle units can be selectively switched during
installation 50 as to be joined to any one of the three
different circuits which extend along the wall system.
With respect to the receptacle unit 61, each panel
can be provided with between zero and four such power-
tap units, since each power block can have a unit 61plugged into either or both sides thereof. Prior to
mounting of the individual receptacle unit 61 on the
power block, the installer initially manually slides the
switchable prong 76 upwardly or downwardly until the
prong 76 is the selected one of the three different
positions, which three different positions permit the
recep-tacle unit to be electrically joined to circuit
"1", "2" or "3" associated with the power block. After
the prong 76 has been manually moved into the selected
position, such as the uppermost position as indicated by
solid lines in Figures 10 and 11, then the selected
circuit will be visible from the front side of the
receptacle unit since the selected circuit, such as the
-
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number "1", will be visible through the window 92.
After the circuit selection has been made, the re-
ceptaele unit 61 is then plugged into the power block
and is fixedly mounted thereon by appropriate manual
slidable displacement of the locking member 101 due to
the locking tabs 102 thereon overlapping a portion of
the rear wall 103 of the receptacle so as to prevent it
from being unplugged from the power block.
When the receptacle unit 61 is plugged into the
power block, the uppermost fixed prongs 77 and 78 of the
receptaele unit project into the slots 42-4 and 42-5 and
hence bridge the gap which is defined interiorly of the
slot so that the prongs 77 and 78 hence are in
eleetrieal engagement with the eonduetors 19-4 and 19-5
respectively, At the same time, the upper power block
prong 43-4 projects through the slot 79 formed in the
rear faee of the reeeptaele unit. The movable prong 76,
when in the illustrated uppermost position, projeets
into the slot 42-3 and eleetrically bridges between the
prong 43-3 and the conductor 19-3, whereby this prong 76
is then connected to one of the circuits, such as
cireuit "1". The power bloek prong 43-3 similarly
projeets through the slot 86 into the receptacle unit
housing and is slidably engaged with the underside of
the prong 76. The remaining two prongs on the power
bloek, namely the prongs 43-1 and 43-2, merely project
through the lower portion of the slot 86 into the
interior of the receptacle unit, and in particular are
positioned within the void or open region defined within
the interior of the receptaele unit housing. Henee,
only a single circuit or electrical phase is hence
transmitted from the power block to the receptacle uni-t
61.
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In a similar fashion, when the prong 76 is switched
into its middle or lowermost positions, such as for
engagement respectively with circuits "2" or "3", then
this prong 76 respectively projects into the power block
slot 42 2 or 42-l.
After the receptacle unit has been plugged into the
power block, it provides a visual indication of the
selected circuit due to the positioning of the indicia
plate 93 behind the window 92, thereby permitting a
quick and accurate determination as to which circuits
are connected to the receptacle units. However, once
the receptacle unit 61 is plugged into the respective
power block, then the receptacle unit cannot be switched
so as to change the circuit without first causing the
receptacle unit to be both physically and electrically
disconnected from the power block. This hence prevents
inadvertent circuit switching of the receptacle units,
and hence permits safe handling and utilization of the
power tap.
While the invention as described above relates
specifically to a power tap formed as a receptacle unit,
it will be appreciated that this power tap could also be
of other forms, such as a connector for a panel-mounted
light fixture or other electrical device.
Although a particular preferred embodiment of the
invention has been disclosed in detail for illustrative
purposes, it will be recognized that variations or
modifications of the disclosed apparatus, including the
rearrangement of parts, lie within the scope of the
present invention.
