Electrical outlet assembly

[0002] This invention relates generally to the installation of outlet devices in outlet boxes or device brackets as components of an electrical distribution system. More particularly, the invention relates to a unique assembly of an outlet device and device bracket that will allow the installer to use one hand in assembling these components in the field.

[0003] Outlet devices have been provided in outlet boxes or device brackets in the past usually be providing two threaded fasteners one at each end of the outlet device, and requiring the installer to use two hands in the process of threading the screws in place, that is threading the screws into the outlet box or device bracket.

[0004] An improvement to this prior art technology has been to provide for snapping the outlet device into a recess provided for it in the device bracket or outlet box, so that opposed projecting portions fit into recess openings. Here again, two hands have generally been required to properly align these components in the process of installation.

[0005] Such prior art snap in installation techniques are shown in the following U.S. Patent. U.S. Pat. No. 3,662,085, Robinson et al. shows ratchet-type teeth at opposed ends of the outlet device that are in turn received in interlocking relationship inside the bracket that supports the outlet plug.

[0006] A similar approach is shown in U.S. Pat. No. 5,223,673, to Mason where internal serrations are provided within the outlet box that cooperate with serrations provided on the edges of the outlet device for anchoring the components together.

[0007] Other examples of such snap in outlet devices can be seen in U.S. Pat. No. 4,500,746 issued to Meehan, Feb. 19, 1985. Here again, accurate alignment must be provided between the components in order to assemble them, so as to require the use of two hands in order to accomplish this task in the field.

[0008] Still another prior art approach utilizes threaded fasteners, generally provided in the outlet plug or device, for insertion into openings in the outlet box cover. U.S. Pat. No. 5,594,205 issued to Rogers et al. Jan. 14, 1997, shows such an arrangement for a surface mounted outlet box. The outlet box cover is provided with openings of unique shape to slidably receive the threaded fasteners normally provided on the ends of the outlet plug. The '205 patent shows the fasteners slidably received in the openings of the outlet so anchored in place as to require unthreading for removal.

[0009] The general purpose of the present invention is to provide an improvement over the above-mentioned prior art where an installer can use one hand to place the electrical device in an outlet box or device bracket, by hooking one end of the outlet device in place and snapping the opposite end into position with a minimum of aligning required between the two components.

[0010] In accordance with the present invention, and in the environment of an electrical distribution system having wires that are accessed at predetermined locations for installation of electrical devices, the electrical devices and device brackets are preferably of molded polymeric material. The electrical device has a housing defining at least one socket defining portion in a front face thereof, and means is provided for coupling the wires to this socket rearwardly of the front face of the outlet device.

[0011] The device bracket is provided with a relieved cavity for receiving the outlet device, and the device bracket has opposed keeper openings adjacent the ends of the cavity.

[0012] The housing of the device further includes rearwardly projecting portions provided at opposite ends of the socket defining portion thereof, and one of these rearwardly projecting portions has a rigid hook shape adapted to fit into one of the opposed keeper openings in the device bracket. The other of the projecting portions is resiliently deformable and defines an abutment or offset end portion which is adapted to be forced into the other of the opposed keeper openings in the device bracket.

[0013] FIG. 1 is an exploded perspective view illustrating the various components of the present invention together with the environment in which they reside.

[0014] FIG. 2 is a perspective view of the underside of the outlet device or plug illustrated in FIG. 1.

[0015] FIG. 3 is an elevational view of the outlet device of FIG. 2.

[0016] FIG. 4 is a rear view of the outlet device illustrated in FIGS. 2 and 3.

[0017] FIG. 5 is a perspective view of the outlet device showing the various components in exploded relationship.

[0018] FIGS. 6, 7 and 8 show in side elevation the method of assembly provided for with this invention.

[0019] FIG. 1 shows an outlet box 10 which is adapted to be fitted with a polymeric double gang device bracket 12 suitable for receiving either a data communications outlet or an outlet plug such as that depicted at 14 in FIG. 1. It will apparent that the outlet box 10 might itself define the cavities or recesses that are adapted to receive the device 14, and the present invention utilizes the term device bracket to identify either a bracket type component such as that illustrated at 12 in FIG. 1, or a junction box similar to that shown at 10 in FIG. 1 but adapted to itself receive outlet devices such as that illustrated at 14 in FIG. 1. Thus, a device bracket need not be a separate such as that depicted at 12 in FIG. 1.

[0020] The components of FIG. 1 are intended for use in a typical electrical distribution system, and more particularly for a system of the surface mounted raceway type. The box 10 can be seen to have knock out openings 10aand 10bwhich are adapted to accommodate raceway (not shown) of the type adapted to carry wiring to or from the box 10 in accordance with conventional electrical distribution systems of this type. The present invention seeks to simplify the manner in which an outlet device such as that illustrated at 14 can be assembled with such an outlet box. As shown, the outlet box is provided with a device bracket 12 that can be preassembled with the box 10, or as mentioned previously can be molded integrally with the box all in accordance with conventional practice.

[0021] The device bracket 12 includes openings 12aand 12bwhich provide relieved cavities for receiving the outlet device 14 and other electrical devices of this type. For example, other such electrical devices might comprise electrical switches, data communication socket configurations, and telephone jacks or the like.

[0022] Still with reference to the device bracket 12 the relieved cavities 12aand 12bfurther define opposed keeper openings 12cand 12dwhich are disposed on the end portions of these cavities 12aand 12brespectively.

[0023] Turning next to a detailed description of FIGS. 2, 3, 4 and 5, the electrical outlet plug or device 14 can be seen to comprise a molded polymeric housing 14ahaving socket defining portions in a front face 14bthat will accommodate a conventional electrical outlet plug. As shown two such socket defining portions are provided in the duplex outlet plug shown.

[0024] The outlet device 14 includes conventional internal means for coupling the wires (not shown) to these socket defining portions, and terminal screws indicated generally at L, N and G are provided for convenience in connecting these wires to such means within the housing 14a.

[0025] In accordance with the present invention the electrical device 14 has rearwardly projecting portions 14cand 14darranged at opposite ends of the socket defining portion of the device, and the first mentioned such rearwardly projecting portion 14cis of relatively rigid configuration and defines a hook 14ethat can be inserted into one of the opposed keeper openings 12cor 12din the device bracket 12 during the process of assembling the electrical device with the bracket 12.

[0026] At the opposite end of the electrical device 14 a second rearwardly projecting portion 14dis formed with a reduced cross-section, as indicated at 14f, so as to be resiliently deformable, and consequently capable of entering the other or the second of the opposed keeper openings 12cor 12din the device bracket 12 as a result of pushing or applying pressure to the end 14gof the electrical device 14 at assembly.

[0027] In summary, the one end of the electrical device 14 associated with the rigid hook 14cis adapted to being first received in one of the keeper openings provided for this purpose in the device bracket, and the opposite or second end 14gof the electrical device is fitted with a resilient leg or wing portion 14gthat must be forcibly received in its associated keeper opening at the opposite end of the device bracket 12. As an added measure of security a rapid insertion or conventional threaded fastener can be inserted into an opening 14hat the end 14gof the device 14, and may also be received in a corresponding opening 10cor 12ein the box 10, as an added measure of security or tamper resistance for anchoring the electrical device 14 in place. The opening 14hcan be concealed by a cover 14i.

[0028] Other variations of the present invention will occur to those skilled in the art. For example, the outlet box 10 is not an essential element of the present invention since all that is required is a device bracket such as that illustrated at 12 in order to receive an electrical device of the type shown for example at 14 in the drawings. A particularly appropriate application of the present invention can be found in a surface mounted raceway system of the type employing device brackets within the raceway itself. Such an environment does not require junction boxes. Several device brackets would be provided in such a raceway, and is an important feature of the present invention that such device brackets have the attributes of the trim ring device bracket 12 shown in the drawings, where relieved cavities are provided to receive the electrical devices, and keeper openings are provided at the opposed ends of these cavities for receiving either the hooked end portion of the device or receiving the rearwardly projecting resilient wing portion at the other end of the devices.

[0029] In light of the above, it is therefore understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described