Electrical interface module for power distribution junction box

Abstract

 An electrical interface module (30) for interconnecting a pair of electrical junction boxes, comprises a dielectric housing (32) having a pair of side walls (34) and a pair of end walls (36) joined together, where the walls define a generally rectangular shape having a pair of peripheral edges (38) for receiving cover members (40). The housing includes a plurality of through cavities (42) extending between the edges, with each cavity receiving a planar metal contact member (70) which extends beyond each edge. The contacts are essentially "Z" configured having a pair of laterally offset legs (76, 78). The cover members to be secured to the housing along the respective edges, include a like plurality of through slots (92) in registry with the contact legs (76,78), where the contact legs project through the slots in the assembled condition, for engagement with the pair of junction boxes.

Description

[0001] This invention relates to an improved power distribution system by the provision of a new electrical interface module that allows for the interconnection of a pair of junction boxes and the redistribution of a power source to multiple distributed circuits.

[0002] A power distribution system, as contemplated by this invention, and by the prior art described in U.S. Patent No. 5,073,120, assigned to the assignee hereof, is a wiring system to provide power to under access or raised floors and to the environmental or open air space above ceilings. As more fully described in said prior art, a major component of a power distribution system is a junction box or bussing distribution connector. Such connector includes a plurality of electrical bussing terminals positioned within an electrically insulative housing. A plurality of electrical terminals are positioned in the housing for distributing more than one electrical circuit; at least one ground terminal, at least one neutral terminal and at least three hot terminals. A grounding shell at least partially surrounds the bussing connector and includes a grounding tab grounding the one ground terminal to the metallic grounding shell. In another embodiment, two bussing connectors are interconnected together, to provide for an increased number of output ports. This alternative embodiment utilizes a jumper connector to join the two bussing connectors.

[0003] The present invention provides for an improved system of interconnecting a pair of junction boxes. The improvement hereof will become apparent from a reading of the following specification, particularly when read in conjunction with the accompanying drawings.

[0004] This invention relates to an electrical interface module for interconnecting a pair of electrical junction boxes for use in a power distribution system. The interface module comprises a unitary dielectric housing having a pair of side walls and a pair of end walls joined together to define a pair of spaced-apart peripheral edges. Within the housing are a plurality of through cavities extending between the peripheral edges, with each cavity receiving a planar metal contact member which extends beyond each peripheral edge. The contact is substantially "Z" configured having a pair of laterally offset legs. Finally, a pair of cover members are secured to the housing along the respective peripheral edges, where the cover members include a like plurality of through slots in registry with the contact legs so that the contact legs project through the slots in the assembled condition. In this assembled condition, the module can suitable join a pair of junction boxes to increase the capability of the power distribution system.

[0005] Embodiments of the invention will now be described by way of example with reference to the accompanying drawings in which:

FIGURE 1 is a perspective view, prior to electrical engagement, of an electrical distribution system according to the prior art, U.S. Patent No. 5,073,120, assigned to the assignee hereof, where such system consists of a junction box and a receptacle component.

FIGURE 2 is a perspective view, prior to electrical engagement, of an improved electrical distribution system according to the present invention, where the improved system includes a pair of junction boxes adapted to be electrically engaged by a single electrical interface module, as more fully described hereinafter.

FIGURE 3 is an exploded perspective view of the electrical interface module shown in Figure 2.

FIGURE 4 is an enlarged, perspective view of the housing forming part of the electrical interface module of this invention.

FIGURE 5 is a perspective view of the assembled electrical interface module of Figure 3.

FIGURE 6 is a perspective view of an array of contact terminals to be mounted within the housing of Figure 4.

FIGURE 7 is a perspective view of a grounding terminal to be mounted within the housing of Figure 4.

FIGURE 8 is a top plan view of the housing illustrated in Figure 4.

FIGURE 9 is a bottom view of the housing illustrated in Figure 4.

FIGURE 10 is a cross-sectional view taken along line 10-10 of the assembled interface module of Figure 5.

FIGURE 11 is a cross-sectional view taken along line 11-11 of Figure 5, illustrating the grounding terminal within its mounting cavity.

[0006] This invention relates to an improved power distribution system by the use of a new electrical interface module to connect a pair of junction boxes, such as taught in U.S. Patent No. 5,073,120, the contents of which is incorporated herein by reference.

[0007] Figure 1, illustrating the prior art connector of U.S. Patent No. 5,073,120, relates to a power distribution assembly comprising an electrical bussing connector 2 and a receptacle component 4. The bussing connector 2, the construction of which is more fully described in U.S. Patent Nos. 5,015,203, and 5,073,120, may comprise a pair of housing members 8,10, end caps 12, with plural bus bars mounted therein. Further, the bussing connector 2 includes plural electrical ports 14 at the ends thereof, where one port may be used as a power supply, with the remaining ports as receptacles for branch circuits for distribution of the power. Along the major side walls 16, a recess 18 is provided. Within said recess, the base 20 includes plural slots 22 communicating with the interior of the bussing connector 2, where the slots are aligned with respective bus bars mounted therewithin.

[0008] For engagement with said recess 18, i.e. "plugged into", a single receptacle component 4 is shown in Figure 1. When the receptacle component 4 is plugged into a powered bussing connector, the receptacle component may then accept conventional three prong electrical plugs, as known in the art. However, by this prior art arrangement, power distribution is restricted. The present invention, by the provision of a new electrical interface module 30 (Figures 2 and 3), has developed a way to increase the number of power distribution ports in a simple, yet effective manner.

[0009] Figure 2 illustrates the new electrical interface module 30 of this invention, where such module is poised to be plugged into a pair of bussing connectors 2, as described above and known in the art. As more clearly illustrated in FIGURE 3, the electrical interface module 30 comprises a dielectric housing 32 formed by a pair of side walls 34 and a pair of end walls 36, configured to be received in the recess 18 of a bussing connector 2, such as illustrated in Figure 2. When molded into the essentially rectangular configuration of the recess 18, the respective sidewalls 34 and end walls 36 define a pair of peripheral, spaced-apart, planar edges 38, where each such edges are arranged to receive a cover member 40.

[0010] Returning now to the housing 32, internally the housing includes an array of narrow, through chambers 42, each chamber to snugly receive a "Z" configured contact to be described hereinafter with regard to Figures 6 and 10. In addition, there is a further, non-aligned chamber 44, adapted to snugly receive a similarly configured grounding contact (Figures 6 and 11), as hereinafter described. The respective chambers 42, 44, as best illustrated in the sectional views of Figures 10 and 11, include a pair of contact guiding walls 50, 50', 52, 52',and a partial, longitudinally extending, intermediate wall 54, 56. In the illustrations of Figures 10 and 11, the portion of the chamber 42, 44 above the intermediate wall 54,56, extends the full length between the respective contact guiding walls, but only a narrow opening 58,60 is found below such intermediate wall 54,56. By this arrangement, loading of the respective contacts may be accomplished from a single direction, i.e. from the top. That is, the individual contacts are positioned within its chamber where a portion thereof, as hereinafter described, rests against the appropriate intermediate wall 54, 56.

[0011] In addition to the respective contact chambers 42, 44, the interior of the housing 32 may be provided with plural heat staking posts 62, extending normal to and above the respective planes formed by the edges 38, to engage the cover members 40, as more fully described hereinafter. Exteriorly, the housing end walls 36 include a pair of recesses 64, where one of each pair opens up into a respective edge 38. The function of such recesses will become more apparent in the description of the cover members 40.

[0012] However, before concluding with a description of the cover members 40, a discussion of the array of power/signal contacts 70 (Figure 6) and the single grounding contact 72 (Figure 7) may be helpful. Each contact forming the array of power/signal contacts 70 comprises a planar member stamped from a sheet metal blank, such as phosphor bronze, into the off-set or "Z" configuration illustrated in FIGURE 10. That is, the contact 70 includes a central portion 74 and a pair of off-set, parallel legs 76,78 extending normal from the respective ends of said central portion. The dimensional height of the contact 70 is greater than the edge-to-edge dimension of the interface module housing to ensure the projection of the off-set legs 76, 78 beyond said edges 38. Finally, one such leg 76 is provided with a planarly directed projection 80, where the projection edge 82 is aligned just below the plane formed by the edges 38. The function of said projections 80 will become clearer hereinafter.

[0013] The grounding contact 72 is similarly configured, except that the central or intermediate portion 84 is much longer. As illustrated in the several Figures, the grounding contact 72 is isolated from the array of power/signal contacts 70, and such longer intermediate portion 84 is needed to longitudinally extend the legs and ensure such isolation.

[0014] Turning finally to the pair of cover members 40, which are essentially identical in design and construction, such members include a planar body portion 90 having a plurality of contact receiving slots 92 aligned with the respective blade contacts 70,72, whereby, in the assembled condition, such contacts extend through the slots 92, a feature to be discussed later. Additionally, the planar body portion 90 is provided with a pair of longitudinally off-set arms 94 along the ends 96 projecting normal to such body portion. In the assembled condition such arms 94 are slidably received in the housing recesses 64. Note also the inclusion of a lateral latching shoulder 95 on the outer surface of each arm 94. Further, to ensure proper alignment of the cover member 40 to its respective top or bottom of the housing 30, a keying feature in the way of an upstanding projection 97 may be provided. To receive projection 97, the housing 30, along one side wall thereof, may be provided with a correspondingly shaped recess 98. Further, the planar body portion 90 includes a plurality of aligned slots 92 positioned to register with the upstanding contact legs 76, and an off-set slot 102 positioned to register with a leg of grounding contact 72. A final feature of the planar body portion 90 is a plurality of through holes 104, where each hole is aligned with and of a size to receive a corresponding heat staking post 62. By this arrangement the respective cover members 40 may be placed upon the housing, in contact with the respective edges 38. Additionally, the cover member 40, overriding the blade contact 70 having the planar extension 80, is urged against the extension surface 82 to provide some stabilizing action thereagainst in the assembled condition. To finally assemble the interface module, a heat staking tool, as known in the art, is applied to the projecting posts 62 to firmly secure the cover members to the housing 30, see Figure 5.

[0015] To interfit the interface module 30 to a pair of junction boxes or bussing connectors 2, as illustrated in Figure 2 the recess 18, which receives the interface module, is provided with end opposing recesses 110 to receive in latching engagement a corresponding lateral latching shoulder 95. That is, as the interface module 30 is plugged into the bussing connector 2, the shoulder 95 overrides the recess portion 112, then locks into the recess edge 114. By this arrangement, premature or accidental disengagement of the interface module from the bussing connector is prevented.

Claims

1. An electrical interface module for interconnecting a pair of electrical junction boxes, said interface module being characterized by:

a unitary dielectric housing (32) having a pair of side walls (34) and a pair of end walls (36) joined together to define a pair of spaced-apart peripheral edges (38), and

a plurality of through cavities (42) extending between said edges, with each cavity receiving a planar metal contact member (70) which extends beyond each said edge, each said contact being substantially "Z" configured having a pair of laterally offset legs (76, 78), and

a pair of cover members (40) to be secured to said housing along the respective said edges, said cover members including a like plurality of through slots (92) in registry with said contact legs (76, 78), where said contact legs project through said slots in the assembled condition.

2. The electrical interface module according to claim 1, wherein there are a plurality of heat staking posts (62) projecting from said housing above said edges to be received in complementary holes (104) in said cover members.

3. The electrical interface module according to claim 1, wherein said housing and said cover members include cooperative alignment means (97, 98).

4. The electrical interface module according to claim 1, wherein one said contact member (72) is remote from the remaining aligned contact members (70) to function as a ground therein for the module.

5. The electrical interface module according to claim 1, wherein one leg (76) of each said contact member includes a planar extension (82) positioned to lie in close proximity to the plane of one of said edges, and that the cover member to be secured along said one edge bears against said extension to provide stability to said contact members.

6. The electrical interface module according to claim 1, wherein each said cavity includes a laterally extending wall (54, 56) against which said contact member abuts.

7. The electrical interface module according to claim 5, wherein said cover members are heat staked to said unitary dielectric housing in compressive engagement with said contact members.

Drawing