Note: Descriptions are shown in the official language in which they were submitted.
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QUICK CONNECT ASSEMBLY
TECHNICAL FIELD
The present invention relates to electrical connectors and fixtures, and more
particularly, to an electrical plug and socket combination allowing quick
connection
and mounting of electrical fixtures at electrical outlets.
BACKGROUND ART
Traditional techniques for installing electrical fixtures and appliances such
as
lighting fixtures and fans on walls or ceilings usually require the assistance
of a
qualified electrician, and the use of a variety of tools and specialized
hardware. The
procedure for installing or uninstalling such fixtures can also be relatively
time
consuming, even when performed by an experienced installer. In addition to the
need for hand-wiring the necessary electrical connections between the fixture
and
electrical power supply wiring, the installer must make separate mechanical
connections for supporting or suspending the fixture in place.
One solution to the problem is disclosed in PCT Publication No. WO 0016442
("PCT '442"). PCT '442 discloses a plug and socket combination that permits
quick
connection of an electrical fixture or appliance at an electrical junction box
on a wall
or ceiling. The socket is secured on the wall or ceiling near electrical power
supply
wiring and includes a pair of hollow, female receptacles which receive male
electrical
prongs carried on the plug. The electrical fixture is secured to the plug. In
addition
to the quick electrical connection provided by this plug and socket
combination, a
mechanical connection between the plug and socket carries the mechanical load
of
the electrical fixture.
An improvement to the plug and socket described above is disclosed in PCT
Publication No. WO 03044906 ("PCT '906"). The plug and socket combination
shown in PCT '906 employs arcuately shaped electrical interconnections in-the
form
of ring shaped male plug elements received within correspondingly
shaped'female
receptacle openings. By this arrangement, the plug, along with the electrical
fixture
to which it is attached, can be freely rotated by the installer to a desire
rotational
position.
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A still further improvement in the art is shown in Israeli Patent Application
No.
159032 filed November 24, 2003. In this Israeli application, a revolvable plug
and
socket combination is disclosed which includes means for selectively locking
the
plug and socket against relative rotation. By this feature, a user may lock
the fixture
against further rotation once the installer has indexed it to a desired
orientation.
Accordingly, there exists a need for a universal device that can be used in a
wider range of applications and gain widespread acceptance, while satisfying
local
and national building codes and standards. The present invention is intended
to
satisfy this need in the art.
SUMMARY OF THE INVENTION
According to one aspect of the invention, a device is provided for quickly
connecting an electrical fixture with electrical power supply wiring, and for
mounting
the fixture on a support. The device includes a socket including-a socket
body.
having at least one internal cavity therein; an electrically conductive
contact terminal
disposed within the cavity for establishing an electrical connection between
the
electrical power supply wiring and the socket,.the contact terminal having a
portion
thereof captured between internal surfaces of the socket body to hold the
contact
terminal in a fixed position without the need for fasteners; a plug rigidly
fixed to the
fixture and insertable into the socket, the plug having at least one male
connector
electrically connected to the fixture and engageable with the contact terminal
within
the socket to establish a circuit between the electrical fixture and the
electrical power
wiring; and, a releasable latch carried on the combination of the plug and the
socket
for releasably mounting the fixture on the support. The elimination of
fasteners to
hold the contact terminal in place not only reduces the cost of the device but
also
speeds manufacturing and assembly of the device.
According to another aspect of the device, compression springs are mounted
within the socket cavities to supplement the spring force of the contact
terminals,
thus assuring reliable connection between the contact terminals and male
connectors within the plug.
According to still another aspect of the invention, wire access holes are
provided in both the top and the sides of the socket, thus giving the
installer a choice
of either top feed or side feed of the electrical supply wires into the
socket. The
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contact terminals are configured to provide a similar choice of top or side
feed,
allowing the device to be installed in a wide range of applications.
According to a further aspect of the invention, a cover may be installed in
the
socket, overlying the wall or ceiling area around the device to provide a more
pleasing aesthetic appearance when a fixture has not yet been installed.
In those installations where it is not possible to gain direct access to the
centrally located latch, a lateral actuator assembly is provided for
controlling the
latch.
Accordingly, it is a primary object of the present invention to provide a
device
that facilitates quick electrical and mechanical connections between an
electrical
fixture and an electrical outlet on a wall, ceiling or floor.
Another object of the invention is to provide a device of the type mentioned
above that can be used by unskilled or inexperienced users to quickly and
easily
install electrical fixtures.
A further object of the invention is to provide a device as described above
which permits the electrical fixture to be rotated into a desired position
during or after
'installation, and then locked in place.
Another object of the invention is to provide a device of the type mentioned
which is suitable for universal use in a complete range of applications and
environments, and which meets existing building codes and national electrical
standards.
A still further object of the invention is to provide a device of the type
referred
to above which allows a user to install or remove an electrical fixture from
an
electrical supply box without the need of special tools or the assistance of a
trained
electrician and to do so easily and quickly.
Another object of the invention is to provide a device as described which is
capable of connecting a wide variety of'electrical appliance and fixture
configurations
to various types of wall, ceiling or floor outlets, electrical junction boxes
or even flat
wall surfaces that are not provided with electrical outlets.
A still further object of the invention is to provide a device as described
above
which possesses a minimum number of parts, avoids the use of fasteners where
possible and can be manufactured in high volume using automated production
techniques.
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These, and further features and advantages of the present invention will be
made clear or will become apparent during the course of a description of a
preferred
embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings, which form an integral part of the specification and are to
be
read in conjunction therewith, and in which like reference numerals employed
to
designate identical components in the various views:
Fig. 1 is a perspective view of a quick connect device for electrical fixtures
which forms an exemplary embodiment of the present invention, the plug being
shown separated from a socket;
Fig. 2 is an exploded, perspective view of the device shown in Fig. 1;
Fig. 3 is a medial cross sectional view of the device shown in Fig. 1 taken
along line 3-3 of Fig. 12, also depicting the plug separated from the socket;
Fig. 4 is a view similar to Fig. 3 but showing the plug installed within the
socket;
Fig. 5 is a perspective view of a modified form of the device, provided with
an
extension rod useful in installing certain types of electrical fixtures;
Fig. 6 is an exploded, perspective view of the socket, depicting the relative
positions of the electrical contact terminals;
Fig. 7 is a perspective view of a modified form of the socket suitable for
installation on a flat ceiling or wall;
Fig. 8 is a perspective view of a blank cover suitable for covering the socket
when not in use;
Fig. 9 is a fragmentary, medial cross-sectional view showing the cover
depicted in Fig. 8 having been installed over a socket mounted in a ceiling-
mounted
electrical box;
Fig. 10 is a fragmentary, partially medial sectioned view showing a modified
form of the device useful for mounting certain types of electrical fixtures
such as
electric fans or chandeliers, and depicting a latching mechanism in its locked
position;
Fig. 11 is a view similar to Fig. 10 but showing the latching mechanism moved
to its released position;
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Fig. 12 is a plan view of the top of the socket, the socket cover having been
removed to reveal details of the contact terminals;
Fig. 13 is a perspective view of the socket of the quick connect device which
forms another exemplary embodiment of the present invention, the socket is
shown
having a plurality of radial projections or ears extending from an outer wall;
Fig. 14 is a cross sectional view of the socket shown in Fig. 13, the socket
includes a central bushing having a plurality of circumferentially extending
shoulders;
Fig. 15 is a perspective view of a spindle assembly of the plug, the spindle
assembly is shown having multiple sets of retaining balls;
Fig. 16 is a cross sectional view of the spindle assembly of Fig. 15;
Figs. 17 and 18 are perspective views of the plug showing the multiple sets of
retaining balls and a plurality of tangential wire channels;
Fig. 19 is a perspective view of a combination including a plug, a latching
mechanism, and a canopy;
Fig. 20 is an enlarged perspective view of the latching mechanism of Fig. 19;1
Fig. 21 is a perspective view of a pivot rod of the latching mechanism of Fig.
20;
Fig. 22 is a perspective view of a leaf spring of the latching mechanism;
Fig. 23 is a perspective view of a handle of the latching mechanism;
Fig. 24 is a perspective view of an adapter of the latching mechanism;
Fig. 25 is a perspective view of a clamp of the latching mechanism;
Figs. 26A-26E are perspective views of exemplary canopies of the present
invention; I
Fig. 27 is a perspective view of yet another embodiment of the latching
mechanism shown with a plug and canopy;
Figs. 28 and 29 are perspective views of the latching mechanism of Fig. 27;
Fig. 30 is a perspective view of the present invention shown with a remote
control unit;
Fig. 31 is an exploded, perspective view of another exemplary embodiment of
a quick connect device for electrical fixtures and the like, the fixture and
outlet box
not shown for purposes of clarity;
Fig. 32 is an exploded, cross sectional view of the device shown in Fig. 31;
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Fig. 33 is a cross sectional view similar to Fig. 32, but showing the plug
portion of the device having been inserted and locked in the socket of the
device;
Fig. 34 is a perspective view of an electrical junction box with a mounting
strap secured thereto;
Fig. 35 is a perspective view of the plug having. a fixture secured thereto,
parts of the fixture being broken away;
Fig. 36 is a perspective view similar to Fig. 35, but showing the plug and
fixture having been installed on the junction box shown in Fig. 34;
Fig. 37 is a perspective of the bottom of the fixture, showing a finger grip
and
push button of the device;
Fig. 38 is a perspective view of the top of the fixture shown in Fig. 37,
depicting the upper end of the plug of the device;
Fig. 39 is an exploded, perspective view of the plug in relationship to a
button
used to operate the plunger;
Fig. 40 is a perspective view of an optional extension rod that may be
installed to operate the plunger;
Fig. 41 is a perspective view of another exemplary embodiment of the quick
connect device of the present invention;
Fig. 42 is an exploded, perspective view of a plug of the device in Fig. 41;
Fig. 43 is an exploded, perspective view of a socket of the device in Fig. 41;
Figs. 44, 44A, and 45 are perspective views of electrical terminal blocks of
the
socket;
Figs. 46 and 47 are perspective views of a socket skirt;
Fig. 48 is a perspective view of a socket cover; and
Fig. 49 is a perspective view of another exemplary latching mechanism.
DETAILED DESCRIPTION OF THE INVENTION
Referring first to Figs. 1-4, a quick connect device 20 for installing
electrical
fixtures comprises the combination of a plug 22 and mating socket 24. The
device
20 functions to both establish an electrical connection between an electrical
fixture
and electrical supply wiring, and mechanically support the fixture on a
surface or
base, typically a wall, ceiling or floor surface. As used herein, the term
"fixture" or
"electrical fixture" means any fixture or appliance such as a lighting
fixture, ceiling
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fan, television camera, security device or any other device which is powered
by
electricity supplied by electrical wiring, and which requires a mechanical
connection
to support or s~uspend the fixture. Plug 22 is fixedly secured to an
electrical fixture
(not shown), while the socket 24 is secured to either the surface (e.g., wall,
ceiling or
floor) on which the fixture is to be mounted, or to an electrical junction
box.
The socket 24 comprises a cylindrically shaped, essentially hollow body 25
having a flat circular cover 66, both formed of non-conductive material such
as
phenolic resin. Four concentric, ring shaped, female recesses or slots 26a,
26b,
26c, 26d are formed in one face of the socket 24, and are configured to
matingly
receive four, later discussed male connector rings on the plug 22 to establish
ele'ctrical connections between the plug 22 and the socket 24. The socket 24
includes a center through hole within which there is fixedly secured a metal
bushing
28. The bushing 28 is provided with two concentric bores 30, 32 of differing
diameters to define a circumferentially extending shoulder 34. In the
illustrated
embodiment, bushing 28 passes through and is fixedly secured to an elongate
mounting strap 36 as by welding. It should be noted here however, that the
bushing
28 and the strap 36 could be of unitary construction, formed of a single piece
of high
strength material, such as metal as by casting, machining or other metal
working
processes.
As best seen in Figs. 1 and 2, mounting strap 36 is generally U-shaped and is
provided with an aperture 92 on each of its outer extremities or flanges 38
which
receives a screw 40 to mount the strap 36, and thus the entire device 20, on a
suitable mounting surface. In the illustrated embodiment, the spacing between
the
apertures 92 is selected so that the strap 36 can be affixed to a common
electrical
junction box (not shown) formed of metal or plastic and having threaded holes
or
nuts into which the screws 40 may be driven. The U-shaped configuration of the
strap 36 allows the socket 24 to be recessed within the junction box, as
illustrated in
Fig. 10. However, in those applications where it is necessary to mount the
socket 24
directly on a wall or ceiling without use of a junction box, a flat strap 36a
may be
employed, as shown in Fig. 7. In the illustrated example, the socket 24 is
secured to
the strap 36 by means of screws passing through openings 76 of the strap 36,
into
the cover 66. However, other techniques may be used to secure the socket body
25 to the combination of the strap 36 and bushing 28. For example, the top of
the
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cover 66 could be provided with nipples that extend through the strap openings
76
and are deformed, as by melting to rigidly fix the strap 36 to the top of the
cover 66.
Alternatively, the bushing 28 could be provided with laterally extending
surface
features that are integrally molded into the body 25 of the socket 24.
The cover 66 is received within a ring shaped recess in one face of the socket
24 and may be affixed to the body 25 of the socket 24 by any suitable means
such
as, for example, ultrasonic welding or snap fit. The cover 66 is provided with
four
upstanding bosses 68 circumferentially spaced around its periphery. Each of
the
bosses 68 includes a tapered access opening 70 communicating with the hollow
interior of the socket 24. A second set of four access openings 72 are
provided in
the outer wall of the socket body 25.
As best seen in Figures 3 and 4, the female slots or recesses 26a - 26d
extend axially into the socket body 25 and each communicates with a contact
opening 64 at a location around the circumference of the slot or recess. In
the
illustrated embodiment, slots or recesses 26a - 26c are of essentially equal
depth,
while recess 26d is of a greater depth for purposes which will become later
apparent. The socket body 25 is provided with circumferential notch 42
defining an
annular face 55 that is intended to engage a later discussed, corresponding
face 55'
on the plug body 27 and acts as a stop to limit the entry of the plug 22 into
the
socket 24. Annular faces 55 and 55' are provided with a plurality of
circumferentially
spaced, radial extending indexing teeth 88, preferably integrally molded into
the
socket and plug bodies 25 and 27 that interengage or mesh when the bodies 25
and
27 are mated to prevent the bodies 25 and 27 from rotating relative to each
other.
Prior to the teeth 88 of the bodies 25 and 27 engaging, the bodies 25 and 27
free to
rotate relative to each other.
Referring now to Figs. 6 and 12, the socket body 25 includes four
circumferentially spaced cavities 44a - 44d therein, as illustrated in Figure
6, within
which there are respectively disposed four electrical contact terminals 48a -
48d.
Contact terminals 48a - 48d are preferably formed from electrically
conductive,
spring beryllium copper or steel using precision stamping techniques to
produce the
individual features of the terminal. Each of the terminals 48a - 48d includes
a flat
intermediate section 58 which rests on a ledge 59 formed within the associated
cavity 44a - 44d. An upper extremity 50 of the terminals 48a - 48d includes a
split
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bent leg or pair of bent legs side by side and include centering lugs on each
side
which respectively contact an inner wall of the body of the plug 24 and the
bottom
face of the cover 66. By this series of contact points between the terminals
48a -
48d and the inside surfaces of the socket 25 and cover 66, the terminals 48a -
48d
are tightly captured within the cavities 44a - 44d, respectively aligned with
an
associated slot or recess 26a - 26d, and are electrically insulated from each
other.
In Fig. 12, two spaced centering lugs 76 are provided on each side, for better
insertion of a wire into the extremity 50.
The lower extremity of each of the contact terminals 48a - 48d includes a
spring leg 54 which extends downwardly into a corresponding one of the contact
openings 64. Each of the spring legs 54 is flexible about its upper end which
is
connected by a bend to the intermediate section 58. The lower end of each of
the
spring legs 54 is provided with an electrical contact member 56 which overlies
and is
in radial registration with a corresponding one of the recesses 26a - 26d, as
best
seen in Figs. 3 and 4. Contacts 56 each include a cylindrical boss on their
upper
end which is received within and functions to retain a compression spring 60
whose
upper end is held in place against the cover 66 by a retainer 62 affixed to
the bottom
side of the cover 66. Compression springs 60 supplement the spring force
provided
by spring legs 54 to urge the electrical contacts 56 downwardly into the
contact
openings 64, adjacent the corresponding recesses 26a- 26d.
Each of the contact terminals 48a - 48d is provided with a split or narrow gap
or slot 52 which extends through the length of angularly offset top and sides
of the
upper extremity of each terminal 48a - 48d. The width of each of the slots 52
is
selected so as to be substantially less (close to zero) than the diameter of
the
electrical connecting wire which delivers power to the socket 24. Thus, the
exact
width of the slots 52 will depend on the gauge of the electrical wiring in a
given
application. The bare, stripped end of the electrical supply wire is connected
to the
socket 24 by inserting the wire end into one of the tapered access openings 70
and
forcing the end of the wire through or into the slot 52 wherein the bifurcated
parts of
the terminal provide a spring pressure against the inserted wire and thereby
tightly
grip the wire. Because the slot 52 extends completely to the end of the upper
extremity of the terminal 48a - 48d, the sides of the upper portion of the
terminal
yields to the entering supply wire, causing slot 52 to expand which both
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accommodates the passage of the supply wire and captures it under spring
pressure, thereby making a reliable electrical connection.
In some applications, it may not be convenient or possible to feed the
electrical supply wires through the top face of the socket body 25. In this
case, the
electrical supply wires may be positioned through access openings 72 in the
side
wall of the socket body 25, where again they are forced through the
corresponding
slot 52 in order to establish electrical connection to the socket 24.
1 Referring now to Figs. 1-4, the plug 22 includes a body 27 formed out of non-
conductive material, which can be identical to the material used to form the
socket
body 25, and includes a cylindrical cavity 86 in one face thereof. Four
concentric,
male connector rings 78a - 78d are integrally molded into the plug body 27,
with
sufficient radial spacing therebetween to electrically insulate them from each
other.
The diameters and spacing of the male connector rings 78a - 78d are such that
they
are alignable with and receivable within the corresponding female recesses 26a
-
26d in the socket 24. Each of the connector rings 78a - 78d includes an
integrally
formed lateral extension 80 which ends in a terminal block 84. The terminal
blocks
84 are circumferentially spaced from each other so as to lie along a circle,
near the
outer periphery of the plug body 27. The plug body 27 is provided with four,
spaced-
apart, lateral wire openings 95 therein which are circumferentially aligned
with the
connector blocks 84. Four additional, circular openings 83 are provided in the
top
face 55' of the plug body 27 which are circumferentially aligned with and
provide
access to the terminal blocks 84. Set screws 82 pass through openings 83 and
are
received within threaded holes in the top of the terminal blocks 84.
Electrical wiring
from the electrical fixture which is attached to the plug 22 is positioned
through the
lateral wire openings 95 so that the stripped ends of the wire pass into the
lateral
openings in the terminal blocks 84. Set screws 82 provide a means of tightly
securing the electrical wire ends on the terminal blocks 84, thereby
connecting the
fixture with the male connector rings 78a - 78d.
The plug 22 as well as the fixture attached thereto, is mechanically connected
to the socket 24 and to the mounting strap 36 by means of a centrally located,
releasable spindle assembly 100 which will now be described in detail. The
spindle
assembly 100 includes a barrel 94 having a series of coaxial bores therein,
and a
plunger or pin 11.4 axially slidable within the barrel 94. The barrel 94
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plurality of retaining balls 104 captured within radial openings 107 in the
barrel 94.
The upper end 106 of pin 114 is provided with a reduced diameter section
forming a
recess or ball detent 122 into which the retaining balls 104 may be inwardly
displaced. The lower end of the barrel 94 includes two axially aligned bores
having
successively greater diameters, so as to define a pair of annular shoulders
110, 124.
A compression spring 112 is sleeved over the pin 114 and is captured between
shoulder 110 and the bottom portion of the pin 114, thereby normally biasing
the pin
114 to move downwardly (outwardly) into a latched or locking position, wherein
the
pin 114 forces retaining balls 104 outwardly until they'rest against the
shoulder 34
within bushing 28. Downward travel of the pin 114 is limited by an annular
retainer
120 received within the end of the barrel 94. Pin 114 includes an annular
flange or
lateral extension 118 which slides within barrel opening 108 until it contacts
the
retainer 120.
In an exemplary embodiment, the spindle assembly 100 is attached to the
plug body 27 by means of annularly shaped, lateral extensions or flanges 105
on the
barrel 94 which are integrally molded into the plug body 27. A push button
116,
which extends from the lower end of the barrel 94, provides a means of
actuating
the spindle assembly 100 using either a finger or a tool. A guard cover 126 is
secured to the lower end of the barrel 94 and includes a splayed lower portion
surrounding the end of the push button 116. As seen in Fig. 2, the lower end
of the
barrel 94 is threaded 96 so as to receive internal threads on the guard cover
126.
The guard cover 126 not only protectively covers the sides of the push button
116 in
order to prevent inadvertent actuation of the latter, but acts as a guide to
lead a
user's finger or tool onto the end of the push button 116. Further, the cover
126
provides a means of gripping and holding the plug 22 during the installation
process;
the user places the index and middle fingers on the splayed lower portion of
the
cover 126 while the thumb actuates the push button. Guard cover 126 can also
be
used to mount a fixture to the plug 22.
The electrical fixture may be secured to the plug 22 in any of a variety of
ways. For example, the fixture may be fixedly attached by or to the guard
cover 126,
or directly to the lower threaded section of the barrel 94. Alternatively, the
fixture
may be secured to a piece of mounting hardware, such as a "hickey" threaded
onto
the lower end of the barrel 94. In any event, it may be appreciated that the
weight of
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the fixture is transmitted through the barrel 94, retaining balls 104, and
bushing 28 to
the mounting strap 36, which in turn is secured to the junction box, wall or
other
structure on which the fixture is to mounted.
Referring now to Fig. 5, in some installations it may be necessary to
effectively extend the length of the spindle assembly 100 where, for example,
a
motor or other parts of the electrical fixture are covered by a downwardly
extending
shroud or canopy (not shown). In this event, additional hardware such as a
threaded hickey 154 is screwed onto the lower threaded portion 96 of the
barrel 94.
A threaded guide barrel 156 is in turn screwed into the lower end of the
hickey 154.
Either a long push rod 152 is utilized which is attached at its upper end to
the pin
114, or the current push rod 116 is provided with a tapped hole and push rod
152 is
provided with a threaded extension for threading into the tapped hole. The
push rod
152 is guided by the guide barrel 156, with its lower end 152 extending beyond
the
lower end of the barrel 156. The configuration shown in Fig. 5 is also
advantageous
in that the electrical fixture may be mechanically mounted on the hickey 154
by
suitable fasteners or by welding, or on the threaded guide barrel 156.
In some installations, a recessed electrical junction box may not be available
to provide the means of mechanically mounting the device 20 on a surface. In
this
case, as shown in Fig. 7, the socket 24 may be secured to a flat mounting
surface,
such as a wall or ceiling, by means of a screw or lag bolt 160 which is
secured to a
modified, flat mounting strap 36a. Mounting strap 36a is in turn attached to
the
cover 66 by means of screws 158. In this embodiment, wires (not shown)
supplying
electricity are positioned through the access openings 72 in the side of the
socket
body 25. As shown in Fig. 7, the strap 36a does not extend beyond the outer
ppriphery of the socket 24, thereby concealing the strap 36a and providing a
more
pleasing appearance.
Figs. 8 and 9 depict a blank cover 136 which may be used to cover the socket
24 where a fixture has not yet been mounted on an electrical outlet. As shown
in
Fig. 9, an electrical junction box 130 is recessed within a ceiling or wall
134 and is
connected with conduits 132 which enclose electrical wires 128 providing
electricity
to the socket 24. Socket 24 is secured to a metal mounting strap 36, as
previously
described which in turn is secured to junction box 130 by means of screws with
or
without nuts 40. The blank cover 136 includes an upstanding, peripheral edge
162,
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and a centrally located, raised mounting ring 164. The mounting ring 164 is
received
in tight frictional engagement over the lower cylindrical portion 45 of the
socket 24.
This frictional engagement is sufficient to hold the cover 136 in place, with
the outer
edge 162 in engagement with the wall or ceiling 134.
In some installations where the electrical fixture includes a structure such
as a
motor, it may not be possible to gain direct access to the centrally located
spindle
assembly 100 and push rod 116, even if the length of the latter is extended.
In such
installations, a modified form of the device 20 may be used, as shown in Figs.
10
and 11. A support member 138 includes a central threaded aperture for
receiving
the lower threaded end 96 of barrel 94, thus securely mounting support member
138
on the junction box 130 through the mounting flange 36. Support member 138
extends laterally on each side of the central axis of the spindle assembly
'100 and
has it outer ends engaging the sidewall of a canopy 148 which may be directly
attached to the support member 138.
Canopy 148, which is employed primarily for aesthetic purposes, encloses the
exposed box 130 as well as wiring and structure such as a motor (not shown) or
other equipment forming part of the electrical fixture. A pair of mounting
spacers
140 secured to the support member 138 extend downwardly from the latter and
have
secured thereto one end of a flexible lever 142 formed, for example, of spring
steel,
synthetic material or other spring-like material, and constitutes a flat leaf
spring
which returns to its original shape after deflection. Medial portions of the
lever 142
are secured to the push rod 116 by a retainer 150, which can simply be the top
portion of rod 116. The opposite end of the lever 142 has an extension rod 144
secured thereto which includes a downwardly extending' reduced diameter
section
146 passing through an opening in the canopy 148 and having a knob 146a on its
free lower end.
With rod 144 in its normal, down position shown in Fig. 10, the spindle
assembly 100 is locked, securing the plug 22 in the socket 24 and forming a
mechanical connection that supports the weight of the fixture on the mounting
strap
36. Although not specifically shown in the drawings, a mechanical structure
such as
a fan motor is mounted inside a canopy 148, directly beneath the push rod 116,
and
extends downwardly through an opening 155 in the canopy 148.
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In order to release the plug 22 from the socket 24 and disengage the
mechanical connection supporting the fixture, the user moves rod 144 upwardly,
causing lever 142 to deflect, which in turn displaces the push rod 116
upwardly.
This upward movement of the push rod 116 also displaces the pin 114 upwardly,
allowing the retaining balls 104 to move into the depressions 122, thus
releasing the
spindle assembly 100 and allowing the barrel 94 to be removed from the bushing
28.
Having described details of the preferred embodiment of the device 20, and
various modifications thereto, the use and operation of the device 20 will now
be
explained. The socket 24 is first installed either on an electrical junction
box 130 or
directly on a wall or ceiling surface. The installer then connects electrical
supply
wires 128 to the socket 24 by passing the bare ends of the wires 128 into
either wire
openings 70 or 72, depending how the socket 24 is mounted. The wire ends are
then forced into the slots 52 in the contact terminals 48a - 48d which
securely retain
the wires within the socket 24 and establish an electrical connection between
the
electrical supply wires 128 and the electrical contact members 56.
The electrical fixture to be installed is first mounted on the plug 22. As
previously discussed, the exact mounting method will vary, depending on the
type,
size and configuration of the fixture. Wiring from the fixture is routed
through the
lateral wire openings 95 in the side of the. plug body 27, and fed into the
lateral
openings in the terminal blocks 84. The set screws 82 are then screwed down
onto
the wire ends to secure the latter in place.
Having secured the fixture to the plug 22, the installer first depresses the
push rod 116, to displace the pin 114 until the depressions 122 align with the
balls
104. The balls 104 move into the depressions 122, allowing the upper
cylindrical
section 106 of the barrel 94 to pass into the bore 30. As the insertion
process
continues, the male connector rings 78a - 78d enter and move through the
respectively associated female socket recesses 26a - 26d until they engage the
respectively associated contact members 56, thereby establishing electrical
connection between the fixture and the contact terminals 48a - 48d. The
springs 60
hold contacts 56 firmly against the rings 78a - 78d to assure a continuous,
reliable
electrical connection. At this point, the installer releases the push rod 116,
whereupon spring 110 axially displaces the pin 114 to its normal locking
position,
forcing the balls 104 outwardly until they engage the shoulder 34 to hold the
pin 114
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in its locked position. The two sets of indexing teeth 88, 90 respectively
carried on
the socket body 25 and the plug body 27 respectively, mesh and matingly engage
each other to lock the plug 22 and socket 24 against relative rotation,
causing the
fixture to be held in a desired orientation selected by the installer.
If it is desired to rotate the fixture to a different position, the installer
need only
depress the push rod 116 and withdraw the plug 22 from the socket 24 a slight
distance sufficient to disengage the teeth 88, 90 from each other, at which
point the
fixture may be rotated to a different position. With the fixture repositioned,
the plug
22 is inserted back into its fully seated position against the socket 24 and
the push
rod 116 is released to lock the fixture in place. The full circle
configuration of the
connector rings 78 and the recesses 26 allows the fixture to be fixed in
virtually any
rotational position. However, it should be noted here that the connector rings
78 in
the plug 22 and the mating recesses 26 in the socket 24, could be configured
to
extend less than a full 360 degrees, for example 180 degrees, in which case
the
fixture will only be rotatable to positions with the range permitted by the
circumferential extent of the connector rings and corresponding recesses.
With the fixture installed as described above using the device 20, the
supplied
electrical power flows from the su'pply wiring to the contact terminals 48a -
48d, and
thence through the contacts 56 to the connector rings 78a - 78d. From the
connector rings 78a - 78d, electrical power flows to the terminal blocks 84,
and then
to the fixture. In an exemplary embodiment, four connections are shown: a
ground,
a neutral and two lines, however, it is to be understood that fewer or a
greater
number of connections can be made (such as three or five), depending on the
requirements of a given application. Advantageously, in the illustrated
embodiment,
connector ring 78d carries the ground connection. Because connector ring 78d
possess a greater depth or height than the other connector rings, the ground
connection is made before the other connections are established, thus assuring
that
any unintended short circuit electrical current present in the device 20 is
safely
carried to ground before the other "hot" connections are made.
In another exemplary embodiment shown in Figs. 13 and 14, a quick connect
device for installing electrical fixtures includes the combination of a plug
22 and
mating socket 24. (Plug 22 is shown in Figs. 17 and 18). The device functions
to
both establish an electrical connection between an electrical fixture and
electrical
CA 02592956 2007-07-03
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supply wiring, and mechanically support the fixture on a surface or base,
typically a
wall, ceiling or floor surface. As used herein, the term "fixture" or
"electrical fixture"
means any fixture or appliance such as a lighting fixture, ceiling fan,
television
camera, security device or any other device which is powered by electricity
supplied
by electrical wiring, and which requires a mechanical connection to support or
suspend the fixture. The plug 22 is fixedly~secured to an electrical fixture
(not
shown), while the socket 24 is secured to either the surface (e.g., wall,
ceiling or
floor) on which the fixture is to be mounted, or to an electrical junction
box.
The socket 24 comprises a cylindrically shaped, essentially hollow body 25
having a flat circular cover, both formed of non-conductive material such as
phenolic
resin. Four concentric, ring shaped, female recesses or slots 26a, 26b, 26c,
26d are
formed in one face of the socket 24, and are configured to matingly receive
four,
later discussed, male connector rings on the plug 22 to establish electrical
connections between the plug 22 and the socket 24. The socket 24 includes a
center through hole within which there is fixedly secured a metal bushing 28.
The
bushing 28 is provided with two or more concentric bores of differing
diameters to
define one or more circumferentially extending shoulders 34. The
circumferentially
extending shoulders 34 within the bushing 28 engage one or more retaining
balls of
a spindle assembly 100 of the plug 22. (The retaining balls and spindle
assembly
are described in more detail later.) For a spindle assembly having one set of
radially
projecting retaining balls, the bushing 28 may include one circumferentially
extending shoulder 34 for engaging the retaining balls and connecting the plug
22 to
the socket 24. Alternatively, the bushing 28 may include two or more shoulders
34
when used with a spindle assembly having one set of retaining balls. In this
embodiment, one circumferentially extending shoulder may engage the retaining
balls to hold the plug 22 in a temporary hanging position to facilitate other
assembly
or maintenance steps before the plug 22 is fully seated in a locked
configuration.
It is further contemplated that the bushing 28 may include two or more
circumferentially extending shoulders 34 dimensioned and configured to engage
two
or more sets of radially projecting retaining balls. (Again, the retaining
balls are
described later.) Increasing the number of shoulders 34 that engage the
retaining
balls increases the holding power of the plug 22 to the socket 24. For
example, a
bushing 28 having two circumferentially extending shoulders 34 engaged with
two
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sets of retaining balls may at least double the strength of the plug/socket
connection
as compared to a single shoulder, single set of balls design. Additionally,
the double
shoulder, double set of balls configuration allows the plug 22 to be
temporarily hung
from the socket 24 to facilitate other assembly steps or maintenance. This is
accomplished by engaging one set of retaining balls of the plug 22, preferably
the
leading set of balls, with a circumferentially extending shoulder 34 of the
bushing 28,
preferably the first encountered shoulder. Thereafter, the plug 22 may be
further
mated with the socket 24 to engage both sets of retaining balls with both
shoulders
34.
The socket 24 of the quick connect device further includes one or more
bosses 68 circumferentially spaced around the periphery of the cover. Each of
the
bosses 68 includes a tapered access opening 70 communicating with the hollow
interior of the socket 24. A second set of four access openings 72 are
provided in
the outer wall of the socket body 25. As shown in Figs. 13 and 14, radial
projections
or ears 73 extend from the outer wall of the socket body 25 thereby extending
the
length or depth of the access openings 72. The radial projections or ears 73
may
have any cross-sectional shape including a rectangle, circle, triangle,
square, etc.
Preferably, the ears 73 are cube shaped with an access opening extending
therethrough. The radial projections or ears 73 provide additional enclosure
of the
electrical wires positioned therein. Without an ear on the outer wall of the
socket
body 25, a stripped end portion of an electrical wire inserted into an access
opening
72 may be exposed and create an unsafe condition. Therefore, the radial
projection
73 enhances the safety of the socket 24 by covering any exposed, stripped
electrical
wire.
Referring now to Figs. 15-18, the plug 22 includes a body 27 formed out of
non-conductive material, which can be identical to the material used to form
the
socket body 25, and includes a cylindrical cavity 86 in one face thereof. Four
concentric, male connector rings 78a - 78d are integrally molded into the plug
body
27, with sufficient radial spacing therebetween to electrically insulate them
from each
other. The diameters and spacing of the male connector rings 78a - 78d are
such
that they are alignable with and receivable within the corresponding female
recesses
26a - 26d in the socket 24. Each of the connector rings 78a - 78d includes an
integrally formed lateral extension which ends in a terminal block 84. The
terminal
17
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blocks 84 are circumferentially spaced from each other so as to lie along a
circle,
near the outer periphery of the plug body 27.
The plug body 27 is provided with four, spaced-apart, lateral wire openings 95
therein which are circumferentially aligned with the connector blocks 84. The
lateral
wire openings 95 form wire channels. A wire channel may extend from a lateral
wire
opening 95 to a connector block 84 thereby making the wire channel radially
extending. Alternatively, the wire channels may be tangentially extending. In
this
configuration, the wire channels extend generally perpendicular to a radius of
the
plug body 27 or generally tangent to a circle passing through the connector
blocks
84 and having its center at the center of the plug 22. Tangentially extending
wire
channels provide for enhanced safety of the plug 22. Since a tangentially
extending
wire channel may be generally greater in length or depth than a radially
extending
wire channel, the stripped end portion of an electrical wire may be more fully
enclosed or covered thereby reducing the risk of electrocution, shorting, or
fire from
the exposed wire. Furthermore, radially extending wire channels may require
the
electrical wires therein to extend from the plug 22 radially outward. This
configuration may require more space surrounding the plug to accommodate the
wires. The tangentially extending wire channels permit the electrical wires
protruding therefrom to reside closer to the outer wall of the plug 22 thereby
requiring less space to accommodate the wires around the plug 22.
Four additional, circular openings 83 are provided in the top face of the plug
body 27 which are circumferentially aligned with and provide access to the
terminal
blocks 84. Set screws 82 pass through openings 83 and are received within
threaded holes in the top of the terminal blocks 84. Electrical wiring from
the
electrical fixture which is attached to the plug 22 is trained through the
lateral wire
openings 95 so that the stripped ends of the wire pass into the lateral
openings in
the terminal blocks 84. Set screws 82 provide a means of tightly securing the
electrical wire ends on the terminal blocks 84, thereby connecting the fixture
with the
male connector rings 78a - 78d.
It is further contemplated that the radial projections or ears 73 previously
described in relation to the socket 24 may be applied to the plug 22. The wire
channels of the plug 22 extending between the lateral wire openings 95 and the
connecter blocks 84 may be extended with ears 73. For radially extending wire
18
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channels, the ears 73 may be radial projections. For tangentially extending
wire
channels, the ears 73 may be tangential projections. In either configuration,
the
projections or ears provide additional enclosure of the stripped wire ends.
The plug 22, as well as the fixture attached thereto, is mechanically
connected to the bushing 28 of the socket 24 by means of a centrally located,
releasable spindle assembly 100 which was previously mentioned but will now be
described in more detail. The spindle assembly 100 includes a barrel 94 having
a
series of coaxial bores therein, and a pin 114 axially slidable within the
barrel 94.
The barrel 94 includes a plurality of retaining balls 104 captured within
radial
openings 107 in the barrel 94. One or more balls may form a set of retaining
balls
104 positioned within radial openings 107 of the barrel 94. Furthermore, one
or
more sets of balls 104 may be spaced apart along the barrel 94. Each set of
retaining balls 104 are captured within radial openings 107 in the barrel 94.
Therefore, a spindle assembly having two sets of retaining balls 104 may
include
two sets of radial openings. It is contemplated that two, three, four, or more
sets of
retaining balls 104 and corresponding sets of radial openings may be included
in the
spindle assembly 100.
As previously described, the retaining balls 104 of the spindle assembly 100
allow for the plug 22 to be mated within the bushing 28 of the socket 24. The
bushing 28 includes one or more circumferentially extending shoulders 34 which
engage the one or more sets of retaining balls 104 of the spindle assembly
100.
Having two or more sets of shoulders 34 and retaining balls 104 increases the
holding strength of the quick connect device.
In further describing the spindle assembly 100, the end portion 106 of pin 114
is provided with one or more reduced diameter sections forming recesses or
ball
detents 122 into which the retaining balls 104 may be inwardly displaced. The
lower
end of the barrel 94 includes two axially aligned bores having successively
greater
diameters, so as to define a pair of annular shoulders 110, 124. A compression
spring 112 is sleeved over the pin 114 and is captured between shoulder 110
and
the bottom portion of the pin 114, thereby normally biasing the pin 114 to
move
downwardly (outwardly) into a latched or locking position, wherein the pin 114
forces
retaining balls 104 outwardly until they rest against the shoulders 34 within
bushing
28 of the socket 24. Downward travel of the pin 114 is limited by an annular
retainer
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WO 2006/060772 PCT/US2005/043934
120 received within the end of the barrel 94. Pin 114 includes an annular
flange or
lateral extension which slides within barrel opening 108 until it contacts the
retainer
120. The spindle assembly 100 is attached to the plug body 27 by way of
extensions or flanges on the barrel. The flanges may be integrally molded into
the
plug body 27. A push rod 116, which is secured to and extends from the end of
the
barrel 94, provides a means of moving the pin 114 to thereby actuate the
spindle
assembly 100.
In some installations where the electrical fixture includes a structure such
as a
motor, it may not be possible to gain direct access to the centrally located
spindle
assembly 100 and push rod 116, even if the length of the latter is extended.
In such
installations, a modified form of the device may be used, as shown in Figs. 19-
25.
The assembly shown in Fig. 19 includes a canopy 200, a latching mechanism 202,
and a plug 22 of the quick connect device. The latching mechanism 202 provides
for the quick release of the spindle assembly 100 from the socket 24 (not
shown).
Moreover, the latching mechanism 202 allows the plug 22 to be released from
the
socket 24 when access to the push rod 116 is prevented.
Generally, the latching mechanism 202 includes a base plate 204, an adapter
206, a leaf spring 208, a clamp 210, a pivot rod 212, and a handle 214. The
adapter
206 is connected to the bottom side of the base plate 204. Preferably, the
adapter
206 includes two feet that may be positioned against the bottom side of the
base
plate 204 and screwed, bolted, adhered, or welded thereto. The adapter 206
also
includes two apertures 216. The apertures 216 are dimensioned and configured
for
receiving a portion of the pivot rod 212. The pivot rod 212 includes a
generally offset
portion 218 which is positioned between the apertures 216 of the adapter 206.
A
proximal portion 220 of the pivot rod 212 extends from the adapter 206.
Preferably,
the proximal portion 220 extends beyond an end of the base plate 204. At the
proximal end of the pivot rod 212, the handle 214 is attached so the rod 212
may be
easily rotated. The clamp 210 is mounted against a leg of the adapter 206.
Preferably, the clamp 210 is positioned on an inner side of a leg and adjacent
to the
pivot rod 212. The clamp 210 includes one or more elements which engage the
offset portion 218 of the pivot rod 212 as the pivot rod 212 is rotated. The
elements
of the clamp 210 restrict the range of motion that the pivot rod 212 may
rotate..
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Connected with the base plate 204 is the plug 22. The distal portion of the
plug 22 is positioned through an opening in the base plate 204 with the distal
portion
being placed adjacent the offset portion 218 of the pivot rod 212. A nut or
other
retaining member 222 may be screwed onto the distal portion of the plug 22 to
secure the plug 22 to the base plate 204. The leaf spring 208 is attached to
the
base plate and positioned adjacent the push rod 116 for selectively contacting
the
push rod 116. The leaf spring 208 may be generally V-shaped having two
portions.
One portion of the leaf spring 208 may be connected with the base plate 204.
For
example, one portion may include an opening which is placed over the distal
portion
of the plug 24. When the nut 222 is screwed onto the distal portion, the plug
24 and
the leaf spring 208 are connected with the base plate 204.
The other portion of the V-shaped leaf spring 208 may be positioned between
the push rod 116 and the offset portion 218 of the pivot rod 212. In its
normal, non-
deformed or non-actuated configuration, the leaf spring does not activate or
press
the push rod 116. However, when the pivot rod 116 is rotated, the offset
portion 218
of the pivot rod 116 pushes the leaf spring into contact with the push rod 116
to
thereby release the plug 22 from the socket 24. This exemplary embodiment of
the
latching mechanism 202 permits an electrician or other person to remove an
electrical appliance from a wall, ceiling, or floor by rotating the handle 214
which is
spaced away from the centerline of the appliance. This embodiment allows the
appliance to be quickly connected and released when the push rod 116 is not
accessible because the appliance or a cover or canopy is in the way. Figs. 26A
-
26E illustrate exemplary embodiments of canopies for use with the present
invention.
In another embodiment shown in Figs. 27 - 29, an electrical assembly
includes a canopy 300, a latching mechanism 302, and a quick connect device.
As
previously described, the latching mechanism 302 provides for the quick
release of
the spindle assembly 100 from the socket 24 (not shown). Moreover, the
latching
mechanism 302 allows the plug 22 to be released from the socket 24 when access
to the push rod 116 is restricted. Generally, the latching mechanism 302
includes a
base plate 304, an adapter 306, a leaf spring 308, a clamp 310, a pivot rod
312, and
a handle 314.
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Unlike the previously described embodiment, in the embodiment of Figs. 27 -
29, the distal portion of the plug 22 is positioned through an opening in the
adapter
306 and is secured with a nut 322. One portion of the V-shaped leaf spring 308
may
be placed between the nut 322 and adapter 306. As described above, the pivot
rod
312 is slideably and rotateably placed within two apertures of the adapter
306. Also,
the clamp 310 is connected to the adapter 306 to limit the range of rotation
of the
offset portion 318 of the pivot rod 312. The handle 314 may be connected with
the
proximal end of the pivot rod 312. The base plate 304 may be attached to two
feet
of the adapter 306. Operation of the present embodiment is similar to the
above
described operation. As the handle 314 is rotated, the offset portion 318 of
the pivot
rod 312 pushes the leaf spring 308 into contact with the push rod 116 of the
plug 22
to thereby release the plug 22 from the socket 24. Accordingly, this
embodiment
permits the release of the plug 22 when access to the push rod 116 is blocked
by
the electrical appliance, canopy, etc.
In a further embodiment, the quick connect device and latching mechanism
may be used in combination with a canopy and a remote control. In Fig. 30, the
latching mechanism 202,302 is positioned between the quick connect device and
a
remote control 402. The handle connected to the pivot rod extends outside the
canopy 400. Rotating the handle permits the remote control 402 and appliance
to
be quickly and safely removed from and attached to the wall, floor, or
ceiling.
Referring to Figs. 31-40, a quick mechanical connect device 420 for installing
fixtures or the like includes the combination of a male portion in the form of
a spindle
assembly 100, and mating female portion in the form of a bushing 28 and
mounting
strap 36. The device 420 functions to establish a quick and easy mechanical
connection that mechanically supports the fixture on a surface or base,
typically a
wall, ceiling or floor surface. As used herein, the term "fixture" means any
fixture or
appliance such as a lighting fixture, ceiling fan, television camera, security
device or
any other electrical or non-electrical device which is requires a mechanical
connection to support or suspend the fixture. Spindle assembly 100 is fixedly
secured to the fixture to be mounted such as a light fixture 69 having a light
bulb 71
or a fan housing 75. The bushing 28 is secured to the mounting strap 36, which
in
the illustrated embodiment is U-shaped.
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The bushing 28 includes a cylindrically shaped, essentially hollow tube having
an enlarged bore 30 in one end thereof which forms an annular internal
shoulder 34.
The tubular bushing 28, which is preferably formed of metal, can be attached
to the
strap 36 by welding or can be integrally formed with the strap 36, if desired.
The mounting strap 36 is provided with apertures on its outer extremities
which receive screws 40 that mount the strap 36 and thus the bushing 28 on an
electrical junction box 130. The U-shaped configuration of the strap 36 allows
the
bushing 28 to be recessed within the junction box 130. However, in those
applications where it is necessary to mount the bushing 28 directly on a wall
or
ceiling without use of a junction box, a flat strap may be employed.
The spindle assembly 100 includes a tubular main body or barrel 94, a
plunger or pin 114 slidably disposed within the barrel 94 and a finger hold or
guard
cover 126 which is screwed onto the threaded lower end of the barrel 94. The
upper
end of the barrel 94 includes openings 107 which receive retaining balls 104.
The
upper end of the plunger 114 includes a reduced diameter section 122 that
allows
the balls 104 to shift radially inward when the reduced diameter potion 122 is
aligned
with the balls 104. A spring 112 captured within the barrel 94 normally urges
the
plunger 114 downwardly, forcing the balls 104 to move outwardly, so that the
weight
of the fixture is loaded onto the shoulder 34. Immobilized in the their most
outward
position, the balls 104 cause interference with the shoulder 34, preventing
the
spindle assembly 100 from withdrawing from the bushing 28, thus mechanically
mounting the fixture 69 on the junction box 130, via the strap 36.
The plunger 114 is fitted with a release button 116 which is -surrounded by
the
finger hold 126. The user may unlock (release) the device 420 by depressing
the
button 116. Displacement of button 116 in this manner moves the plunger 114
upwardly, until the balls 104 align with the reduced diameter portion 122 of
the
plunger 114, which allows the balls 104 to move inwardly, so as to clear the
shoulder
34. While continuing to hold the button 116 in its depressed position, the
user may
then remove the spindle assembly 100 from the bushing 28 and strap 36 and
disconnect the fixture 69 from the junction box 130. A long push rod 152 may
be
thread into the end 117 of the release button 116 to extend the button for
easier
access. Furthermore, the push rod 152 may be replaced by a threaded extension
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rod 152' where it is necessary to operate the device 420 from a greater
distance
beneath the device due to fixture obstructions or the like.
The fixture 69 can be secured to the spindle assembly 100 in a variety of
ways. As shown in the drawings, the barrel 94 includes a ring shaped outer
flange
105. A portion of the fixture 69 can be captured between this flange 105 and a
nut
67, thereby tightly securing the fixture to the spindle assembly 100 of the
device 420.
The finger hold 126 not only protectively covers the sides of the push button
116 in order to prevent inadvertent actuation of the latter, but acts as a
guide to lead
a user's finger onto the end of the button 116. Further, the finger hold 126
provides
a means of gripping and holding the spindle assembly 100 during the
installation
process; the user places the index and middle finger fingers on the sprayed
lower
portion of the hold 126 while the thumb actuates the push button 116.
As previously mentioned, the electrical fixture may be secured to the spindle
assembly 100 in any of a variety of ways. For example, the fixture may be
fixedly
attached to the finger hold 126, or directly to the barrel 94. Alternatively,
the fixture
may be secured to a piece of mounting hardware, such as a "hickey" 154
threaded
onto the lower end of the barrel 94. In any event, it may be appreciated that
the
weight of the fixture 69 transmitted through the barrel 94, retaining balls
104, and
bushing 28 to the mounting strap 26, which in turn is secured to the junction
box,
wall or other structure on which the fixture is to mounted.
In some installations it may be necessary to effectively extend the length of
the push button 116 where, for example, a motor or other parts of the
electrical
fixture are covered by a downwardly extending shroud or canopy (not shown). In
this event, additional hardware such as the threaded hickey 154 is screwed
onto the
lower threaded portion of the barrel 94. A threaded guide barrel 94a is in
turn
screwed into the lower end of the hickey 154. An elongate push rod 152 or 152'
is
utilized which is attached at its end to the plunger 114. The push rod 152 or
152' is
guided by the guide barrel 94a, with its lower end extending beyond the lower
end of
the guide barrel 94a.
After a fixture is installed using the device 420, electrical wiring between a
supply line and the fixture may be performed in the normal manner. For
example,
electrical supply lines 128 fed into the junction box 130 are connected with
lead
wires 129 on the fixture using a connector junction 131, wire terminals or the
like.
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Having described details of the preferred embodiment of the device 420, and
various modifications thereto, the use and operation of the device 420 will
now be
explained. The bushing 28 and strap 36 are first installed either on an
electrical
junction box 130 or directly on a wall or ceiling surface. The electrical
fixture to be
installed is first mounted on the spindle assembly 100. As previously
discussed, the
exact mounting method will vary, depending on the type, size and configuration
of
the fixture. Having secured the fixture to the spindle assembly 100, the
installer first
depresses the push button 116 to displace the plunger 114 until the depression
in
the sides of the plunger 114 aligns with the balls 104. The balls 104 move
into the
plunger depression 122, allowing the upper cylindrical section of the barrel
94 to
pass into the central bore in the bushing 28. At this point, the installer
releases the
push button 116, whereupon spring 112 axially displaces the plunger 114 to its
normal locking position, forcing the balls 104 outwardly until they engage the
shoulder 34 to hold the plunger 114 in its locked position. This sequence of
events
is revered when the user wishes to disconnect the fixtu're from the junction
box 130.
Another exemplary embodiment of the quick connect device is shown in Fig.
41. The device includes the socket 24 and mounting strap 36b, and further
includes
the plug 22 with the spindle assembly 100. The plug 22 is configured and
dimensioned to mate with the socket 24 to form the quick connect device of the
present invention. As previously described, the quick connect device can be
used to
attach or mount a fixture, such as a light fixture, to the ceiling or other
surface.
An exploded view of the plug 22 is shown in Fig. 42. The spindle assembly
100 of the plug 22 includes a barrel 94 having a longitudinal channel
extending
therethrough. A plunger or pin 114 is positioned within the longitudinal
channel of
the barrel 94 and is slidable with the channel. A spring 112 is positioned
around the
pin 114 and within the channel of the barrel 94 to thereby allow the pin 114
to be
actuated (i.e. movable) within the channel. Disposed on'the distal section of
the pin
is a plurality of depressions or ball detents 122. Each detent 122 is a
circumferential
groove in the pin 114. As illustrated, there are two ball detents 122 on the
pin
spaced apart from each other. The ball detents 122 are of a configuration to
maintain or capture a portion of one or more retaining balls 104. The two ball
detents 122 may be spaced approximately 7.5 mm from each other.
1 25
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As shown in Fig. 42, four retaining balls 104 correspond to each ball detent
122, providing a total of eight retaining balls 104. The distal portion of the
barrel 94
includes a plurality of radial openings 107 extending through the wall of the
barrel
94. Each radial opening 107 is dimensioned and configured to maintain or
capture a
portion of one retaining ball 104 in such a manner to prevent the retaining
ball from
being able to passing completely through the radial opening 107. When the
spindle
assembly 100 is in an assembled state, the pin 114 is positioned within the
barrel 94
with the spring 112 located between the pin 114 and barrel 94 to provide
spring
activation of the pin 114. The pin 114 remains in the barrel 94 with an o-ring
115.
The retaining balls 104 are located within the longitudinal channel of the
barrel 94
and within the radial openings 107.
In an unactuated configuration, the retaining balls 104 are pressed by the pin
114 in a radial direction forcing a portion of each ball 104 to extend out of
the radial
openings 107. In an actuated configuration when the pin 114 is pressed and the
spring 112 is compressed, the depressions 122 on the pin 114 are aligned with
the
radial openings 107 of the barrel 94 allowing the retaining balls 104 to move
radially
inward and not extend outwardly from the radial openings 107. The spindle
assembly 100 is secured to the plug body 27 by way of extensions or flanges
105.
The plug body 27 is generally cylindrical in shape, like a wheel. The plug
body 27 is hollow or has a cavity on one side. In Fig. 42, the hollow portion
of the
plug body 27 is on the bottom side which is not shown. A plurality of lateral
wire
openings 95 is located on the circumference of the plug body 27. The wire
openings
95 are dimensioned to receive a stripped end of an electrical wire and are
therefore,
preferably, configured like a cylindrical passage. The longitudinal axes of
the wire
openings 95 are generally perpendicular to the radius of the socket body 27
and/or
generally tangential to the circumference of the socket body 27. As
illustrated, there
are three wire openings 95 in the socket body 27: one to receive a "hot"
electrical
wire, one to receive a "neutral" wire, and one to receive a "ground" wire.
Disposed within the cavity of the plug body 27 are a ring support member 79
and a plurality of connector rings 78a, 78c, and 78d. The support member 79
and
rings 78 may be fastened to or molded within the socket body 27. As seen in
Fig.
42, connector ring 78a is smaller in diameter than connector ring 78c which is
smaller in diameter than connector ring 78d. Connector ring 78a may have a
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diameter of about 1.9 cm; ring 78c may have a diameter of approximately 2.9
cm;
and ring 78d may have a diameter of about 3.4 cm. The connector rings 78 may
include a plurality of notches 81. The notches 81 of a connector ring serve to
increase the distance between the ring and adjacent rings to thereby reduce
the
chance of current/voltage arcing between the connector rings. For example,
connecter ring 78d includes two notches 81: one to increase the distance
between
an extension arm 80 of connector ring 78c and one to increase the distance
between the extension arm 80 of connector ring 78a.
When the plug 22 is assembled, the ring support member 79 is positioned
within the cavity of the plug body 27. Each connector ring 78 is positioned
within the
cavity of the plug body 27 with the center axes of the rings 78 being
generally
aligned with the center axis of the plug body 27. In this configuration, since
the
connector rings 78 have different diameters, the rings are 78 are spaced apart
from
each other. The extension arms 80 of the rings 78 extend radially outward
toward
the outer edge portion of the plug body 27. A plurality of terminal blocks 84
is
positioned in the outer edge portion of the body 27 generally adjacent to and
in line
with the wire openings 95. Each terminal block 84 is connected with one of the
arms
80 of a ring 78 such that an electrical wire positioned in a wire opening 95
is
connected with a terminal block 84 with a screw 82. For each of the connector
rings
78, an electrical connection is made from a wire to a terminal block to an
extension
arm and to a connector ring. The plug body 27 may include three terminal
blocks
84: one for the "hot" wire, one for the "neutral" wire, and one for the
"ground" wire.
The three terminal blocks 84 may be positioned in the plug body 27 and spaced
apart about 45 degrees from each other.
The socket 24 of the quick connector device is illustrated in Fig. 43. The
socket 24 includes a socket body 25. The socket body 25 is generally
cylindrical in
shape like the plug body 27 and may have a diameter of about 5 cm. The socket
body 25 includes central passage and a plurality of ring shaped slots 26a -
26d
disposed around the central passage. Each slot 26 is dimensioned and
configured
to receive a connector ring 78 from the plug 22. The slots 26 extend through
the
socket body 27 providing access to one or more cavities formed in the bottom
side
of the socket body 25. The cavity or cavities and bottom side are not shown in
Fig.
43, but are similar to the embodiment shown in Fig. 12. The socket body 25 of
Fig.
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43 includes four slots 26a - 26d. When a socket 24 with four slots is mated
with a
plug 22 with four connector rings 78, each slot receives a corresponding ring
to
make an electrical connection. However, when a socket 24 with four slots is
mated
with a plug 22 with three rings 78 as shown in Fig. 42, one of the slots of
the socket
will not be filled with a ring. In this configuration, ring 78a is disposed in
slot 26a;
ring 78c is disposed in slot 26c; and ring 78d is disposed in slot 26d to
thereby form
three electrical connections: hot, neutral and ground.
The socket body 25 further includes a sunken rim disposed on the same side
of the body 25 as the slots 26a - 26d. The rim allows the socket body 25 to be
mated with the plug 22 by permitting that portion of the socket body 25 which
creates the slots 26 to be positioned within the cavity of the plug body 27
and
thereby positioning the connector rings 78 within the slots 26. A surface of
the rim of
the socket body 25 may include teeth or ridges 88. A surface of the plug body
27
may also include teeth or ridges 88 as best seen in Fig. 1. When mated, the
teeth
88 of the socket body 25 and teeth 88 of the plug body 27 engage to prevent
the
plug 22 and socket 24 from rotating relative to each other. Each of the teeth
88 may
be approximately 1 mm in height and about 2 mm in width.
Radial projections or ears 73 and 73a extend from the outer wall of the socket
body 25 thereby extending the length or depth of access openings 72. The
radial
projections or ears 73 may have any cross-sectional shape including a
rectangle,
circle, triangle, square, etc. Furthermore, the ears 73 and 73a may be spaced
equidistantly about the circumference of the socket body 25; for example, at
90; 1
270, and 360 degrees. Preferably, ear 73, which holds or contains the "ground"
wire, is cube shaped with an access opening extending therethrough. The other
ears 73a, which contain "hot L1" and "hot L2" and "neutral", have a half-round
edge.
The radial projections or ears 73 and 73a provide additional enclosure of the
electrical wires positioned therein. Without an ear on the outer wall of the
socket
body 25, a stripped end portion of an electrical wire inserted into an access
opening
72 may be exposed and create an unsafe condition. Therefore, the radial
projection
73 and 73a enhances the safety of the socket 24 by covering any exposed,
stripped
electrical wire.
Within the cavity or cavities of socket body 25, a plurality of terminal
blocks 84
are aligned with the access openings 72 and the slots 26. Each terminal block
84
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provides an electrical connection between an electrical wire and slot. The
terminal
block 84 holds or pinches the wire between a terminal frame 84a and a spring
plate
84b which are described in more detail later. Each terminal block includes a
spring
arm 54 and a contact member 56 positioned at the distal end of the arm. A
spring
60 is positioned between each contact member 56 and a cover plate 66. The
cover
plate 66 is generally a flat disk dimensioned to cover the cavity or cavities
of the
socket body 25. The plate 66 may include a flat edge which aligns with a flat
edge
of the socket body 25 to limit the positioning of the cover 66 to one
orientation
relative to the socket body 25. The cover plate 66 may also include an opening
through which a grounding strap, described in more detail later, may be
positioned.
When assembled, the socket completes electrical connections as follows: an
electrical wire is positioned with an access opening 72 and is connected with
a
terminal block 84. Current travels from the wire to the terminal block 84,
through the
spring arm 54, and to the contact member 56. When the plug 22 is mated with
the
socket 24, the current continues to flow from the contact member 56, to a
connector
ring 78, through an extension arm 80, to a terminal block 84, and to an
electrical wire
connected with the terminal block 84.
To mount the socket 24 to a junction box or other structure, a mounting strap
36b is connected to the socket body 25 with screws 158. As shown in Fig. 43,
the
strap 36b is generally U-shaped and includes a central orifice 39. The strap
36b
includes a plurality of reinforcement ridges 37 disposed on a surface thereof.
The
reinforcement ridges 37 increase the load bearing capacity of the strap 36b to
safely
install heavy fixtures and may be located on the underside and/or topside of
the
strap 36b. As illustrated in Fig. 43, there may be three pairs of ridges 37. A
bushing
28 is positioned through the orifice 39 and fixedly attached to the mounting
strap 36
by welding or by an o-ring 115. The bushing 28 is generally tubular and is
positioned within the central passage of the socket body 25 and within the
center of
connector ring 26a. The bushing 28 also includes a channel extending
therethrough. The channel is dimensioned and configured to receive the spindle
assembly 100 of the plug 22 and hold the spindle assembly 100 by providing one
or
more shoulders on which the retaining balls 104 can engage. The features of
the
bushing 28 are more fully shown in Fig. 14 and described in the corresponding
text.
As illustrated in Fig. 14, the channel of the bushing 28 has two different
diameter
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bores 30 and 32. Bore 30 may have a diameter of about 7.5 mm, while bore 32
may
have a diameter of approximately 8 mm.
When the plug 22 and socket 24 are mated, they not only form electrical
connections as previously described, but also provide a mechanical connection
between the fixture and ceiling/mounting surface. For example, the fixture is
attached to the spindle assembly 100; the spindle assembly 100 is firmly
secured in
the bushing 28; the bushing 28 is fixed to the mounting strap 36b; and the
mounting
strap 36b is connected to a junction box or other structure. In this
configuration, the
weight of the fixture is transmitted through metal components and not through
the
material of the socket 24 and plug 22.
Figs. 44, 44A, and 45 illustrate the terminal blocks 84 of the present
invention.
The terminal blocks 84 are positioned within the socket body 25. The terminal
block
84 designed to retain the "ground" wire includes a grounding strap 85. As seen
in
Fig. 44, the grounding strap 85 extends from the terminal block 84 and through
the
cover 66 of the socket 24. When the socket 24 is connected with the mounting
strap 36b, the grounding strap 85 connects the mounting strap 36b to thereby
complete a grounding circuit. The grounding circuit created by the grounding
strap
85 may be in addition to the grounding circuit created by the terminal block
84 and
grounding wire.
The terminal frame 84a and spring plate 84b are shown in Fig. 45. The
terminal frame 84a includes an orifice through which an electrical wire may be
positioned. A stripped end of the electrical wire is positioned in a groove
84c formed
between the terminal frame 84a and spring plate 84b. In use, an electrical
wire is
passed through the orifice of the terminal frame 84a and pushed into the
groove
84c. The spring plate 84b is flexible such that it deflects as the wire is
inserted into
the groove 84c. The wire is pinched between the top portion of the terminal
frame
84a and an end portion of the spring plate 84b. In this configuration, with
the spring
plate 84b deflected, the wire is prevented from being pulled straight out of
the
terminal block 84. If it is desired to intentionally pull the wire out of the
terminal block
84, the above described configuration permits the wire to be twisted and
pulled out
of the block 84.
A socket skirt 137 is illustrated in Figs. 46 and 47. The skirt 137 is
generally a
circular plate with an opening in the middle. The opening is dimensioned to
receive
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the socket 24. The skirt 137 is secured to the socket 24 by a plurality of
tabs 139.
Tabs 139 are deflectable such that as the skirt 137 is placed about the socket
24 the
tabs 139 deflect radially outward and squeeze the socket 24 to hold the skirt
137 to
the socket 24. The socket skirt 137 is useful for covering up the mounting
strap and
other components which are not intended to be seen.
Fig. 48 illustrates a socket cover 136a which is generally a circular plate
with
a knob 135 at the center thereof. The knob 135 is dimensioned to be positioned
in
and held within the barrel 28 of the socket 24. The knob 135 may include a
slit
dividing the knob 135 into two portions. As the knob 135 is inserted into the
barrel
94, the two portions deflect towards each other closing the slit and
frictionally holding
the cover 136a within the barrel 94. The socket cover 136a is useful for
covering up
the socket 24 and surrounding area when a plug 22 is not inserted within the
socket
24.
As previously shown in Figs. 20 and 28, latching mechanisms 202,302 allow a
user to engage and disengage the plug 22 from the socket 24 when access to the
plug 22 is restricted by, for example, a fixture or canopy. Fig. 49
illustrates another
embodiment of activating the latching mechanism 202,302. A female receptacle
224
is connected with the latching mechanism 202,302. A male tool 226 is
configured
for insertion in the female receptacle 226, and thereafter, the tool 226 and
receptacle 224 may be rotated to engage and disengage the plug 22 from the
socket
24 in a manner previously described. In an alternative embodiment, it is
contemplated that the male component may be connected with the latching
mechanism 202,302 while the female component may be the tool. In either
configuration, the component attached to the latching mechanism may be
positioned
entirely behind the canopy so as not to be seen. A cover may be removed from
an
opening in the canopy to gain access to the component for rotation thereby
engaging and disengaging the plug 22 from the socket 24.
It will be appreciated by persons skilled in the art that the present
invention is
not limited to what has been particularly shown and described herein above. In
addition, unless mention was made above to the contrary, it should be noted
that all
of the accompanying drawings are not to scale. A variety of modifications and
variations are possible in light of the above teachings without departing from
the
scope and spirit of the invention.
31
