U.S. patent application number 12/778886 was filed with the patent office on 2010-09-02 for adjustable plaster ring cover.
This patent application is currently assigned to ProtectConnect, Inc.. Invention is credited to Dennis L. Grudt, John Karns, Steve Purves.
Application Number | 20100218969 12/778886 |
Document ID | / |
Family ID | 39149937 |
Filed Date | 2010-09-02 |
United States Patent
Application |
20100218969 |
Kind Code |
A1 |
Purves; Steve ; et
al. |
September 2, 2010 |
ADJUSTABLE PLASTER RING COVER
Abstract
A power distribution system has an electrical box configured to
attach a power cable, a plaster ring releasably mounted to the box
and one or more electrical devices installed. A pre-wired ground
extends from a first end physically and electrically connected to a
ground terminal on the electrical device. The plaster ring is
movable between a closed position proximate the box and an open
position distal the box. The pre-wired ground is configured as a
lanyard so as to support the plaster ring as a wiring platform in
the open position for connecting wires between the power cable and
the electrical device or devices.
Inventors: |
Purves; Steve; (Costa Mesa,
CA) ; Grudt; Dennis L.; (Long Beach, CA) ;
Karns; John; (Victorville, CA) |
Correspondence
Address: |
KNOBBE MARTENS OLSON & BEAR LLP
2040 MAIN STREET, FOURTEENTH FLOOR
IRVINE
CA
92614
US
|
Assignee: |
ProtectConnect, Inc.
Tigard
OR
|
Family ID: |
39149937 |
Appl. No.: |
12/778886 |
Filed: |
May 12, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
12176828 |
Jul 21, 2008 |
7718893 |
|
|
12778886 |
|
|
|
|
11829796 |
Jul 27, 2007 |
|
|
|
12176828 |
|
|
|
|
60833966 |
Jul 29, 2006 |
|
|
|
Current U.S.
Class: |
174/59 ;
29/592.1 |
Current CPC
Class: |
H02G 3/12 20130101; H01R
13/502 20130101; H02G 3/083 20130101; Y10T 29/49002 20150115; H05K
5/0204 20130101; H01R 9/24 20130101; H02G 3/18 20130101; Y10T
29/532 20150115; H05K 5/0008 20130101; H02G 3/14 20130101; Y10T
29/49174 20150115; H02G 1/00 20130101; H02G 3/16 20130101 |
Class at
Publication: |
174/59 ;
29/592.1 |
International
Class: |
H02G 3/14 20060101
H02G003/14; H05K 13/04 20060101 H05K013/04 |
Claims
1. An apparatus for use in an electrical distribution system, the
apparatus comprising: an electrical box configured to accept at
least one electrical power cable; a plaster ring configured to be
mounted to the electrical box, wherein the plaster ring has an open
front face that provides access to an interior of the electrical
box; an electrical wiring module within the interior of the
electrical box, the electrical wiring module including one or more
conductors that couple the electrical wiring module to one or more
of the power cables, the electrical wiring module further including
one or more connectors to electrically couple to a functional
module; a first cover configured to protect one of more of the
connectors on the wiring module; and a second cover configured to
substantially cover the open front face of the plaster ring.
2. The apparatus of claim 1, wherein at least one of the wiring
module conductors is electrically connected to the electrical
box.
3. The apparatus of claim 2, wherein the wiring module conductors
are configured with wire connectors.
4. The apparatus of claim 1, wherein the second cover is attached
to the plaster ring with one or more screws.
5. The apparatus of claim 4, wherein the second cover includes a
plate.
6. The apparatus of claim 1, where one of the first and second
covers is flexible.
7. The apparatus of claim 1, wherein the first cover is flexible
and the second cover is hard.
8. The apparatus of claim 1, further comprising mounting brackets
configured to mount the apparatus to ensure the center of the
functional module when coupled with the wiring module will be
between 10 and 24 inches from the floor.
9. The apparatus of claim 1, further comprising mounting brackets
configured to mount the apparatus to a construction stud allowing
the box to be moved to a variety of positions vertically on the
stud or to move the apparatus horizontally between two studs on a
wall, ceiling or floor.
10. The apparatus of claim 1, wherein the electrical box is
configured to be mounted to a hard surface or within a hard
surface.
11. The apparatus of claim 1, wherein the first cover must be
removed to electrically couple a functional module with the wiring
module.
12. The apparatus of claim 1, wherein the second cover must be
removed to electrically connect the functional module.
13. The apparatus of claim 1, wherein the second cover protects the
wiring module, the first cover and one or more of the
conductors.
14. The apparatus of claim 1, further comprising a functional
module.
15. An electrical apparatus manufacturing method comprising:
placing one or more electrical wiring modules within an interior of
an electrical box, each electrical wiring module including one or
more fixed conductors that couple the electrical wiring module to
one or more power cables, the electrical wiring module further
including one or more connectors disposed thereon that are
configured to electrically couple to a functional module; mounting
a plaster ring to the electrical box wherein the plaster ring
includes an open front face that provides access to the interior of
the electrical box; and mounting a hard protective cover to the
plaster ring.
16. The electrical apparatus manufacturing method of claim 15,
wherein the plaster ring is removeably mounted with two or more
screws.
17. The electrical wiring method of claim 9, wherein the hard
protective cover is attached with two or more screws.
18. The electrical apparatus manufacturing method of claim 15,
further comprising: respectively mounting a functional module to
each wiring module.
19. The electrical apparatus manufacturing method of claim 9,
wherein at least one of the wiring modules fixed conductors is
connected to the electrical box with a screw or wire connector.
20. The electrical apparatus manufacturing method of claim 9,
wherein at lease one conductor from each of the wiring modules is
connected to the electrical box via a wire connector or screw.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent
application Ser. No. 12/176,828, filed Jul. 21, 2008 and entitled
ADJUSTABLE PLASTER RING COVER, which is a continuation of U.S.
patent application Ser. No. 11/829,796, filed on Jul. 27, 2007, and
entitled "PRE-WIRED POWER DISTRIBUTION SYSTEM," which claims
priority from U.S. Provisional Application No. 60/833,966, filed
Jul. 29, 2006 and entitled "PRE-WIRED POWER DISTRIBUTION SYSTEM,"
each of which is incorporated by reference herein in its
entirety.
INCORPORATION BY REFERENCE
[0002] Wiring modules and corresponding functional modules are
described in U.S. Pat. No. 6,884,111 entitled Safety Module
Electrical Distribution System, issued Apr. 26, 2005; U.S. Pat. No.
6,341,981 entitled Safety Electrical Outlet And Switch System,
issued Jan. 29, 2002; and U.S. Pat. No. 6,894,221 entitled Safety
Outlet Module, issued May 17, 2005. Modular electrical devices,
electrical boxes and adjustable mounts are described in U.S. patent
application Ser. No. 10/924,555 entitled Universal Electrical
Wiring Component, filed Aug. 24, 2004. A wiring support platform is
described in U.S. patent application Ser. No. 11/108,005 entitled
Hinged Wiring Assembly, filed Apr. 16, 2005. All of the
above-referenced patents and patent applications are hereby
incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0003] A power distribution system may comprise an electrical box,
a plaster ring and an electrical device, such as an outlet or
switch. During a roughing phase of construction, electrical boxes
with attached plaster rings are mounted to wall studs at
predetermined locations. A journeyman electrician routes power
cables through building framing to the appropriate box. Then power
cables are fed through openings in the rear or sides of the boxes
and folded back inside. During a trim phase, electrical devices are
mounted to the plaster rings.
SUMMARY OF THE INVENTION
[0004] Conventional electrical distribution systems consist of
either prefabricated components customized for particular
electrical distribution points within a building or individual
components that must be planned for, ordered, allocated to building
locations and then attached together and wired during installation
at each electrical distribution point. Further, it is impractical
to test each wired installation for conformance to construction
standards.
[0005] A pre-wired power distribution system, in contrast,
advantageously combines installation flexibility, convenience and
verifiability. A combination electrical box, plaster ring, one or
more electrical devices installed in the plaster ring and one or
more pre-wired grounds between the electrical box and the
electrical device or devices provides for a pre-tested ground path.
In an embodiment, the electrical device is a wiring module
configured to accept any of various functional modules. The
pre-wired ground also functions as a lanyard between the electrical
device and the electrical box, allowing the plaster ring to be
pivoted to, and supported in, an open position to provide
hands-free connection of power wires to the electrical device. This
feature is particularly useful for wiring gang electrical boxes
housing multiple electrical devices. In an embodiment, a ground bus
bar mounted to the electrical box provides further flexibility by
accommodating multiple grounds for power cables routed to the
electrical box. In this manner, an electrical box, a plaster ring
and wiring module or other electrical device or devices may be
manufactured, assembled, distributed and/or installed as a
pre-wired power distribution component, by itself or in combination
with an adjustable mount.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIGS. 1A-B are perspective views of a pre-wired power
distribution system in an open position and a closed position,
respectively;
[0007] FIG. 2 is a perspective view of a pre-wired power
distribution system embodiment having a writing module with
external push wire connectors;
[0008] FIG. 3 is a perspective view of a pre-wired power
distribution system embodiment having a wiring module with internal
push wire connectors;
[0009] FIG. 4A is a front perspective view of an embodiment of a
wiring module with internal push wire connectors;
[0010] FIG. 4B is a rear perspective view of the wiring module of
FIG. 4A; and
[0011] FIG. 5 is a perspective view of a pre-wired power
distribution system embodiment having a box-mounted ground bus
bar;
[0012] FIG. 6 is a front view of a modular integrated wiring system
utilizing various embodiments of a universal electrical wiring
component;
[0013] FIG. 7 is a front perspective exploded view of a universal
electrical wiring component having modular electrical devices
combined with an adjustable, modular mount;
[0014] FIG. 8 is a front perspective view of a floor bracket
electrical wiring component;
[0015] FIG. 9 is a front perspective view of a stud bracket
electrical wiring component;
[0016] FIG. 10 is a front perspective view of a box bracket
electrical wiring component;
[0017] FIG. 11 is a front perspective view of an extended box
bracket electrical wiring component;
[0018] FIG. 12 is an exploded perspective view of a junction box
assembly;
[0019] FIG. 13 is an exploded perspective view of a floor bracket
assembly;
[0020] FIG. 14 is an exploded perspective view of a stud bracket
assembly;
[0021] FIG. 15 is an exploded perspective view of a box bracket
assembly;
[0022] FIG. 16 is an exploded perspective view of an extended BOX
bracket assembly;
[0023] FIG. 17 is an exploded perspective view of an adjustable
plaster ring;
[0024] FIG. 18 is a perspective view of a junction box; and
[0025] FIGS. 19A-D are top, perspective, front and side views,
respectively, of a support arm.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0026] FIGS. 1A-B illustrate a pre-wired power distribution system
100 having an electrical box 120 configured to attach at least one
power cable, an adjustable plaster ring 140, an electrical device
160 mounted to the plaster ring 140 and a ground lanyard 180
pre-wired between the electrical device 160 and the electrical box
120. The electrical box 160 can be any type known in the art.
[0027] In some embodiments, the electrical device 160 is a wiring
module that is configured to connect to a source of electrical
power via a plurality of cables (e.g., hot, neutral, and ground
cables). The plurality of cables (not shown) are fed through the
electrical box 120 and connected to a wiring portion of the wiring
module, as disclosed herein. In some embodiments, once the wiring
module is connected to power cables and fully installed within the
electrical box 120, the wiring portion of the wiring module is
substantially enclosed by the electrical box 120 and the adjustable
plaster ring 140, and is inaccessible to users. The wiring module
also includes a user-accessible portion that removably accepts a
functional module (not shown) that provides a selected electrical
power distribution function. For example, the functional module may
be an outlet receptacle or a switch. The user-accessible portion of
the wiring module includes shielded connectors, or sockets, that
mate with the functional module. The shielded connectors help
reduce the risk of electrical shock to users when a functional
module is not installed in the wiring module. In FIG. 1B, the
shielded connectors are concealed by a protective cover 161 that
protects the connectors from foreign objects, for example, during a
rough-in phase of construction. The functional module can be
installed without accessing the wiring portion of the wiring module
or the power cables.
[0028] In some embodiments, the electrical device 160 (e.g., a
wiring module) is mounted to the adjustable plaster ring 140. The
adjustable plaster ring provides for an adjustable distance between
the electrical device 160 and the electrical box 120. For example,
the adjustable plaster ring may include adjusting screws that can
be turned to increase or decrease the distance between the
electrical device 160 and the electrical box 120. In this way, the
depth of the electrical device 160 within a wall can be adjusted to
result in the desired fit with the wallboard.
[0029] One lanyard end 182 is connected to a box ground junction
122 and another lanyard end 184 is connected to an electrical
device terminal 162. The plaster ring 140 can be releasably
attached to the electrical box 120. The plaster ring 140 is movable
between an open position FIG. 1A distal the electrical box 120 and
a closed position FIG. 1B proximate the electrical box 120. The
plaster ring 140 can be releasably attached to the electrical box
120 in the closed position. The ground lanyard 180 provides a
ground path from the electrical device 160 to the electrical box
and mechanically supports the plaster ring in the open position. In
some embodiments, however, the ground lanyard 180 does not
necessarily support the plaster ring in the open position.
[0030] In an embodiment, the ground lanyard 180 is a ground wire
connected between a single point ground 222 (FIG. 2) on the
electrical box 120 and a ground terminal 252 (FIG. 2) on the
electrical device 160, as described in further detail with respect
to FIGS. 2-3, below. In another embodiment, the ground lanyard 180
includes multiple ground wires connected between a ground bus bar
450 (FIG. 4) mounted on a multi-gang electrical box 420 (FIG. 4)
and the ground terminals 462 (FIG. 4) of multiple electrical
devices 460 (FIG. 4) mounted in a multi-gang plaster ring 440 (FIG.
4), as described in further detail with respect to FIG. 4, below.
As described herein, the electrical devices 160 may be wiring
modules that are configured to accept various functional modules.
The electrical box 120 is adapted to utilize various adjustable or
fixed stud brackets, and the plaster ring 140 may be adjustable.
These aspects facilitate the positioning of the mounted electrical
devices during wall installation of the ground wire supporting
wiring assembly 100. With this combination of features, a pre-wired
power distribution system provides a broadly adaptable electrical
system component.
[0031] The connections between the ground lanyard 180 and the
electrical box 120 can be formed using any type of connection known
in the art. For example, a connection between the ground lanyard
180 and the electrical box 120 or the electrical device 160 may
comprise an electrical screw terminal or a push-in connector. In
some embodiments, the electrical screw terminal is treated with a
threadlocker material once the connection is made to improve the
mechanical reliability of the connection. The ground lanyard 180
can also be soldered or clamped to the electrical box 120 or the
electrical device 160. Advantageously, in cases where the
electrical device 160 is a wiring module, the connection between
the ground lanyard 180 and the electrical box 120 or the electrical
device 160 can be made substantially permanent because the wiring
module need not be removed to replace an outlet receptacle, switch,
or other similar functional module. In contrast, it would generally
be undesirable to form a permanent ground connection between a
conventional outlet receptacle or switch and an electrical box 120
because doing so may prevent the replacement of the conventional
outlet receptacle or switch. The fact that the connections between
the ground lanyard 180 and the electrical device 160 or the
electrical box 120 can be made substantially permanent can also
allow the connections to be made stronger (allowing the ground
lanyard to support the weight of the electrical device 160 and
adjustable plaster ring 140, as described herein) and more
reliable, both from a mechanical and an electrical standpoint.
[0032] The pre-wired ground lanyard 180 can be advantageously
tested at the manufacturer. In an embodiment, the ground lanyard
180 is subjected to a mechanical pull test and an electrical
continuity test. In a particular embodiment, the pull-test has at
least a 20 lb. force. The mechanical pull test and the electrical
continuity test would otherwise be too cumbersome to perform on
ground connections installed by an electrician at a worksite.
However, since the ground connection between the electrical device
160 and the electrical box 120 is installed at the manufacturer,
these tests can be performed more efficiently than can be done at a
worksite. Moreover, these tests can be performed using equipment
that is too expensive or bulky to use at a worksite where the
ground connection might otherwise be installed. In some
embodiments, however, the ground lanyard 180 is not pre-wired but
is instead configured to be connected upon installation of the
electrical device 160 within the electrical box 120.
[0033] Since the ground connection between the electrical device
160 and the electrical box 120 acts as a pull-tested lanyard 180,
the plaster ring 140 can be supported in an open position (FIG. 1A)
by the ground lanyard 180, advantageously allowing an electrician
hands-free access to one or more electrical devices 160 so as to
wire these devices to power cables routed to the electrical box
120. Upon wiring completion, the plaster ring 140 is moved to a
closed position (FIG. 1B) and secured to the electrical box 120.
Multiple electrical devices 160 can be pre-attached to the plaster
ring 140 because doing so does not block access to the electrical
box 120 or impede the wiring process. Further, the use of a ground
bus bar as the electrical box ground junction 184 advantageously
allows the ground wiring of one or more power cables to the bus bar
without resorting to ad hoc pigtail junctions or the use of the
electrical device connectors.
[0034] FIG. 2 illustrates a pre-wired power distribution system
embodiment 200 having a wiring module 260 pre-wired with push-wire
connectors 250. A ground wire 280 extends between the wiring module
260 and an electrical box 120. In some embodiments, the ground wire
280 includes a push-wire connector at some point along its length
to be connected to a ground cable fed into the electrical box 120
along with other power distribution cables. The ground wire 280 has
a first end 282 attached to a ground push-wire connector 252 and a
second end 284 secured to a ground attachment point 222 in the
interior of the electrical box 120. In some embodiments, the ground
attachment point 222 is a screw terminal. The push-wire connectors
250 are connected to internal crimp wires of the wiring module 260
and adapted to accept power and ground wires from cables (not
shown) routed to the electrical box 120. An electrician can easily
and quickly attach the power wires to the appropriate push wire
connectors 250 while the plaster ring 140 is supported by the
ground wire 280.
[0035] FIG. 3 illustrates another pre-wired power distribution
system embodiment 300 having a wiring module 360 with internal
push-wire connectors 350. A ground wire 280 extends between the
wiring module 360 and an electrical box 120. The ground wire 280
has a first end 282 attached to a ground push-wire connector 352
and a second end 284 secured to a ground attachment point 222 in
the interior of the electrical box 120. The push-wire connectors
350 are adapted to accept power and ground wires from cables (not
shown) routed to the electrical box 120.
[0036] FIG. 4A is a front perspective view of an embodiment of a
wiring module 460 having internal push-wire connectors 407. The
wiring module 460 has a mounting bracket 406 with an aperture 401
to mount the wiring module 460 to an adjustable plaster ring (e.g.,
140) and an aperture 402 to attach a protective cover (e.g., 161)
to the wiring module 460. The wiring module 460 also includes
shielded connectors 403 for receiving a functional module (e.g., an
outlet receptacle functional module or a switch functional
module).
[0037] FIG. 4B is a rear perspective view of the wiring module 460.
The wiring module 460 includes a screw terminal ground lanyard
connection point 452. In other embodiments, the ground lanyard
connection point is, for example, an internal push-wire connector,
a soldered joint, or a clamped joint. The wiring module 460 also
includes internal push-wire connectors 407 for receiving power
cables (e.g., hot, neutral, and ground power cables) routed to an
electrical box (e.g., 120). The internal push-wire connectors 407
can also be used for creating a ground connection between the
wiring module 460 and an electrical box (e.g., 120). For example,
the wiring module 460 could be mechanically and electrically
coupled to an electrical box via a pre-wired ground lanyard (e.g.,
180). The internal push-wire connectors 407 can be, for example,
any type of push-in connector housed wholly or partially within the
wiring module 460 for receiving power cables. In some embodiments,
the internal push-wire connectors 407 are stab-in connectors. The
wiring module 460 also includes a tab 405 that covers screw
terminals that are in electrical contact with individual ones of
the internal push-wire connectors 407. The screw terminals can be
used as an alternative to the internal push-wire connectors 407 if
desired.
[0038] The internal push-wire connectors 407 are particularly
advantageous in situations where space within the electrical box
160 is limited or in any other setting where it is desirable to
conserve space within the electrical box 160. This may be true, for
example, in relatively shallow walls (e.g., walls measuring less
than about 3.degree. from the outside edge of a wall stud to the
back wall). The internal push-wire connectors 407 conserve space
within the electrical box 160 (or allow for the usage of a
shallower depth electrical box 160) because they do not include a
length of wire between the wiring module and a connector as is the
case for the embodiment illustrated in FIG. 2 having external
push-wire connectors 250. While such external push-wire connectors
250 are desirable under some circumstances, the internal push-wire
connectors of FIGS. 3-4 can result in space and cost savings due to
the elimination of wire joining the connectors (e.g., 250) to the
wiring module (e.g., 260). It should be understood that the wiring
module 460 with internal push-wire connectors can be used with or
without a pre-wired ground lanyard (e.g., 180).
[0039] FIG. 5 illustrates a pre-wired power distribution system
embodiment 500 having a 3-gang electrical box 520, a 3-gang
adjustable plaster ring 540, a ground bus bar 550 mounted directly
to the electrical box 520, three wiring modules 560 attached to the
plaster ring 540 and a multiple wire ground lanyard 580. The ground
lanyard 580 extends between the bus bar 550 and ground terminals
562 on each of the wiring modules 560. The bus bar 550 is
configured to accept additional ground wires from power cables
routed to and from the electrical box 520. As such, the ground
lanyard 580 supports the plaster ring 540 in the open position
shown, providing a wiring platform for the electrician to wire all
three wiring modules 560 as a unit without having to handle and
hold each of the wiring modules individually during the wiring
process.
[0040] Advantageously, the bus bar 550 is configured to allow the
attachment of multiple ground wires 580 so as to provide ground
connections for not only wiring modules, but also power cables
routed in and out of the electrical box 520. The bus bar 550 has a
plurality of sections 552 and individual terminals 551 within each
section. In an embodiment, there is one section 552 corresponding
to each of the wiring modules 560 and multiple terminals 551 in
each section. Each of the sections can be in electrical contact or
electrically isolated. In this manner, ground wiring capacity
increases with the size and electrical device mounting capacity of
the electrical box 520. Each terminal 551 is configured to accept a
ground wire 580 from either a wiring module 560 or an attached
power cable. In a 3-gang embodiment, the bus bar 550 has three
sections corresponding to three wiring modules, and each section
has four terminals configured to accept up to four ground wires,
though other numbers of sections and terminals are also possible.
The bus bar 550 advantageously eliminates the need for pigtail
ground connections or the equivalent use of electrical device
terminals. The bus bar 550 can be configured for use with external
push wire connector wiring modules 260 (FIG. 2), internal push wire
connector wiring modules 360 (FIG. 3) or any electrical devices
having push-wire, screw terminal or similar wire connectors.
[0041] Although described and illustrated herein with respect to 1-
and 3-gang embodiments, a pre-wired power distribution system can
be configured for any number of electrical devices, including
2-gang, 4-gang, and other many-gang embodiments. A pre-wired power
distribution system 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 art will appreciate many
variations and modifications.
[0042] FIG. 6 illustrates a modular integrated wiring system 600
utilizing universal electrical wiring component embodiments
800-1100. A floor bracket component 800, a stud bracket component
900, a box bracket component 1000 and an extended box bracket 1100
are included, providing adaptability for different electrical power
distribution designs. Each wiring component 800-1100 provides
mounting flexibility by adjusting to various wall dimensions, stud
configurations, and electrical distribution point locations.
Specifically, each component 800-1100 has an adjustable depth into
the wall, guaranteeing a flush finish with the wall surface at
every electrical distribution point. In addition, the floor bracket
component 800 provides an adjustable height. The stud bracket
component 900 can be positioned at any height and provides an
adjustable distance between studs. The box bracket component 1000
can be positioned at any height, and the extended box bracket
component 1100 can be positioned at any height and at various
locations between studs. Further, each wiring component 800-1100
accommodates a variety of functional modules, including various
outlets, switches, GFCI devices, and motion detectors to name few.
Advantageously, the color of the functional modules and even some
functionality can be readily changed at anytime without rewiring,
as described below. The resulting modular integrated wiring system
600 has the labor saving advantages of prefabrication with the
design and installation flexibility of individually configured and
wired components.
[0043] A universal electrical wiring component combining modular
electrical devices and an adjustable, modular mount is described
with respect to FIG. 7, below. A floor bracket component 800 is
described in further detail with respect to FIG. 8, below. A stud
bracket component 900 is described in further detail with respect
to FIG. 9, below. A box bracket component 900 is described in
further detail with respect to FIG. 9, below, and an extended box
bracket component 1100 is described in further detail with respect
to FIG. 11, below. Adjustable mounts are described in detail with
respect to FIGS. 12-16, below.
[0044] FIG. 7 further illustrates a universal electrical wiring
component 700 having an adjustable mount 705 combined with a wiring
module 701. The adjustable mount 705 includes a bracket 707 and a
box assembly 1200. The bracket 707 can be, for example, a
vertically adjustable floor bracket 1300 (FIG. 13), a horizontally
adjustable stud bracket 1400 (FIG. 14), a box bracket 1500 (FIG.
15), or an extended box bracket 1600 (FIG. 16). The box assembly
1200 is mounted to the bracket 707 and the wiring module 701 is
mounted in the box assembly 1200. The wiring module 701 may be a
regular wiring module 710 or a GFCI wiring module 720. The
adjustable mount 705 is configured to position the wiring module
701 at any of various locations within a building wall. The wiring
module 701 is configured to connect to a source of electrical power
and to removably accept a functional module 703. Advantageously,
the combination of adjustable mount and wiring module form a
universal electrical wiring component that can implement a variety
of electrical distribution points of an electrical system. For
example, a universal electrical wiring component can accept various
outlet modules 750-760 and can be adjusted to implement a wall
outlet. As another example, a universal electrical wiring component
can accept various switch modules 740 and can be adjusted to
implement a switch outlet. A universal electrical wiring component
200 may be, for example, a floor bracket component 800 (FIG. 8), a
stud bracket component 900 (FIG. 9), a box bracket component 1000
(FIG. 10) or an extended box bracket component 1100 (FIG. 11). A
cover 704 may be used to protect a wiring module 701 from damage
prior to functional module installation.
[0045] FIG. 8 illustrates a floor bracket component 800 having a
wiring module 701 and an adjustable mount comprising a box assembly
1200 and a floor bracket 1300. In this embodiment, the floor
bracket 1300 provides the wiring module 701 an adjustable height
from the floor and the box assembly 1200 provides the wiring module
701 an adjustable distance from the box assembly 1200 for a flush
position with a wall surface.
[0046] FIG. 9 illustrates a stud bracket component 900 having a
wiring module 701 and an adjustable mount comprising a box assembly
1200 and a stud bracket 1400. In this embodiment, the stud bracket
1400 provides the wiring module 701 an adjustable distance between
studs and the box assembly 1200 provides the wiring module 701 an
adjustable distance from the box assembly 1200 for a flush position
with a wall surface.
[0047] FIG. 10 illustrates a box bracket component 1000 having a
wiring module 701 and an adjustable mount comprising a box assembly
1200 and a box bracket 1500. In this embodiment, the box bracket
1500 allows positioning of the wiring module 701 along a vertical
stud. Also, the box assembly 1200 provides the wiring module 701 an
adjustable distance from the box assembly 1200 for a flush position
with a wall surface.
[0048] FIG. 11 illustrates an extended box bracket component 1100
having a wiring module 701 and an adjustable mount comprising a box
assembly 1200 and an extended box bracket 1600. In this embodiment,
the extended box bracket 1600 allows vertical positioning of the
wiring module 701 along a stud and horizontal positioning between
studs. Also, the box assembly 1200 provides the wiring module 701
an adjustable distance from the box assembly 1200 for a flush
position with a wall surface.
[0049] FIG. 12 illustrates a box assembly 1200 having a junction
box 1800, an adjustable plaster ring 1700 and a support arm 1900.
The plaster ring 1700 removably attaches to the junction box 1800
and a wiring module 701 (FIG. 7) attaches to the plaster ring 1700.
The plaster ring provides the wiring module 701 (FIG. 7) with an
adjustable distance from the junction box 1800, as described in
detail with respect to FIG. 17. The junction box 1800
advantageously has an attached ground wire that can be quickly
connected to a wiring module 701 (FIG. 7). The plaster ring 1700
has slotted fastener apertures so that the plaster ring 1700 along
with an attached wiring module can be removed from, and reattached
to, the junction box 1800 by merely loosening and tightening,
respectively, the fasteners. The support arm 1900 attaches to the
back of the junction box to provide support against an inside wall
surface, as described in further detail with respect to FIGS.
19A-D, below.
[0050] FIG. 13 illustrates a floor bracket 1300 having an open
front 1301 and ruled sides 1310. The floor bracket 1300 has tabs
1320 for attaching the bracket 1300 to one or both of a floor joist
or a wall stud. Side grooves 1330 allow fasteners to attach the
junction box 1800 at an adjustable height from the floor. Conduit
supports 1340 are adapted for attachment to conduits running to the
junction box 1800. The plaster ring 1700 is attached to the box
1800 through the open front 1301 so that the plaster ring 1700 can
be removed from the box 1800 without removing the box 1800 from the
bracket 1300.
[0051] FIG. 14 illustrates a stud bracket 1400 having a horizontal
bar 1401 and ends 1403. The ends 1403 are folded perpendicularly to
the bar 1401 and adapted to secure the bracket 1400 horizontally
between wall studs. The bar 1401 has grooves 1410 and a slot 1420
that extend horizontally to proximate both ends 1403 of the bracket
1400. The grooves 1410 are adapted to slideably retain
corresponding box tongues 1812 (FIG. 18). The slot 1420 is centered
between the grooves 1410 and accommodates a fastener that secures
the junction box 1800 to the bracket 1400 while allowing the box to
slideably adjust in position along the bar 1401. The plaster ring
1700 is attached to the box 1800 and can be removed from the box
1800 without removing the box 1800 from the bracket 1400.
[0052] FIG. 15 illustrates a box bracket 1500 having a stud
mounting face 1501 and a box mounting face 1503. The stud mounting
face 1501 is disposed perpendicular to the box mounting face 1503
and is adapted to fasten to a wall stud. Either side of the
junction box 1800 attaches to the box mounting face 1503. The box
mounting face 1503 has a keyhole slots 1511 allowing the junction
box 1800 to fasten and unfasten to the bracket 1500 without
removing the fasteners 1520. The stud mounting face 1501 has a
plurality of mounting holes 1610 to accommodate fasteners that
allow the junction box 1800 to be positioned along a stud.
[0053] FIG. 16 illustrates an extended box bracket 1600 having an
extended stud mounting face 1601 and a box mounting face 1603. The
box mounting face 1603 is disposed perpendicular to the extended
stud mounting face 1601 and is adapted to fasten to the junction
box 1800. The extended stud mounting face 1601 is adapted to fasten
to a wall stud. The extended stud mounting face 1601 has a
plurality of mounting holes 1610 spaced along the length of the
bracket 1600 to accommodate fasteners that allows the junction box
1800 to be position vertically along a stud and horizontally
between studs.
[0054] FIG. 17 further illustrates an adjustable plaster ring 1700
having a base ring 1710, an insert ring 1720 and adjusting screws
1730. The insert ring 1720 is slideably retained by the base ring
1710 and secured to the base ring 1710 by the adjusting screws
1730. The insert ring 1720 is adapted to mount a wiring module and
to adjust the wiring module position relative to the base ring 1710
in response to turning of the screws 1730. The base ring 1710 has
keyhole slots 1714 adapted to accommodate fasteners that attach the
plaster ring 1700 to a junction box. The keyhole slot 1714 allows
the plaster ring 1700 to fasten and unfasten to the junction box
without removing the fasteners.
[0055] FIG. 18 further illustrates a junction box 1800 having a
ground wire 1810, a tongue 1812 and knockouts 1814. The ground wire
1810, being pre-wired to the box, advantageously saves a
fabrication step on the job site. Further, the ground wire 1810 is
configured to insert into a push-wire connector on a pre-wired
wiring module, providing a plug-in function module with a path to
ground. The tongue 1812 stabilizes the box within a groove on a
stud bracket, if used. The knockouts 1814 provide attachment points
for power cable conduits.
[0056] FIGS. 19A-D further illustrate a support arm 1900 adapted to
attach to a back face of the junction box 1800 (FIG. 18) and
provide support against an inside wall surface. In particular, the
support arm 1900 has an attachment section 1901 and a support
section 1902 extending generally perpendicularly from one end of
the attachment section 1901. The attachment section is generally
planar having an inside face 1904 that is disposed against the
junction box 1800 and an opposite outside face 1905 that is
disposed distal the junction box 1800. The support section 1902 has
a support face 1907 that is disposed against an inside wall
surface. The attachment section 1901 has an adjustment slot 1910, a
fastener hole 1920, and a plurality of bending slots 1930
distributed along and extending perpendicularly across the
adjustment slot 1910. The attachment section 1901 is configured to
bend along one of the bending slots 1930 so as to provide a
variable length support extending generally normal to the junction
box back face. The support arm 1900 is held to the box 1800 with a
fastener that is slideable along the adjustment slot 1910,
providing an adjustable support arm position.
[0057] 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.
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