U.S. patent number RE31,033 [Application Number 06/251,929] was granted by the patent office on 1982-09-21 for electrical power distribution assembly.
Invention is credited to Stephen A. Machcinski, Lester E. Wilson, Jr..
United States Patent |
RE31,033 |
Wilson, Jr. , et
al. |
September 21, 1982 |
Electrical power distribution assembly
Abstract
An electrical power distribution assembly having over and under
contacts is disclosed. In the preferred embodiment, the electrical
power distribution assembly utilizes stacked upper and lower
contact decks, each having two independent electrical circuits to
provide a four circuit plug-in distribution assembly. Using modular
components, the distribution assembly can be configured to provide
switched and unswitched outputs as well as switched taps for the
electrical power circuits.
Inventors: |
Wilson, Jr.; Lester E.
(Bedford, MA), Machcinski; Stephen A. (Winthrop, MA) |
Family
ID: |
26941904 |
Appl.
No.: |
06/251,929 |
Filed: |
April 7, 1981 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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Reissue of: |
893398 |
Apr 4, 1978 |
04148546 |
Apr 10, 1979 |
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Current U.S.
Class: |
439/654; 439/687;
439/724 |
Current CPC
Class: |
H02G
3/16 (20130101); H01R 31/02 (20130101) |
Current International
Class: |
H02G
3/16 (20060101); H01R 31/02 (20060101); H01R
31/00 (20060101); H01R 013/10 () |
Field of
Search: |
;339/19,192,193,194,198C,205,222 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: McGlynn; Joseph H.
Attorney, Agent or Firm: Birch; Richard J.
Claims
What we claim and desire to secure by Letters Patent of the United
States is:
1. An electrical power distribution assembly comprising:
(1) a electrically insulating, electrical contact deck means
having:
(a) first and second, spaced generally planar surfaces;
(b) means defining a peripheral edge between said surfaces;
(c) means defining at least two electrical contact channels in the
first surface and at least two congruent electrical contact
channels in the second surface, said contact channels each
extending from one location on the peripheral edge to at least one
other location on the peripheral edge;
(2) a first electrical contact positioned within one of said
contact channels in the first surface and extending between said
one peripheral edge location and the other location, said
electrical contact having a portion thereof extending around the
peripheral edge of the .[.first.]. .Iadd.electrical contact
.Iaddend.deck means at each location and into the congruent channel
in the second surface along a portion thereof; and,
(3) a second electrical contact positioned within the second
surface channel that is congruent to the other of said first
surface contact channels, said second electrical contact extending
between said one peripheral edge location and the other location
and having a portion thereof extending around the peripheral edge
of the deck means at each location and into said other first
surface channel along only a portion thereof.
2. An electrical power distribution assembly comprising:
(1) a first electrically insulating, electrical contact deck means
having:
(a) first and second, spaced generally planar surfaces;
(b) means defining a peripheral edge between said surfaces;
(c) means defining at least two electrical contact channels in the
first surface and at least two congruent electrical contact
channels in the second surface, said contact channels each
extending from one location on the peripheral edge to at least one
other location on the peripheral edge;
(d) a first electrical contact positioned within one of said
contact channels in the first surface and extending between said
one peripheral edge location and the other location, said
electrical contact having a portion thereof extending around the
peripheral edge of the first deck means at each location and into
the congruent channel in the second surface along only a portion
thereof;
(e) a second electrical contact positioned within the second
surface channel that is congruent to the other of said first
surface contact channels, said second electrical contact extending
between said one peripheral edge location and the other location
and having a portion thereof extending around the peripheral edge
of the deck means at each location and into said other first
surface channel along only a portion thereof.
(2) a second electrically insulating, electrical contact deck means
having:
(a) first and second, spaced generally planar surfaces;
(b) means defining a peripheral edge between said surfaces;
(c) means defining at least two electrical contact channels in the
first surface and at least two congruent electrical contact
channels in the second surface, said contact channels each
extending from one location on the peripheral edge to at least one
other location on the peripheral edge;
(d) a first electrical contact positioned within one of said
contact channels in the first surface and extending between said
one peripheral edge location and the other location, said
electrical contact having a portion thereof extending around the
peripheral edge of the second deck means at each location and into
the congruent channel in the second surface along only a portion
thereof; and;
(3) means for securing said first and second deck means in
superimposed relation with the first deck means contact channels
being congruent to the second deck means contact channels. .Iadd.
3. An electrical power distribution assembly comprising:
(1) an electrically insulating, electrical contact deck means
having:
(a) first and second, spaced generally planar surfaces;
(b) means defining an edge between said surfaces;
(c) means defining at least two electrical contact channels in the
first surface and at least two congruent electrical contact
channels in the second surface, said contact channels each
extending from one location on the edge to at least one other
location on the edge;
(2) a first electrical contact positioned within one of said
contact channels in the first surface and extending between said
one edge location and the other location, said electrical contact
having a portion thereof extending around the edge of the first
deck means at each location and into the congruent channel in the
second surface along a portion thereof; and,
(3) a second electrical contact positioned within the second
surface channel that is congruent to the other of said first
surface contact channels, said second electrical contact extending
between said one edge location and the other location and having a
portion thereof extending around the edge of the deck means at each
location and into said other first surface channel along only a
portion thereof. .Iaddend. .Iadd. 4. An electrical power
distribution assembly comprising:
(1) a first electrically insulating, electrical contact deck means
having:
(a) first and second, spaced generally planar surfaces;
(b) means defining an edge between said surfaces;
(c) means defining at least two electrical contact channels in the
first surface and at least two congruent electrical contact
channels in the second surface, said contact channels each
extending from one location on the edge to at least one other
location on the edge;
(d) a first electrical contact positioned within one of said
contact channels in the first surface and extending between said
one edge location and the other location, said electrical contact
having a portion thereof extending around the edge of the first
deck means at each location and into the congruent channel in the
second surface along only a portion thereof;
(e) a second electrical contact positioned within the second
surface channel that is congruent to the other of said first
surface contact channels, said second electrical contact extending
between said one edge location and the other location and having a
portion thereof extending around the edge of the deck means at each
location and into said other first surface channel along only a
portion thereof;
(2) a second electrically insulating, electrical contact deck means
having:
(a) first and second, spaced generally planar surfaces;
(b) means defining an edge between said surfaces;
(c) means defining at least two electrical contact channels in the
first surface and at least two congruent electrical contact
channels in the second surface, said contact channels each
extending from one location on the edge to at least one other
location on the edge;
(d) a first electrical contact positioned within one of said
contact channels in the first surface and extending between said
one edge location and the other location, said electrical contact
having a portion thereof extending around the edge of the second
deck means at each location and into the congruent channel in the
second surface along only a portion thereof; and,
(3) means for securing said first and second deck means in
superimposed relation with the first deck means contact channels
being congruent to the second deck means contact channels.
.Iaddend.
Description
BACKGROUND OF THE INVENTION
The present invention relates to electrical power distribution
assemblies in general and, more particularly, to an electrical
power distribution assembly having over and under electrical
contacts.
The use of modular, removable wall panels, lighting components and
other fixtures in offices and buildings is well known to those
skilled in the art. Various plug-in assemblies, and cables have
been suggested to minimize the amount of conventional hard wiring
of electrical power, lighting and communication circuits in and
between such wall panels, lighting components and fixtures.
It is a general objective of the present invention to provide an
improved electrical power distribution assembly.
It is a specific objective of the invention to provide an
electrical power distribution assembly that utilizes modular
components to obtain a wide variety of circuit configurations.
It is another objective of the invention to provide maximum
electrical contact density within the assembly while maintaining
circuit integrity for a plurality of circuits.
It is a another feature of the invention that the electrical power
distribution assembly maintains a given physical circuit contact
location to provide a uniform system-wide circuit coding.
It is still another feature of the invention that the electrical
power distribution assembly can accept an assembly of plug-in
electrical connectors having a common electrical contact
orientation while maintaining electrical separation of the
distributed power circuits.
BRIEF DESCRIPTION OF THE INVENTION
The electrical power distribution assembly has a generally planar
electrical contact deck and a plurality of electrical contacts
mounted thereon in spaced relation on both the "upper" and "lower"
surfaces of the deck. The electrical contacts wrap-around the edge
of the deck from the upper surface to the lower surface and vice
versa to provide "over" and "under" contacts.
A four circuit assembly is provided by assembling two electrical
contact decks in superimposed relation with two electrical circuits
on each deck. In this "quad" version, the ground and neutral
circuits are on one deck, while the two power circuits are on the
upper deck. This configuration is especially suited for power and
lighting circuits in offices and other locations having modular
and/or movable walls and lighting fixtures.
The above-listed objectives and features and other objectives and
features of the invention will best be understood from a detailed
description of a preferred embodiment of the invention selected for
purposes of illustration and shown in the accompanying drawings, in
which:
FIG. 1 is a view in perspective showing a three deck, six circuit
version of the electrical power distribution assembly of the
present invention and the associated six contact plug;
FIG. 2 is an exploded view in perspective of a two deck, four
circuit version of the electrical power distribution assembly of
the present invention showing the two electrical contact decks, two
contacts positioned on the lower deck and the split housing
shells;
FIG. 3 is a plan view of one configuration of the electrical
contact;
FIG. 4 is a plan view of another configuration of the electrical
contact that is electrically the same as the contact shown in FIG.
3, but mechanically formed by folding two arms of the "H"-shaped
stamped contact;
FIG. 5 illustrates in plan view an asymmetrical length "L"-shaped
electrical contact;
FIG. 6 depicts a three arm electrical contact in plan view;
FIG. 7A illustrates in plan view the upper and lower electrical
contacts on one of the contact decks;
FIG. 7B illustrates diagrammatically the circuitry of the FIG. 7A
contacts;
FIG. 7C illustrates in plan view the upper and lower contacts on
the other of the contact decks;
FIGS. 8A through 17A depict in plan view other configurations of
the upper deck electrical contacts;
FIGS. 8B through 17B depict diagrammatically the electrical
circuitry of the corresponding electrical contacts shown in FIGS.
8A through 17A;
FIGS. 18A through 22A illustrate in plan view various housing
configurations for the electrical power distribution assembly;
FIGS. 18B through 22B depict the corresponding electrical contact
decks for use with the housings shown in FIGS. 18A through 22A;
FIGS. 21C and 22C illustrate the electrical contacts for use in the
contact decks of FIGS. 21B and 22B, respectively.
FIG. 23 illustrates in perspective view a snap fastening cap for
covering one of the output contact assemblies shown in FIG. 1;
FIG. 24 illustrates diagrammatically a four circuit, ("Red",
"Black", "White" neutral and "Green" ground) cable assembly with
the "red" and "black" circuits reversed; and,
FIGS. 25 through 31 depict other cable configurations with the
White neutral and Green ground circuits omitted for purposes of
clarity.
DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT
Turning now to the drawings and particularly to FIGS. 1 and 2
thereof, there is shown an electrical power distribution assembly
constructed in accordance with the present invention and indicated
generally by the reference numeral 10. The term "electrical power"
as used therein refers to AC and DC and includes communication
circuits with modulated carriers.
The major components of the electrical power distribution assembly
10 comprise one or more electrical contact decks 12 having
generally planar upper and lower surfaces 14 and 16, respectively,
and a peripheral edge 18. The upper surface has a plurality of ribs
20 that define at least two electrical contact channels 22 and 24
which extend from one peripheral edge location to at least one
other peripheral edge location. Corresponding ribs 26 on the lower
surface define congruent contact channels 28 and 30 which extend
from one peripheral edge location to at least another location on
the peripheral edge.
Each deck has one or more electrical contacts 32 positioned within
the deck contact channels as shown in FIG. 2. The configuration of
the FIG. 2 electrical contacts is illustrated in FIG. 3 and 4. Both
Figures depict electrically identical contacts. The FIG. 3 contact
is formed by stamping or cutting the contact from a sheet of
electrically conductive material. This method of fabrication is
wasteful of material. FIG. 4 shows a more economic way of producing
the contact 32 by folding two arms 32a and 32b of an "H"-shaped
contact.
Looking back at FIG. 2, it can be seen that each contact has a
portion 32c that is folded around the peripheral edge of the deck
and into the corresponding congruent contact channel. As viewed in
FIG. 2, the lower surface contact is folded upwardly into the upper
surface channel 20 while the upper surface contact is folded
downwardly into the lower surface channel 30. This arrangement
produces an over/under configuration for adjacent electrical
contacts with the contacts vertically spaced apart.
Each deck has a plurality of upwardly extending spacers 33 that
maintain the decks in spaced electrically separate, relationship
when the decks are stacked together as shown in FIGS. 1 and 2. FIG.
1 illustrates a three deck, six input circuit arrangement while
FIG. 2 illustrates a two deck, four input circuit configuration.
The decks are formed, preferably by molding, from an electrically
insulating material. Thermosettable or thermoplastic materials can
be used as desired.
The deck or decks 12 are assembled in superimposed relation with
identical housing shells 34 having rivet holes 35. The resulting
assembly is secured together by suitable means such as by rivets
36. The assembled electrical power distribution assembly 10 can be
plugged into a corresponding cable assembly indicated generally by
the reference numeral 38 in FIG. 1. By way of illustration only,
the cable assembly 38 terminates in a plurality of electrical
connectors 40 of the type described in U.S. Pat. Nos. 3,218,599 and
3,259,870.
FIGS. 5 and 6 illustrate (together with FIGS. 3 and 4) electrical
contacts that are employed to achieve the circuit variations shown
in FIGS. 7 through 17. These Figures depict three and four circuit
arrangements, using a pair of contact decks as shown in FIG. 2. The
"upper" deck shown in plan view in FIGS. 7A through 17A contains
the "power circuits," while the lower deck shown once in FIG. 7C
contains the "ground" and "neutral" circuits. For ease of
description, the two power circuits have been identified in the
Figures as the "Red" and "Black" circuits 40 and 42. The ground and
neutral circuits 44 and 46, respectively, are depicted only in FIG.
7C. However, these circuits on the "lower" contact deck are
repeated for each of the circuit configurations shown in FIGS. 8A
through 17A. It should be understood that the terms "upper" and
"lower" are used only by way of illustration and both the decks and
circuits can be reversed or the circuits can be varied on the two
decks.
Looking at FIGS. 7A and 7B, there is shown a threeway distribution
of two circuits, "Red" and "Black" to three outputs. FIG. 7B
illustrates diagrammatically the circuit of the FIG. 7A electrical
contacts. The "Black" and "Red" circuit contacts are either a FIG.
3 or 4 contact.
FIGS. 8A and 8B depict a switched "Black" circuit and an unswitched
"Red" circuit. The "Black" circuit employs a FIG. 6 contact while
the "Red" circuit uses a FIG. 5 "L"-shaped contact. The "Black"
circuit also uses a symmetrical length "L"-shaped contact.
FIGS. 9A and 9B show switched "Black" and "Red" circuits using both
symmetrical and asymmetrical "L"-shaped contacts.
FIGS. 10A and 10B show a switched "Red" circuit and an unswitched
"Black" circuit. The "Red" circuit uses a FIG. 6 contact and a
symmetrical "L"-shaped contact while the "Black" circuit uses both
symmetrical and asymmetrical "L"-shaped contact. Compare this
circuit with the FIG. 8A-8B circuit.
FIGS. 11A-11B and 12A-12B depict, respectively, "Black" only two
switched circuit outputs and "Red" only two switched circuit
outputs. In each case, a FIG. 6 contact (flipped over) is used
together with an a symmetrical "L"-shaped contact.
FIGS. 13A and 13B show a circuit configuration that provides a
"Red" and "Black" output, a single "Red" output and a single
"Black" output. The "Black" circuit uses a FIG. 6 contact while the
"Red" circuit uses a flipped over FIG. 6 contact.
FIGS. 14A-14B and 15A-15B show, respectively, an arrangement for
two "Red" and "Black" outputs and a single "Red" output (FIGS.
14A-14B) and two "Red" and "Black" outputs and a single "Black"
output (FIGS. 15A-15B). FIG. 14A uses a "Black" FIG. 6 contact and
a "Red" FIG. 3 or 4 contact. FIG. 15A employs a flipped over FIG. 6
contact for "Red" and a FIG. 3 or 4 contact for "Black".
FIGS. 16A-16b and 17A-17B illustrate, respectively, an all "Black"
or an all "Red" circuit using either the FIG. 3 or FIG. 4
contact.
FIGS. 18A through 22A depict in plan view the housing shell
configurations for: a single input and three outputs (FIG. 18A);
one input and two outputs and a blank station (FIG. 19A); one
input, one output and two blank stations (FIG. 20A); an
equi-angular "Y" shaped, one input and two outputs (FIG. 21A) and
the variation on the "Y" shape (FIG. 22A). The electrical connector
decks for the FIG. 18A-22A housings are depicted in plan view in
FIGS. 18B through 22B. The "Y"-shaped electrical contacts for the
FIGS. 21 and 22 configurations are shown in FIGS. 21C and 22C,
respectively.
Although the use of blank stations is desirable, as shown in FIGS.
19A and 20A, this requires special housings. One can more easily
cap off one of the stations on the quad housings of FIG. 18A by
using a flexible, snap-on insulating cap 48 as shown in perspective
view in FIG. 23.
It has already been mentioned that the electrical power
distribution assembly 10 can be part of a physically coded power
distribution system. Referring back to FIG. 7 through 17, it can be
seen that the "Red" circuit is always on the right-hand side when
looking into the power input of the assembly and when looking into
the power output of the assembly (excluding outputs to switches).
In order to maintain this coding from one distribution assembly to
another, a reversing cable 50 shown diagrammatically in FIG. 24 is
used. This cable reverses the physical positions of the "Red" and
"Black" circuits. The corresponding "White" neutral and "Green"
ground circuit physical positions are also reversed.
FIGS. 25 and 26 illustrate straight "Black" and "Red" circuit pairs
for use in switching circuits. FIGS. 27 and 28 show single circuit
"Red" and "Black" cables with physical reversal. The neutral and
ground circuits have been omitted from FIGS. 25-28 for purposes of
clarity.
FIGS. 29-31 illustrate a single "Red" cable, a single "Black" cable
and a dual cable for direct connection to a power consuming device;
e.g., a lighting fixture. Again, the neutral and ground circuits
have been omitted for purposes of clarity.
Having described in detail a preferred embodiment of our invention,
it will now be apparent to those skilled in the art that numerous
modifications can be made therein without departing from the scope
of the invention as defined in the following claims.
* * * * *