Abstract:
An electrical wiring system for use in an AC electrical power distribution circuit including a plurality of AC electric power transmitting wires having termination ends disposed within a device box. The system includes a plug connector device configured to terminate the plurality of AC electric power transmitting wires. The system additionally includes an electrical wiring device including at least one AC electric circuit element and at least one electrical interface operatively coupled to the at least one circuit element. The electrical wiring device also includes a receptacle, wherein the receptacle is configured to receive the plug connector device such that electrical continuity is established between the AC electric circuit element and the plurality of AC electric power transmitting wires when the plug connector device is inserted into the receptacle.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a Continuation of U.S. patent application Ser. No. 11/385,346 filed on Mar. 20, 2006, which is a Continuation of U.S. patent application Ser. No. 10/913,084 filed on Aug. 6, 2004, which is a Divisional of U.S. Pat. No. 6,774,307, filed May 7, 2002 and issued on Aug. 10, 2004. The disclosure of the above applications are incorporated herein by reference. 
    
    
     FIELD OF INVENTION 
     The invention relates generally to electrical outlet systems. 
     BACKGROUND OF THE INVENTION 
     Efforts are continuously being made to simplify electrical systems or networks, and the components used in these networks which represent a substantial percentage of the labor and material in commercial and residential construction. 
     Presently, when it is desired to locate electrical outlets and/or electrical control modules such as switches, rheostats, or any other similar electrical control module that monitors or controls the flow of electricity, on opposite sides of a common wall or partition, an electrician typically installs separate electrical boxes facing in opposite directions. Electrical outlets are sometimes referred to as electrical sockets or receptacles, but will be referred to as electrical outlets herein. Additionally, each electrical box is typically installed on wall structural supports, e.g. wall studs. This procedure is time consuming and involves using extra electrical wire, boxes, standoffs, conduit and other components used during installation of an electrical wiring network, or system. Further, the electrician must avoid cavities in the walls that will not accommodate two electrical boxes in a certain area of the wall or partition. For example, electrical boxes cannot be installed between studs that define a cold air return space. 
     Additionally, electrical outlets and control modules are typically installed by attaching wires to screws appending from the sides of the outlet or the sides of the control module. These screws can present a safety hazard when they are connected within a live electrical wiring network, e.g. having live electrical current flowing through the network, and come into contact with a conductive surface, such as a metal electrical box or metal wall stud. Also, if the electrical outlet or control module is connected to a live wiring network, a person could be severely shocked upon contacting the screws. Furthermore, the screws can cause accidental injuries to the hands of the person installing the outlet or the control module if a screwdriver that is used to tighten the screws slips off one of the screws. 
     Through-way electrical boxes have been developed in an attempt to reduce the additional labor and material costs incurred in the installation of electrical wiring networks. However, known through-wall boxes do not allow for using one cavity in a wall to install electrical outlets and/or control modules on opposing sides of the wall without subjecting the electrician, or person installing the outlets and/or control modules, to time consuming mechanical detail work. Some known through-wall boxes require numerous components and fittings which must be adjusted during the installation process, while other known through-wall boxes are not suitable for installing multiple electrical outlets and/or control modules on each side of the wall. 
     Additionally, plaster ring plates that cover existing electrical boxes, also referred to herein as frames, typically include an aperture for receiving the electrical outlet and/or control module that is centered in the frame. This placement of the aperture does not permit the most efficient use of space within the electrical box nor ease of electrical outlet and/or control module installation in a back-to-back installation. 
     Furthermore, at least some electrical codes require the electrician to install pigtails on each outlet and control module, which are then connected to the incoming power source, e.g. the electrical wiring network, with electric wire nuts. The installation of pigtails is labor intensive and increases the material costs of installing outlets and control modules. 
     Thus, it would be desirable to develop a system that provides access to an electrical wiring network from opposing sides of a wall. More specifically, it would be desirable to provide a through-wall electrical system that overcomes the shortcoming of known through-wall systems, thereby reducing labor and material costs of installing such systems. For example, it would be desirable to provide a through-wall electrical system that reduces the complicity of installation caused by numerous components and fittings that must be adjusted during the installation process. Thus, the system should be suitable for installing multiple electrical outlets and/or control modules on each side of the wall, and should also reduce the risks associated with connecting the outlets and/or control modules to the wiring network via screws appending from the outlets and control modules. Additionally, the system should also satisfy code requirements to connect pigtails to the outlet and/or control module prior to connecting the module. 
     BRIEF SUMMARY OF THE INVENTION 
     In various embodiments of the present invention, an electrical wiring system is provided for use in an AC electrical power distribution circuit including a plurality of AC electric power transmitting wires configured to be disposed between an AC power distribution point and a device box, wherein the device box includes a wiring ingress aperture and an open front face for accessing an interior of the device box. The plurality of AC electric power transmitting wires are routed through the wiring ingress aperture and extend into the interior of the device box. The system includes a plug connector device configured to terminate the plurality of AC electric power transmitting wires accessible via the open front face of the device box using a termination arrangement. The plug connector device and the termination arrangement are arranged in a detached relationship relative to the device box after termination. The system additionally includes an electrical wiring device configured to be mountable to the open front face of the device box and includes at least one AC electric circuit element disposed in a device housing having a front cover joined to a rear body member. The electrical wiring device further includes at least one electrical interface operatively coupled to the at least one circuit element and configured to direct AC electric power to an electrical load. The electrical wiring device also includes a receptacle disposed in the body member, wherein the receptacle is configured to receive the plug connector device such that electrical continuity is established between the at least one AC electric circuit element and the plurality of AC electric power transmitting wires when the plug connector device is inserted into the receptacle. 
     In other embodiments of the present invention, a method is provided for installing an electrical wiring system in an AC electrical power distribution circuit including a plurality of AC electric power transmitting wires configured to be disposed between an AC power distribution point and a device box. The device box includes a wiring ingress aperture and an open front face for accessing an interior of the device box, and the plurality of AC electric power transmitting wires are routed through the wiring ingress aperture and extend into the interior of the device box. The method includes terminating the plurality of AC electric power transmitting wires, accessible via the open front face of the device box, with a plug connector, wherein the plug connector terminates the plurality of AC electric power transmitting wires using a termination arrangement. The plug connector device and the termination arrangement are arranged in a detached relationship relative to the device box after termination. The method additionally includes providing an electrical wiring device including at least one AC electric circuit element disposed in a device housing that includes a front cover joined to a rear body member. The electrical wiring device further including at least one electrical interface operatively coupled to the at least one AC electric circuit element and configured to direct AC electric power to an external electrical load, and the electrical wiring device also includes a receptacle disposed in the rear body member. Furthermore, the method includes inserting the plug connector into the receptacle to thereby establish electrical continuity therebetween. 
     In yet other embodiments of the present invention, an electrical wiring is provided. The system includes an electrical wiring device that includes at least one AC electric circuit element disposed within a device housing, and at least one electrical interface operatively coupled to at least one circuit element and configured to direct AC electric power to an electrical load. The electrical wiring device also includes a predefined area in which a first plurality of electrical contacts are positioned. The system additionally includes a connector device configured to be positioned in contacting relation with the electrical wiring device. The connector device includes a plurality of termination elements configured to terminate a plurality of AC electric power transmitting wires extending through a wiring ingress aperture of a device box and accessible via an open front face of the device box. The termination elements and the connector device are arranged in a detached relationship relative to the device box after termination. The connector device additionally includes a second plurality of electrical contacts disposed in the connector device and electrically coupled to the plurality of termination elements. The second plurality of electrical contacts are configured to be placed in electrical contact with the first plurality of electrical contacts when the connector device is coupled in contacting relation with the electrical wiring device. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The present invention will become more fully understood from the detailed description and accompanying drawings, wherein; 
         FIG. 1  is a schematic of a system for accessing an electrical wiring network from opposing sides of a common wall, in accordance with a preferred embodiment of the present invention; 
         FIG. 2  is a perspective view of a frame used in the system shown in  FIG. 1 ; 
         FIG. 3  is a perspective view of an electrical outlet used in the system shown in  FIG. 1 ; 
         FIG. 4  is a perspective view of an alternate embodiment of the electrical outlet shown in  FIG. 3 ; and 
         FIG. 5  is a schematic of an alternate embodiment of the system shown in  FIG. 1  including a plurality of electrical control modules. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       FIG. 1  is a schematic of a system  10  for accessing an electrical wiring network  16  from opposing sides of a common wall or partition (not shown), in accordance with a preferred embodiment of the present invention. Wiring network  16 , sometimes referred to as an electrical system, is a network of wires installed in a building or other structure that provide and distribute electrical power throughout the building or structure. Wiring network  16  includes a plurality of network branches  22  which are installed inside the walls or partitions of the building or structure, thereby providing and distributing power throughout the building or structure. As used herein, the term plurality is defined as at least two. Wiring network  16  is typically connected to a load center (not shown), also referred to as a breaker box or fuse box, which is the incoming point for electrical service to a residential or commercial building. However, for smaller buildings or structures other than buildings, wiring network  16  may be a sub-network of a larger wiring network and therefore not directly connected to a breaker box. 
     It is generally known that walls and partitions are typically constructed of at least one structural support, such as a wall stud, and have a wall or partition surface attached to opposing sides of the structural support. System  10  includes a through-wall electrical box  28  that is mounted to one of the structural supports using mounting devices  34  prior to the wall surface being attached to the structural support. Although electrical box  28  is shown in  FIG. 1  as having a rectangular shape, it is envisioned that electrical box  28  could have any suitable shape, such as circular, oval, or square. Mounting devices  34  include mounting apertures  36  for receiving nails, screws, or any other fastening device suitable to mount electrical box  28  to the wall or partition structural support. Electrical box  28  is constructed of any material suitable for use in electrical wiring networks, such as plastic or metal. Although mounting device  34  is shown in  FIG. 1  as an L-shaped bracket coupled to electrical box  28 , it should not be so limited. Mounting device  34  could be any device, system or apparatus suitable for mounting any type of electrical box or similar device to the structural support of a wall or partition, as is well known by those skilled in the art. 
     Electrical box  28  includes a perimeter wall  40  and two open sides  46  located at opposing ends of perimeter wall  40  thereby defining a passageway through electrical box  28 . In a preferred embodiment, perimeter wall  40  has a depth ‘d’ approximately equal to the width of the structural support to which it is to be mounted. Therefore, electrical box  28  is constructed such that perimeter wall  40  has a specific predetermined depth ‘d’ that is based upon the width of the structural support used to construct the wall in which electrical box  28  is to be installed. Additionally, in the preferred embodiment, perimeter wall  40  has a uni-body molded construction or is constructed from a single piece of material joined at opposing ends. In an alternate embodiment, electrical box  28  is constructed such that perimeter wall  40  is adjustable to be adapted to walls of various thicknesses. In another alternate embodiment, perimeter wall  40  is constructed of at least two pieces of material joined end-to-end. In yet another embodiment, electrical box  28  is constructed such that perimeter wall  40  has a depth ‘d’ approximately equal to the width of the structural support plus twice the thickness of the wall surface that is to be attached to both sides of the structural support. Thus, perimeter wall  40  would have a depth ‘d’ that extends past both outer edges of the structural support a distance approximately equal to the thickness of the wall surface. 
     Additionally, electrical box  28  includes at least one wiring aperture  52  that allows at least one network branch  22  to pass therethrough. Wiring aperture  52  is shown in  FIG. 1  as a wiring aperture commonly known in the art as a knockout, but should not be so limited. Wiring aperture  52  could be any suitable aperture in electrical box  28  configured to allow at least one network branch  22  to pass therethrough. For example, wiring aperture  52  could be an aperture in electrical box  28  fashioned to provide a strain relief feature that allows network branch  22  pass therethrough, but inhibits network branch  22  from being easily retracted from wiring aperture  52 . Although  FIG. 1  shows wiring network  16  and network branches  22  free from an enclosure, such as electrical conduit, it is envisioned that wiring network  16  may include a plurality of interconnectable enclosure sections, for example electrical conduits. The interconnectable enclosure sections enclose network branches  22 , are connected to the structure, and coupled at one end to electrical box  28  utilizing a wiring aperture  52 . Therefore, it is to be understood that wiring aperture  52  may be formed in perimeter wall  40  in any known manner for accommodating one or more enclosure sections that enclose and provide protection for network branches  22 . 
     System  10  further includes a pair of frames  58  that are coupled to electrical box  28  at open sides  46  prior to the wall covering being coupled to the structural support. Frames  58  are sometimes referred to in the art as plaster rings or plaster frames, and are constructed of any material suitable for use in electrical wiring networks, such as plastic or metal. In the preferred embodiment, frames  58  are coupled to electrical box  28  using a plurality of screws  64  inserted through a plurality of frame slots  70 . Alternatively, frames  58  are coupled to electrical box  28  in any other suitable manner. For example, frames  58  could include apertures through which screws  64  would be inserted, or screws  64  could be replaced with any other type of suitable connector such as, rivets or nylon press-in snap retainers. Further yet, frames  58  could be hingedly connected at one side of perimeter wall  40  and coupled to perimeter wall  40  at the opposing side using any type of connector such as screws, rivets, a latch, or nylon press-in snap retainers. Frames  58  are further described below in reference to  FIG. 2 . 
     In the preferred embodiment, system  10  includes at least one electrical outlet  76  that includes a plurality of integral leads  82 . Again, plurality as used herein means at least two. At least one lead  82  is connected to a network branch  22  thereby providing electrical power to the respective electrical outlet  76 , that is coupled to one frame  58 . Electrical outlet  76  provides a source of, or connection point to, electricity flowing through electrical network  16 . A person accesses the electricity by inserting a suitable plug adapter connected to any device that utilizes electricity (not shown), into mating electrical receptor holes  88  in electrical outlet  76 . Electrical outlet  76  is sometimes known in the art as an electrical socket, or an electrical receptacle, but will be referred to herein as an electrical outlet. Electrical outlet  76  is further described below in reference to  FIG. 3 . 
       FIG. 2  is a perspective view of one of the frames  58  shown in  FIG. 1 . As described above, frames  58  couple to electrical box  28  (shown in  FIG. 1 ) at open sides  46  (shown in  FIG. 1 ) prior to the wall surface being coupled to the structural supports. Although frame  58  is shown in  FIG. 2  having a rectangular shape it should not be so limited. It is envisioned that frame  58  could have any suitable shape, such as circular, oval, or square. Each frame  58  includes a frame aperture  94  that is located off-center in frame  58 , such that a centerline ‘C’ of aperture  94  is substantially closer to one edge of frame  58  than the opposing edge of frame  58 . Aperture  94  receives electrical outlet  76  (shown in  FIG. 1 ) when outlet  76  is coupled to frame  58 . In an alternate embodiment, aperture  94  of at least one frame  58  receives at least two electrical outlets  76 . Although aperture  94  is shown in  FIG. 2  having a rectangular shape, it is envisioned that aperture  94  could have any suitable shape, such as circular, oval, or square, and could have dimensions larger or smaller with respect to the overall size of frame  58  than is shown in  FIG. 2 . In the preferred embodiment, aperture  94  includes a raised lip  100  extending along the perimeter of aperture  94  that has a predetermined height approximately equal to a thickness of the wall surface to be coupled to the structural support on which outlet box  28  is mounted. Raised lip  100  includes a plurality of tabs  106  that include threaded tab holes  112 . Outlet  76  is mounted within aperture  94  by coupling outlet  76  to tabs  106 . In an alternative embodiment, aperture  94  includes at least two raised lips  100  located at separate points along the perimeter of aperture  94 , and each lip  100  includes at least one tab  106  that includes at least one threaded hole  112 . 
       FIG. 3  is a perspective front and back view of electrical outlet  76  used in the system  10  (shown in  FIG. 1 ). As described above, outlet  76  includes a plurality of integral leads  82  wherein at least one lead  82  is connected to wiring network  16  (shown in  FIG. 1 ). Additionally, outlet  76  includes an internal conductive electrical receptor structure  114  having a plurality of receptors  116  configured to receive the plug adapter when the plug adapter is inserted through mating electrical receptor holes  88 . Integral leads  82  are connected to electrical receptor structure  114  such that when outlet  76  is connected to wiring network  16 , via leads  82 , electrical current is provided at outlet  76  accessible via electrical receptor holes  88 . Furthermore, each electrical outlet  76  includes at least one outlet mounting bracket  118  that includes at least one mounting hole  124 . In the preferred embodiment, outlet  76  is coupled to frame  58  (shown in  FIG. 1 ) by inserting a screw through outlet mounting bracket hole  124  and threading the screw into tab hole  112  (shown in  FIG. 1 ). Alternatively, outlet  76  can be mounted to one of frames  58  by inserting a rivet or nylon press-in snap retainer through bracket hole  124  and into tab hole  112 , or by any other suitable means. 
     Electrical outlet  76  further includes an outlet housing  130  constructed of a non-conductive material, such as plastic or rubber. In addition to being constructed of a non-conductive material, outlet housing  130  has a comprehensively non-conductive outer surface  136  free from conductive appendages or surfaces that are electrically active, or live, when outlet  76  is connected to wiring network  16 . Known electrical outlets do not include leads  82 , but instead typically include metal screw posts appending from the outlet housing to which a wiring network is connected either directly or via pigtails connected to the metal screw posts. In the present invention, the entire outer surface  136  of each outlet housing  130  is free from any actively conductive appendages or surfaces, such as metal screw posts, or any other actively conductive metal appending from, protruding from, attached to, or otherwise exposed via an aperture in outlet housing  130  that would be in contact with or connected to wiring network  16 . 
     As used herein ‘actively conductive’ appendage or surface is defined to mean any appendage or surface that is designed to have live current flowing through it once outlet  76  is connected to wiring network  16  as described herein. Therefore, when wiring network  16  is connected to an outlet  76 , outlet housing outer surface  136  can be contacted by a person, or come into contact with a conductive surface, such as an outlet box  40  constructed of metal, without the risk of electrical shock or shorting. It is envisioned that housing  130  is of two part construction comprising a first part having receptor holes  88  and a second part from which leads  82  extend. 
     Each lead  82  includes a proximal end  142 , a distal end  148 , a wire  154 , and an insulating layer  160  covering wire  154 . Insulating layer  160  is constructed of any electrically insulating material, such as plastic or rubber. In the preferred embodiment, at least one lead  82  has a predetermined length of insulating layer  160  pre-stripped from distal end  148  thereby exposing a predetermined length of wire  154 . Outlet  76  is thereby connected to wiring network  16  by connecting the pre-stripped end of at least one lead to a network branch  22 . In an alternate embodiment, insulating layer  160  covers wire  154  from proximal end  142  to distal end  148 , and outlet  76  is connected to wiring network  16  by stripping a desired length of insulating layer  160  from at least one lead  82 , thereby exposing a desired length of wire  154 , then connecting the exposed length of wire  154  to a network branch  22 . 
     In the preferred embodiment, proximal end  142  of each lead  82  extends through outlet housing  130  and is connected to actively conductive electrical receptor structure  114  inside outlet  76  such that each lead  82  is integrally formed, or assembled, with outlet  76 . Proximal ends  142  are connected to receptor structure  114  inside outlet  76  using any suitable means such as soldering ends  142  to receptor structure  114 , or using a crimping type connection, or using any type of suitable connector assembly, e.g. a jack, a plug, or a strain relief. Therefore, leads  82  are integrally formed or assembled with outlet  76 . 
     Furthermore, in the preferred embodiment, leads  82  extend from a back side  166  of outlet housing  130 . Alternatively, leads  82  can extend from any other side of outlet housing  130 . It is envisioned that outlet  76  is suitable for use as part of system  10 , as described above, and also suitable for use as a stand-alone electrical outlet for use in conjunction with other known types and configurations of outlet boxes. Additionally, in the preferred embodiment, leads  82  all extend individually from housing  130 . In another alternate embodiment, leads  82  are bundled together inside a non-conductive casing and only a predetermined length of each distal end  148  extends past a distal end of the non-conductive casing. 
       FIG. 4  is an alternate embodiment of outlet  76  wherein outlet  76  includes a first connector  161  of a connector module  162 . First connector  161  is connected to receptor structure  114 . Additionally, the proximal ends  142  of each lead  82  are connected to a mating second connector  163  of connector module  162 , thereby forming a subassembly that can be coupled with and decoupled from first connector  161 . Therefore, the subassembly can be connected to network branch  22 , and outlet  76  can subsequently be connected to network branch  22  by coupling the subassembly second connector  163  with mating first connector  161  of outlet  76 . Connector module  162  can be any suitable electrical connection assembly such as a pronged plug assembly or any suitable modular electrical connection device. 
       FIG. 5  is an alternate embodiment of system  10  including a plurality of electrical control modules  172 . Control modules  172  include a plurality of integral leads  178  that are integrally formed or assembled with control module  172  in the same manner and fashion as lead  82  (shown in  FIG. 3 ) are integrally formed with outlet  76  (shown in  FIG. 3 ). Additionally, integral leads  178  connect to a network branch  22  in the same manner and fashion as leads  82 . Control modules  172  are any electrical control module, such as switches or rheostats that monitor and/or control the flow of electricity. Additionally, control modules  172  connect to frames  58  in the same manner and fashion as electrical outlets  76  (shown in  FIG. 1 ). In yet another alternate embodiment, system  10  includes any combination of at least one electrical outlet  76  and at least one control module  172 . 
     Although system  10  has been described in conjunction with a commercial or residential electrical supply network, it is envisioned that system  10  could be utilized in conjunction with other networks that are utilized for the transmission of mediums other than electricity, such a light or sound. For example, system  10  could be implemented in conjunction with a fiber optic network, or a low voltage communications network, e.g. telephone network, or a coaxial communication network, e.g. a cable television network, or a satellite communication network, or an audio network, e.g. an audio entertainment network or public address network. In which case outlets  76  and control modules  172  would be outlets and control modules associated with such networks. 
     While the invention has been described in terms of various specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the claims.