Universal electrical wiring component
A modular electrical wiring component comprises includes a wiring module having a wiring portion for coupling to a source of electrical power and a user-accessible portion configured to accept and provide electrical power to a functional module that provides a selected electrical distribution function, wherein the wiring module is configured to accept the functional module without access to the wiring portion. The modular electrical wiring component also comprises includes an adjustable plaster ring configured to couple to the wiring module and to an electrical junction box, wherein the adjustable plaster ring provides a variable distance between the electrical junction box and the wiring module.
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Notice: More than one reissue application has been filed for the reissue of U.S. Pat. No. 7,572,977. The reissue applications include the present application, which is a continuation reissue application of reissue application Ser. No. 13/208,260, filed Aug. 11, 2011, both of which are broadening reissues of U.S. Pat. No. 7,572,977.
This application U.S. Pat. No. 7,572,977 is a continuation of co-pending U.S. application Ser. No. 10/924,555 filed Aug. 24, 2004 and entitled “Universal Electrical Wiring Component,” now U.S. Pat. No. 7,312,396, issued on Dec. 25, 2007, which claims priority from U.S. Provisional Application No. 60/552,546 filed Mar. 13, 2004 and entitled “Modular Integrated Wiring System,” both of which are incorporated by reference in their entirety.
BACKGROUND OF THE INVENTIONConventional AC electrical systems are comprised of a junction box and an electrical device, such as an outlet or switch, installed within the box. During a rough-in phase of construction, power cables are routed through building framing to junction boxes mounted at predetermined electrical distribution locations. The power cables are fed through openings in the rear or sides of the junction boxes and folded back inside, unterminated, so as to be out of the way until the next phase. During a makeup phase, wall panels are installed and painted, and electrical devices are installed into the boxes. After conductors are wired to an electrical device, it and the attached conductors are pushed into the electrical box and the device is attached to the top and bottom of the box. During a trim phase, face plates are mounted over the open-end of the junction boxes, completing the conventional electrical wiring process.
SUMMARY OF THE INVENTIONConventional electrical wiring installation is a logistical nightmare of schedules, inventory, design changes and rework to correct design and installation errors and product defects. Prefabricated units having brackets with pre-mounted junction boxes and pre-wired outlets and switches installed within the boxes are sometimes utilized in an effort to save installation time. These units are manufactured per contractor specification and delivered to the job site. An electrician attaches a particular unit at a specific location and attaches a corresponding power cable to a standard connector.
Such prefabricated electrical systems, however, do not solve all of the logistical problems associated with electrical wiring system design and installation and create additional ones. Each prefabricated unit is typically specified as to mounting height, plaster ring depth, support arm length and electrical device type, to name a few, and are given unique part numbers. Each part number represents a different stock keeping unit (SKU) for the distributor and contractor. The contractor must sort each SKU to corresponding installation locations at the job site. If an SKU malfunctions, there is typically no replacement part, and the SKU has to be returned to the manufacturer. Each prefabricated part is custom made so there is much room for mistakes to be made in the specification and assembly process. If an electrician opens the SKU to fix a problem inside, the product warranty may be void.
A universal electrical wiring component advantageously combines an adjustable, modular mount with modular electrical devices to reduce installation costs over conventional wiring in much the same manner as a typical prefabricated system. Because a universal electrical wiring component is modular, a limited number of such components can be combined and configured as a substitute for many conventional assemblies. This significantly reduces the number of SKUs and associated inventory and planning headaches. Because a universal wiring component is adjustable, it greatly reduces specification requirements and eliminates the possibility of assembly errors associated with custom prefabricated parts. A universal electrical wiring component also advantageously accommodates design changes including the location and the type of an electrical distribution point and the function and color of an installed electrical device. Testing of the wiring system can be accomplished at the rough-in phase while walls are open rather than the trim-out phase. Trim-out can be completed without touching a wire. Devices can finish flush with the wall every time.
A universal electrical wiring component combining modular electrical devices and an adjustable, modular mount is described with respect to
A universal electrical wiring component has been disclosed in detail in connection with various embodiments. These embodiments are disclosed by way of examples only and are not to limit the scope of the claims that follow. One of ordinary skill in the art will appreciate many variations and modifications.
Claims
1. A modular electrical wiring component comprising:
- a wiring module having a first portion configured to couple to a source of electrical power and a second portion configured to couple and provide the electrical power to a separate functional module that provides a selected electrical distribution function, wherein the wiring module is configured to couple to the functional module without accessing the wiring first portion;
- an adjustable plaster ring configured to couple to the wiring module and to an electrical box, wherein the adjustable plaster ring is configured to provide a variable distance between the electrical junction box and the wiring module; and
- a protective cover to shield the second portion of the wiring module when no functional module is coupled to the wiring module.
2. The modular electrical wiring component of claim 1, wherein the adjustable plaster ring comprises a base ring and an insert ring that is slidably retained within the base ring.
3. The modular electrical wiring component of claim 2, wherein the insert ring is slidably retained within the base ring by adjusting screws.
4. The modular electrical wiring component of claim 3, wherein turning the adjusting screws varies the distance between the electrical box and the wiring module.
5. The modular electrical wiring component of claim 2, wherein the base ring is configured to couple to the electrical box and the insert ring is configured to couple to the wiring module.
6. The modular electrical wiring component of claim 1, wherein the wiring module is configured to accept a plug-in functional module.
7. The modular electrical wiring component of claim 1, further comprising the electrical box.
8. An electrical wiring method comprising:
- providing a wiring module having a first portion configured to couple to a source of electrical power and a second portion configured to couple and provide electrical power to a functional module that provides a selected electrical distribution function, wherein the wiring module is configured to couple to the functional module without accessing the first portion;
- providing an adjustable plaster ring configured to couple to the wiring module and to an electrical box, wherein the adjustable plaster ring is configured to provide a variable distance between the electrical junction box and the wiring module;
- coupling the wiring module to the adjustable plaster ring; and
- coupling a protective cover with respect to the wiring module so as to shield the second portion of the wiring module when no functional module is coupled to the wiring module.
9. The electrical wiring method of claim 8, further comprising mechanically coupling the adjustable plaster ring to the electrical box.
10. The electrical wiring method of claim 9, further comprising adjusting the distance between the electrical box and the wiring module using the adjustable plaster ring.
11. The electrical wiring method of claim 8, further comprising electrically and mechanically coupling the functional module to the wiring module.
12. The electrical wiring method of claim 11, wherein electrically and mechanically coupling the functional module to the wiring module comprises plugging the functional module into the second portion of the wiring module.
13. A modular electrical wiring component comprising:
- a wiring module coupled to an electrical box, the electrical box comprising a front, a back and sides, the wiring module coupled to the electrical box via a ground wire, wherein the ground wire connects the electrical box with a first portion of the wiring module, the first portion of the wiring module configured to couple to a source of electrical power via a plurality of electrical wires, and a second portion of the wiring module configured to couple and provide the electrical power to a functional module that provides a selected electrical distribution function, wherein the second portion of the wiring module is configured to couple to the functional module without accessing the first portion of the wiring module coupled to the source of electrical power;
- a plaster ring configured to couple to the front of the electrical box;
- a protective cover configured to shield the second portion of the wiring module when no functional module is coupled to the wiring module; and
- a mounting bracket configured to attach to the electrical box and mount the electrical box to a wall stud.
14. The modular electrical wiring component of claim 13 wherein the mounting bracket is a vertically adjustable floor bracket configured to vertically adjust the location of the electrical box with respect to the floor.
15. The modular electrical wiring component of claim 13 wherein the mounting bracket is a vertically adjustable floor bracket comprising ruled sides.
16. The modular electrical wiring component of claim 13 wherein the mounting bracket is a stud bracket configured to mount the electrical box to the wall stud.
17. The modular electrical wiring component of claim 13 wherein the mounting bracket is a horizontally adjustable stud bracket configured to horizontally adjust the location of the electrical box.
18. The modular electrical wiring component of claim 13 wherein the mounting bracket comprises a horizontal bar configured to horizontally adjust the location of the electrical box.
19. The modular electrical wiring component of claim 13 wherein the mounting bracket is configured to adjust the location of the electrical box both vertically and horizontally.
20. An electrical wiring method comprising:
- providing a wiring module coupled to an electrical box, the electrical box comprising a front, a back and sides, coupling the wiring module to the electrical box via a ground wire that connects the electrical box with a first portion of the wiring module, the first portion of the wiring module configured to couple to a source of electrical power via a plurality of electrical wires, and coupling the wiring module to a functional module via a second portion of the wiring module, the second portion of the wiring module configured to couple and provide electrical power to a functional module that provides a selected electrical distribution function, wherein the second portion of the wiring module is configured to couple to the functional module without accessing the first portion of the wiring module coupled to the source of electrical power;
- providing a plaster ring configured to couple to the front of the electrical box;
- coupling the plaster ring to the front of the electrical box;
- coupling a protective cover to shield the second portion of the wiring module when no functional module is coupled to the wiring module; and
- attaching a mounting bracket to the electrical box, the mounting bracket configured to mount the electrical box to a wall stud.
21. The electrical wiring method of claim 20 wherein the mounting bracket is a vertically adjustable floor bracket that vertically adjusts the location of the electrical box with respect to the floor.
22. The electrical wiring method of claim 20 wherein the mounting bracket is a vertically adjustable floor bracket comprising ruled sides.
23. The electrical wiring method of claim 20 wherein the mounting bracket is a stud bracket that mounts the electrical box to a wall stud.
24. The electrical wiring method of claim 20 wherein the mounting bracket is a horizontally adjustable stud bracket that horizontally adjusts the location of the electrical box.
25. The electrical wiring method of claim 20 wherein the mounting bracket comprises a horizontal bar that horizontally adjusts the location of the electrical box.
26. The electrical wiring method of claim 20 wherein the mounting bracket adjusts the location of the electrical box both horizontally and vertically.
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Type: Grant
Filed: Oct 10, 2013
Date of Patent: Mar 24, 2015
Assignee: ProtectConnect (Oceanside, CA)
Inventor: Michael P. Gorman (Laguna Niguel, CA)
Primary Examiner: Dhirubhai R Patel
Application Number: 14/050,794
International Classification: H01H 9/02 (20060101);