Note: Descriptions are shown in the official language in which they were submitted.
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ELECTRICAL INTERCONNECTION ASSEMBLY
BACKGROUND OF THE INVENTION
Field of the Invention
The invention pertains to electrical interconnection systems and more
particularly to such systems for use in distributing electrical power to
modular wall
panels or the like.
Prior Art
Knowa interior wall systems typically employ prefabricated modular wall
units which are joined together in various configurations to divide a work
space into
smaller offices or work areas. Generally, such modular wall panels are
equipped with
raceways, for example along a bottom edge of the modular panels, for housing
electrical cable assemblies and junction blocks in order to provide electrical
outlets and
electrical power connections to adjacent panels. The electrical cable
assemblies
typically include a flexible conduit housing a plurality of electrical wires.
Rigid end
connectors are mechanically attached to the flexible conduit and electrically
attached
to the wires for joining the wires to a junction block.
The modular panels of a space-divider system may be configured such
that adjacent panels are in a straight line or at various angular positions
relative to each
other. It is common to configure intersecting walls in such a fashion that
three or four
modular wall panels intersect at right angles. Each of the panels typically
requires
electrical outlets, and may require outlets on both sides of the panels. In
any event,
electrical power has to be provided to all of the panels and often only one of
the panels
at the multiple panel junction is connected to a power supply source. Some
modular
wall panels and their associated raceways are narrow in cross-section. These
narrow
wall panels are typically joined together in a particular configuration such
that an angle
is formed between any two adjacent wall panels. In this instance, it becomes
very
difficult if not impossible to feed an electrical cable assembly between the
adjacent wall
panels, due to the size of the rigid end connectors of the cable assemblies.
An example of a prior art system is shown in U.S. Patent No. 5,096,434
to Byrne, and includes an interconnecting system in each wall panel comprising
an electrical junction block
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having four receptacle connectors formed integral thereto for receiving
electrical outlet
receptacles and a pair of rigid end connectors electrically connected to the
junction
block for connection to similar end connectors from adjacent panels. However,
when
this system is installed in narrow or thin-line wall panels, the length of the
rigid end
connectors do not permit the cable assemblies to fit around the comers created
by two
adjacent wall panels.
SUMMARY OF THE INVENTION
These and other problems of the prior art are overcome by means of an
interconnecting system comprising an electrical interconnection assembly for
each panel
which includes an electrical junction block having a plurality of receptacle
connectors
formed integral thereto for interchangeably receiving electrical outlet
receptacles and
power cable assemblies. A power cable attaches between a wall panel junction
block
and a power source for supplying power to the junction block. The power cable
assemblies can be connected between junction blocks of adjacent panels in
order to
supply power to the junction blocks and/or to any cables or outlet receptacles
attached
thereto. The electrical cable assemblies include a flexible conduit housing a
plurality
of electrical wires. Pivoting end connectors are mechanically attached to the
flexible
conduit and electrically attached to the wires for joining the wires to a
junction block.
In accordance with another aspect of the invention, an end connector is
pivotal at a point spaced away from the intersection of the end connector and
conduit.
BRIEF DESCRIPTION OF THE DRAWING
An illustrative embodiment of the invention is described in the following
detailed description, with reference to the drawing in which:
FIG. 1 is a fragmentary plan view of raceway areas of four wall panels,
illustrating wall panel interconnection assemblies in accordance with the
invention;
FIG. 2 is an enlarged perspective view of one of the junction block
assemblies of an electrical interconnection assembly of FIG. 1;
FIG. 3 is an enlarged side view of a receptacle block which forms part
of the junction block assembly of FIG. 2;
FIG. 4 is a top plan view of a pivotal cable assembly according to the
present invention;
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FIG. 5 is an exploded orthographic view of the pivotal cable assembly
of FIG. 4;
FIG. 6 is an orthographic view of the assembled components of FIG. 4.
FIG. 7 is top plan view of a pivotal cable assembly according to a
second embodiment of the present invention;
FIG. 8 is an exploded orthographic view of the pivotal cable assembly
of FIG. 7; and
FIG. 9 is an orthographic view of the assembled components of FIG. 8.
DETAILED DESCRIPTION
FIG. 1 is a fragmentary plan view of raceway areas of four wall panels
illustrating the connections of interconnection assemblies of the invention in
a
configuration in which the four panels are disposed at right angles to each
other. As
will be apparent from the following description, the specific angle at which
the panels
are positioned is not particularly significant. Furthermore, the invention is
equally
applicable to any number of panels configured at various angles. FIG. 1 shows
the
raceway portions 12, 14, 16, and 18 of a four-panel configuration 10 wherein
the
panels are disposed at right angles to each other. Each of the four panels is
provided
with an interconnection assembly 19, comprising one or more junction blocks 22
and
power cable assemblies 20A-20F interconnecting the junction blocks 22. A
junction
block 22 is disposed within each panel raceway, such that opposite sides of
the junction
block can be exposed outside the raceway through raceway openings. Each
junction
block has a pair of recesses 32 for mounting one or more electrical outlet
receptacle
blocks 100 (FIGS. 2 and 3). Receptacle blocks 100 provide power to electrical
equipment (not shown) located in proximity to the panels. Each junction block
22
includes a female connector block pair 34 at one end and a female connector
block pair
34A at another end as illustrated in FIG. 2. Each female connector block pair
34, 34A
can be independently interconnected to one or more power cable assemblies 20A-
20F,
and are each provided with two columns 38, 40 of a plurality of female
connector
terminals for connection to male connector terminals of the power cable
assemblies.
Column 38 is electrically connected to column 40 in a similar manner as
described in
my U.S. Patent No. 5,096,434. As shown in FIG. l, a power cable 21 connects
junction block 22A to an external power source. Power cable assembly 20A
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electrically interconnects junction blocks 22A and 22B; power cable assembly
20B
electrically interconnects junction blocks 22B and 22C; and power cable
assembly 20C
is adapted for electrically interconnecting junction blocks 22C and 22D. Thus,
the
single power cable 21 can provide power to all of the junction blocks through
the
S power cable assemblies located in the wall panel configuration 10. Power
cable
assemblies 20D-20G are provided for the electrical connection of additioml
junction
blocks (not shown) which may be part of the four-panel configuration or other
panels.
Additional details regarding the interconnection assembly 19 are
illustrated in the enlarged orthographic view as shown in FIG. 2. A junction
block 22
has a lower wall 26, an upper wall 28 and a middle wall 30 which form a recess
32 on each side of the junction block 22 (only one side of which is
illustrated in
FIG. 2). In addition, the block 22 includes a female connector block pair 34
extending
outwardly from a first end 35 of junction block 22, and a second female
connector
block pair 34A extending outwardly from a second end 35A of junction block 22.
One
female connector block pair 34 can be electrically connected to the other
female
connector block pair 34A of junction block 22 through internal wiring (not
shown) in
the junction block.
A female receptacle connector 88 is located within each half of junction
block 22 within open spatial area 32. Electrical outlet receptacle blocks 100
(FIGS.
2 and 3) are adapted to engage the female receptacle connectors 88. In this
manner,
each of the junction blocks 22 is adapted to support, if desired, two
electrical outlet
receptacle blocks 100, one on each side of the junction block 22.
With further reference to FIG. 2, female connector block pairs 34, 34A
are each provided with a pair of side flanges 90 having upper and lower
recessed areas
91, for engagement with flanges 125 of a pivotal male connector 120 which
forms part
of power cable assembly 20. Flanges 90 are made of a resilient plastic
material and
formed integral to the housing to which they are connected and are provided
with an
outwardly extending inclined end surface 92. When end surfaces 92 of the side
flanges
90 are engaged by flanges 125 of male connector 120, the side flanges 90 will
be
deflected inward, allowing flanges 125 to engage recess areas 91 to provide a
mechanical lacking engagement of the male and female connectors. The female
connector block pairs 34, 34A are each provided with two columns 38, 40 of a
plurality of female connector terminals 94 and a key lug 95. The pivotal male
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connector 120 of cable assembly 20 is provided with a plurality of male
connector
terminal spaces for the reception of male connector terminals, and a key
opening 124 for receiving key lug 95.
For the purpose of releasably securing junction block 22 to the wall
panel raceways 12, 14, 16 and 18, a mounting system includes a pair of L-
shaped
mounting lugs 75, 76 and interlocking latch members 78, 80 integrally mounted
on or
molded to the top of the upper wall 28. The junction block 22 may also be
provided
with connection lugs 84 for securing preformed halves of the junction block 22
together along a seam line 86 as further illustrated in FIG. 2. This mounting
system
is similar to my U.S. Patent No. 4,993,576. It is to be noted that the two
halves of
junction block 22 as defined by seam line 86 are identical and therefore a
description
with respect to one half of the junction block refers also to the other half.
Wining now to FIGS. 2 and 3, an electrical outlet receptacle block 100
for connection to female receptacles 88 of junction block 22 is shown.
Receptacle
block 100 includes a first open end 101 and a second open end 102. First and
second
open ends 101, 102 include a plurality of terminal spaces 103 for the
reception of male
terminals 103A for connection with a plurality of female terminals (not shown)
located
in the female receptacle connectors 88 on the junction block 22. An upper
receptacle
portion 104 includes one or more receptacles 105 for receiving receptacle
plugs (not
shown) of electrically operated equipment. An upper wall 106 and lower wall
107 are
spaced apart in order to provide a snug fit between upper wall 28 and lower
wall 26
of the junction block. Receptacle 100 is provided with a spring latch 108
disposed in
recess 110 in the lower wall 107 of receptacle 100. Lower wall 107 engages the
lower
wall 26 when the receptacle 100 is installed in the junction block. The
locking flange
31 on lower wall 26 will be aligned with recess 110 when the receptacle 100 is
inserted
between the upper and lower walls 28, 26, causing the spring latch 108 to be
depressed. The receptacle 100 may then be moved to either the left or to the
right
(depending on which side of the junction block receptacle 100 is being
installed) to
engage one of the open ends 101, 102 such that male terminals 103A engage
female
terminals (not shown) within receptacle 88. Recesses 112 are provided in
receptacle
100 to accommodate locking flange 31 on lower wall 26. Movement of the
receptacle
to either the left or the right by a sufficient distance will cause the spring
latch 108 to
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be moved past locking flange 31, causing the spring latch 108 to return to its
extended
position. Hence, receptacle 100 will be retained in a locked position. The
receptacle
100 may be removed by depressing spring latch 108 and sliding the receptacle
100 to
either the left or right to align the locking flange 31 with recess 110.
S The female receptacle connector 88 and the columns 38, 40 of female
connector terminals 94 can each be provided with eight separate terminals for
the
reception of eight separate electrical wires (FIGS. 5, 8) from a power cable
assembly
20. By way of example, these may include two ground terminal wires, three
neutral
wires and three positive wires representing three separate circuits, with a
shared ground
for two of the circuits. Similarly, 10-wire or 12-wire systems may be readily
accommodated, having corresponding numbers of terminals on each of the
connectors
and providing a greater number of separate circuits. Some of the separate
circuits may
be dedicated circuits having surge protection, battery back-up, etc. for
computers or
other electrically sensitive equipment.
Referring again to FIG. 1, depending on the type of panel configuration
used, a power cable assembly, for example assembly 20C, is pulled from an
opening
in one raceway to an opening 27 in an adjacent raceway typically by a snake or
by any other well-known means. When assembly 20C includes a typical rigid male
connector, it is extremely difficult to feed the connector portion around the
comer
20 created by the intersection of the two wall panels, since a longitudinal
dimension of the
connector portion is longer than the length of the diagonal defined between
points 29,
29A of the intersecting panels.
According to one feature of the present invention, and referring to FIGS .
1 and 4-6, a power cable assembly 20 includes a conduit 114 attached to the
pivotal
25 male connector 120. The conduit 112 is preferably a flexible conduit which
may be
bent to accommodate a connection to adjacent panels which are disposed at
angular
positions with respect to each other, as well as in a straight line as shown
in FIG. 1.
The pivotal male connector 120 attaches to a junction block 22 or to another
cable
assembly having a mating female connector (not shown). As the pivotal male
connector 120 is fed from one raceway to another in two adjacent wall panels,
and as
the male connector 120 (shown in phantom line) approaches the corner at the
intersection of the two wall panels, a portion of the male connector will
pivot to
accommodate the corner, thus effectively shortening the length of the male
connector.
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Male connector 120 includes a male connector module 140 for housing
male connector terminals connected to electrical wires 142 and for
supporting the flanges 125 as described above. A pair of lugs 144 are located
on each
side of connector module 140 distally from the flanges 125. A first connector
housing
half 146 is identical to a second connector housing half 148. Housing halves
146 and
148 each include an upper flange 150 and a lower flange 152. A plurality of
holes 155
are located in each housing half, such that when the housing halves are
aligned, the
holes are also aligned for securing the housing halves together through
suitable
fasteners, such as rivets, nut and bolt assemblies, etc. Upper flange 150 of
each
housing half includes a semi-cylindrical opening 154 for engaging a pin 160
attached
to a collar 159 at the end of conduit 114, while lower flange 152 of each
housing half
includes a semi-cylindrical opening 156 for engaging a pin 161 attached to the
collar
159. A pair of lug openings 158 are provided in each housing half to
accommodate
the lugs 144 located on each side of the connector module 140. The collar 159
is
attached at an end of conduit 114 and includes the upper and lower pins 160,
161
integrally molded or otherwise attached thereto. Collar 159 includes an
opening (not
shown) which receives wires 142 when connector 120 is assembled. Upper and
lower
flanges 150, 152 define a funnel-shaped opening 153 to direct wires 142 into
the
conduit 114.
In assembly, lugs 144 of module 140 are aligned with openings 158
while pins 160 and 161 of collar 159 are aligned with openings 154 and 156,
respectively, of the two housing halves 146 and 148. The housing halves are
then
secured together with suitable fasteners through holes 155 into the pivotal
assembly as
shown in FIG. 6. Thus, male portion 120 can pivot through any desired angle
with
respect to conduit 114, as shown in FIG. 4 in phantom line, for fitting around
tight
corners in wall panel raceways.
Referring now to FIGS. 7-9, there is shown a second embodiment of a
pivotal male connector 220 of a power cable assembly 20 according to a
preferred
arrangement of the present invention. Like numerals in the previous embodiment
are
used to identify like parts in the present embodiment, and therefore will not
be
described in further detail. The power cable assembly 20 includes a flexible
conduit
114 attached to the pivotal male connector 220. Male connector 220 includes a
male
connector module 240 for housing the male connector terminals 122A (FIG. 2)
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connected to electrical wires 142 and for supporting the flanges 125 as
described
above. An upper cylindrical pin 242 and lower cylindrical pin 244 are
integrally or
otherwise attached to the male connector module 240 distally from the flanges
125.
A first connector housing half 246 is identical to a second connector housing
half 248.
Housing halves 246 and 248 each include an upper flange 250 and a lower flange
252.
A plurality of holes 255 are located in each housing half, such that when the
housing
halves are aligned, the holes are also aligned for securing the housing halves
together
through suitable fasteners, such as rivets, nut and bolt assemblies, etc.
Upper flange
250 of each housing half includes a semi-cylindrical opening 254 for engaging
the
upper pin 242 of module 240, while lower flange 252 of each housing half
includes a
semi-cylindrical opening 256 for engaging the lower pin 244 of module 240. A
channel 258 having opposed channel edges 260, 261 is located in each housing
half
246, 248 distally from the openings 254, 256. The channel 258 is shaped to
accommodate a collar 262. The collar 262 is attached at an end of conduit 114
and
includes two flanges 264, 266 integrally molded or otherwise attached thereto.
Collar
262 includes an opening (not shown) which receives wires 142 when connector
220 is
assembled. Upper and lower flanges 250, 252 define an opening 253 to direct
wires
142 into the conduit 114. A pair of oppositely curved channels 241 are located
adjacent to the pivot pins of module 240 in order to provide clearance for the
outer
edges 25'7 of the housing halves such that module 240 can rotate relative to
the housing
halves.
In assembly, pins 242 and 244 of module 240 are aligned with openings
254 and 256, respectively, of the two housing halves 246, 248. The collar 262
is
aligned with channels 258 of the two housing halves such that flanges 264 and
266 are
located at channel edges 260 and 261, respectively, to restrain the collar
from
movement. The housing halves are then secured together with suitable fasteners
through holes 255 into the pivotal assembly as shown in FIG. 9. Thus, male
connector
module 240 can pivot through any desired angle with respect to conduit 114, as
shown
in FIG. 7 in phantom line, for fitting around tight corners in wall panel
raceways.
Although the above description refers to a specific embodiment having
a specific arrangement of male and female terminals with their mechanical
interconnection, it is to be noted that such an arrangement is illustrative
only. The
male and female terminals and/or the mechanical interconnection may be
reversed on
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the junction blocks, power cable assemblies, receptacle blocks, etc. to
produce similar
results.
It will be understood that the embodiments disclosed herein are only
illustrative of the invention and numerous other arrangements may be devised
by those
skilled in the art without departing from the true spirit and scope of the
invention.
