Universal electrical module

[0001] The present patent application claims priority to provisional patent application Ser. No. 60/592,256 filed on Jul. 29, 2004 and titled “Universal Electrical Module.”

[0002] 1. Field of the Invention

[0003] The present invention relates to a universal electrical module that improves ease and speed of installation of electrical devices during building construction. More specifically, the present invention relates to a universal electrical module that facilitates the installation of different types of an electrical device by enabling a technician to simply insert prongs that extend from each of the electrical devices into matching slots on the universal electrical module.

[0004] 2. Description of Related Art

[0005] In the building industry, electrical boxes are typically installed during the framing of the building structure. Conduits such as electrical wires are drawn to the electrical boxes after the boxes are installed and connect the electrical boxes with each other and with a power disconnect, such as a circuit breaker. Instead, the individual electrical devices are lodged in the electrical boxes only after the wallboards are applied to the framing members. Such devices include single pole switches, three way switches, four way switches, and receptacles, which must all conform to U.S. building regulations related both to device construction and device installation.

[0006] The installation of each electrical device is a laborious task that is generally performed by hand by a trained electrician. As a building contains different types of electrical devices, each type of device must be connected to different connector wires inside the electrical box in order to operate properly, and the unused wires remaining in the electrical box are typically spliced together with a WIRE-NUT® brand twist on wire connector or similar components.

[0007] At the end of the installation process, all the wires within the electrical box are compressed inside the box by pushing the electrical device into the box. Power is prevented from flowing within the building circuit during the installation process, in order to protect the installation technicians, and is eventually released into the building circuit when the installation of the electrical devices is completed and the circuit is closed.

[0008] Therefore, there is a need to reduce the amount of handwork required to install electrical devices and to splice and connect wires after wallboard application.

[0009] There is also a need to reduce the level of skill required for the installation of electrical devices, and for the change-over from one type of device to another.

[0010] There is a further need to generate a flow of power as early as possible during the construction process, in order to have easy access to power.

[0011] There is an additional need to be able to install electrical devices without interrupting the flow of power once power has been released into the circuit.

[0012] In one embodiment, a universal electrical module is provided that facilitates the quick and safe installation of different types of electrical devices in an electrical box by enabling a technician to simply insert prongs extending from the electrical devices into matching slots on a first face of the universal electrical module. The universal electrical module is connected to the hot, ground and neutral wires of the building circuit by means of a bus on a second face of the module, and may be produced in different sizes to support one or more electrical devices. Additionally, meter reading slots may be provided on the first face to enable meter reading from the front face of the module.

[0013] In another embodiment, an electrical device is provided that comprises a plurality of prongs extending from the device, wherein each of the prongs is structured to mate with a slot on an electrical module.

[0014] In still another embodiment, a method is provided for making a universal electrical module that comprises the steps of providing a housing having a first face with a plurality of slots and a second face with a bus and a plurality of ports; of causing each of the slots to create contact with a bus portion or with one of the ports; and of providing a retention system that extends from the housing and that is shaped to retain the universal electrical module within an electrical box. Each of the slots is structured for mating with a prong that extend from an electrical device.

[0015] A primary advantage of the present invention to significantly reduce the time required to install electrical devices in a building after wallboard application.

[0016] Another advantage of the present invention is to reduce the time and skill level required to install electrical devices in a building, or for changing over from one type of device to another.

[0017] A further advantage of the present invention is to provide for the availability of power in a building structure during the framing stage without undue risk to the working personnel.

[0018] Yet another advantage of the present invention is to enable a safer installation of electrical devices during building construction or remodeling.

[0019] Still another advantage of the present invention is to provide for single or multiple gang modules having a single point of connection to a power, neutral, and ground source.

[0020] These and other advantages of the present invention will become apparent from a reading of the following description, and may be realized by means of the instrumentalities and combinations particularly pointed out in the appended claims.

[0037] Detailed descriptions of embodiments of the invention are provided herein. It is to be understood, however, that the present invention may be embodied in various forms. Therefore, the specific details disclosed herein are not to be interpreted as limiting, but rather as a representative basis for teaching one skilled in the art how to employ the present invention in virtually any detailed system, structure, or manner.

[0038] In accordance with one embodiment of the present invention, there are shown in FIGS. 1A-1C different views of a single gang universal electrical module 10 that is designed for positioning inside an electrical box. More specifically, FIG. 1A illustrates a front view of module 10, FIG. 1B illustrates a left side view, and FIG. 1C illustrates a rear view.

[0039] Module 10 comprises a front face 12, a rear face 30, and two retention plates 62 enabling the permanent positioning of module 10 into an electrical box. A plurality of slots, indicated with reference numerals 14, 16, 18, 20, 22, 24, 26 and 28, are located on front face 12, wherein slots 20, 26, and 28 are connected to a bus 32 on rear face 30, and slots 14, 16, 18, 22, and 24 are connected to ports 70, 72, 74, 76, and 78 also on rear face 30. More specifically, slot 20 is connected to a power-carrying (“hot”) portion 34 of first bus 32; slot 26 is connected to a ground portion 36 of first bus 32; and slot 28 is connected to a neutral portion 38 of first bus 32, and all the remaining slots are connected to a plurality of ports on rear face 30 as follows: slot 14 to port 76; slot 16 to port 74; slot 18 to port 72; slot 22 to port 70; and slot 24 to port 78. Among the slots connected to hot portion 34, slot 18 is designed as a “load” slot, slot 20 as a “power” or “line” slot, slot 26 as a “ground” slot, and slots 14, 16, 22, and 24 as “travelers,” because ports 70-78 are intended for connection with “traveler” wires. The relative positions of bus 32 and of ports 70-78 enable a comfortable access of an electrician's screwdriver during installation.

[0040] One skilled in the art will recognize that the terms “slots” and “prongs” employed in this written description and in the drawings herein are only exemplary of two types of contacts, and that other types of contacts, including contacts of shorter depths, fall within the scope of the present invention. In particular, contacts of different depths may be desired to conform to building regulations in certain areas where the invention is practiced.

[0041] In accordance with a further aspect of the present embodiment, bus 32 may be tested while an electrician faces front face 12 (for instance, after the universal electrical module has been installed in the electrical box). By accessing meter reading row 66 on first face 12, bus portions 34, 36, and 38 can be accessed from front face 12 and meter readings can be obtained. More specifically, hot meter slot 48 enables an electrician to test hot portion 34, while neutral meter slot 52 enables testing of neutral portion 38, and ground meter slot 50 enables testing of neutral portion 36.

[0042] The configuration of slots 14-28 enable the installation of different types of electrical devices on module 10. For the purpose of this description, “electrical devices” are defined as devices interconnected by a plurality of electrical conduits, for instance, by electrical wires that supply power from a power disconnect such as a circuit breaker. Different types of electrical devices are well known to one skilled in the art and comprise, among others, single pole switches, three way switches, four way switches, single receptacles, duplex receptacles, half switch receptacles, and single pole/receptacles.

[0043] The configuration of slots 14-28 shown in FIG. 1A is exemplary of one design choice. Slots 14-28 may also be arranged according to other design choices, all achieving the same purpose as the configuration shown in FIG. 1A. Further, slots 14-28 are shown in FIG. 1A as cylindrical in shape with round cross sections; however, slots 14-28 may be designed with a variety of different shapes, for instance, may be cylindrical with rectangular or star shaped cross-sections, or may be hemispherical. Likewise, the configuration of slot 26 shown in FIG. 1A is only exemplary of one of different design choices available for a ground slot.

[0044] The following Table I exemplifies how a few, exemplary electrical devices that may connect to the different slots illustrated in FIG. 1.

[0045]

	TABLE I
	Type of Electrical Device	Slots Connections
	Single Pole Switch	18 and 20
	Three Way Switch	14, 16, and 20
	Second Three Way Switch	22, 24, and 18
	Four Way Switch	14, 16, 22, and 24
	Receptacle	20, 28, and 26

[0046] Turning now to FIG. 2, there is shown a cross-section of module 10, as seen from the same side as a front side viewpoint. A plurality of contact plates 68 provide an electrical connection from the slots on front face 12 to the corresponding elements on rear face 30. The individual shapes of contact plates 68 may vary depending to the relative positions of each slot on front face 12 and of the corresponding element on rear face 30.

[0047] The operation of universal electrical module 10 may be better understood upon reference to FIGS. 3, 4A-B, and 5A-B, which illustrate the connection of a single pole switch 40 to single gang module 10. FIGS. 5A and 5B are the same as FIGS. 1A and 1C, and are reproduced here for the convenience of the reader.

[0048] Prongs 42 extend from single pole switch 40 and mate with slots 18 and 20, thereby enabling a proper functioning of single pole switch 40. More particularly, slot 18 operates as a “load” slot connected to port 72, while slot 20 operates as a “line” slot connected to hot portion 34. In the illustrated application, the ground prong of single pole switch 40 is plate-shaped, and is connected to ground slot 26 by means of a screw to eventually connect single pole switch 40 to ground portion 36. It should be noted that a single pole switch may also be configured to have two prongs arranged to mate with“load” slot 20 and with “neutral” slot 19.

[0049] Because module 10 is affixed to an electrical box 80 by means of retention plates 62, and because single pole switch 40 is affixed to module 10, single pole switch 40 becomes also affixed to electrical box 80.

[0050] FIGS. 6A-6H show a different application related to of a 3-way switch system employing an electrical module constructed according to the present embodiment of the universal electrical module. A first switch 84 (shown in FIG. 6A from a right side view and in FIG. 6B from a rear view) comprises three prongs, that are indicated by reference numerals 86, 88, and 90 and that extend from the rear face of switch 84. Prongs 86, 88, and 90 mate with slots 92, 94, and 96 on the front face of a module 98, wherein slot 92 and 94 are “travelers” and slot 96 is a “line” slot. In turn, slot 92 is connected to a port 100, slot 94 to a port 104, and slot 96 to a hot portion 106.

[0051] It should be noted that switch 84 comprises two plate-shaped ground prongs, to enable the connection with the ground slot on module 98 regardless of whether the switch is employed in an upside position, as in FIG. 6A, or on an upside-down position, as in FIG. 6H.

[0052] A second module 102 is connected to a second switch 105, wherein a prong 106 is connected to a “load” slot 108, and prongs 110 and 112 to traveler slots 114 and 116 (in turn, connected to ports 120 and 118). A first traveler wire (typically, a red conductor wire) connects port 104 with port 118, and a second traveler wire (typically, a black conductor wire) connects port 100 to port 120, closing the circuit.

[0053] FIGS. 7A-7D, 8A-8D, 9, 10A-10D, and 11A-11D illustrate other exemplary, non-limiting applications of the first embodiment. In particular, FIGS. 7A-7D illustrate the application related to a single receptacle 122, wherein receptacle 122 (shown in FIG. 7A with a front view and in FIG. 7B with a rear view) has two prongs 124 and 126 extending from the rear side, and mating with slots 128 and 130 on module 132, and wherein slot 128 is a “neutral” slot and slot 130 is a “power” slot. Instead, FIGS. 8A-8D and 9 illustrate the application related to a duplex receptacle 134, wherein receptacle 134 has two prongs 136 and 138 mating with slots 140 and 142 on module 144, and wherein slot 140 is a neutral slot, and slot 142 is a power slot. Further, FIGS. 10-10D illustrate the application related to a half switch receptacle 146, wherein three prongs 148, 150, and 152 mate with three slots 154, 156, and 158 on module 160, and wherein slot 154 is a “load” slot, slot 156 is a “neutral” slot, and slot 158 is a “power” slot. Still further, FIGS. 11A-11D illustrate the application related to a single pole/receptacle 162, wherein three prongs 164, 166, and 168 mate with slots 170, 172, and 174 on a module 176, and wherein slot 164 is a “load” slot, slot 166 is a “neutral” slot, and slot 168 is a “power” slot.

[0054] While FIGS. 6A-6H illustrates a 3-way switch system, a 4-way switch system that still employs a plurality of universal electrical modules constructed according to the present embodiment is illustrated in FIGS. 12A-12L. A first switch 180 comprises three prongs 181, 182, and 183 extending from its rear face and disposed as shown. Prongs 181 and 182 mate with slots 185 and 186 on the front face of a first module 184, which are “traveler” slots, while prong 183 mates with slot 187, which is a “line” slot. In turn, slots 185 and 186 are connected with ports 188 and 189 on the rear face of first module 184.

[0055] A second switch 190, having four prongs 191, 192, 193, and 194 disposed as illustrated, is connected to second module 195, wherein each of prongs 191, 192, 194, and 194 is mated with a traveler slot 196, 197, 198, and 198, as shown in FIGS. 12F-12G. In turn, traveler slots 196, 197, 198, and 199 are connected with traveler ports 200, 201, 202, and 202. Therefore, while both switches 180 and 190 operate as switches, their different position within the 4-way switch circuit provides for a different disposition of the prongs extending from each switch, in order to fit the relative position of each switch within the circuit, while the design of modules 184 and 195 is identical.

[0056] A third switch 204 is connected to a third module 205, wherein third switch 204 has three prongs 206, 207, and 207 extending from its rear face and mated with one load slot 209 and two traveler slots 210 and 212 on third module 205. Within third module 205, load slot 209 is connected with load port 214, and traveler slots 210 and 212 are connected with traveler slots 216 and 218. To close the circuit, a first traveler wire connect port 188 with port 201, and a second traveler wire (typically, both black conductor wires) connects port 203 with port 216. A third traveler wire connects port 189 with port 200, while a fourth traveler wire (typically, both red conductor wires) connects port 202 with port 218.

[0057] In other embodiments of the invention, the universal electrical module is built wider than a single gang, although still as a single component. As can be seen from FIGS. 13A-13D, 14A-14D, and 15A-15D, two equal or different electrical devices can be affixed to a universal electrical module 214 that is two gangs wide; three equal or different electrical devices can be affixed to a universal electrical module 216 that is three gangs wide, and four equal or different electrical devices can be affixed to a universal electrical module 218 that is four gangs wide.

[0058] In particular, FIGS. 13A-13C show front, left side, and rear views of two-gang module 214, while FIG. 13D is a cross-section of two-gang module 214 (as seen from the front side) showing contact plates 220 that correspond to the slots on the front face of two-gang module 214. As shown in FIG. 13C, one or more busses are provided on the rear face of two-gang module 214, enabling line (or power), neutral, and ground connections in the same manner as for single gang module 10. Likewise, meter reading slots 224, corresponding to bus 222, are provided on the front face of two-gang module 214, as well as one or more retention plates 226, to affix the module to the electrical box. The slots on the front face of two-gang module 214 are arranged in two equal groups, each positioned on adjacent portions of the front face.

[0059] FIGS. 14A-14C show front, left side, and rear view of three gang module 216, while FIG. 14D shows a cross-section of three-gang module 216 illustrating in detail the arrangement of contact plates 228. Again, the slots on the front face of three-gang module 216 are arranged in three equal groups, each positioned on adjacent portions of the front face. Instead, FIGS. 15A-15C show front, left side, and rear view of four-gang module 218, while FIG. 15D shows a cross-section of four-gang module 218 illustrating in detail the arrangement of contact plates 230. Once more, the slots on the front face of four-gang module 218 are arranged in three equal groups, positioned on adjacent portions of the front face.

[0060] Covers (not shown in the drawings) may be provided that snap over the open face of an electrical box that houses a universal electrical module. These covers shield the universal electrical module during wallboard installation, prior to installation of the desired electrical device.

[0061] A person skilled in the art will recognize from the foregoing that the present invention generates significant time savings during electrical installations in buildings, because the times required to install the different types of electrical devices are significantly reduced. It will be further recognized that the present invention eliminates the need for twist on wire connectors such as WIRE-NUT® brand twist on wire connectors, and for jumper wires during building construction, and that the safety of operators will be enhanced by reducing the possibility of human errors. Still further, it will be recognized that the present invention is suitable for use with all existing U.S. electrical boxes, wires, and wiring methods, and complies with present building codes.

[0062] Although these techniques and structures have been disclosed in the context of certain embodiments and examples, it will be understood by those skilled in the art that these techniques and structures may be extended beyond the specifically disclosed embodiments to other embodiments and/or uses and obvious modifications and equivalents thereof. Thus, it is intended that the scope of the structures and methods disclosed herein should not be limited by the particular disclosed embodiments described above.