Electrical receptacle assembly

An electrical receptacle for use with an electrical distribution harness. The electrical distribution harness including a first connector and a second connector, a plurality of electrical conductors electrically connecting the first connector and the second connector, a conduit member at least partially enclosing the plurality of electrical conductors between the first connector and the second connector, at least one fastener element having a head, and at least one structural member connected to the conduit member by way of the fastener element, the head projecting above a surface of the structural member. The electrical receptacle including a housing with at least one recess and a connector extending from the housing. The electrical receptacle being electrically connectable to the first connector or the second connector of the harness. The recess being configured to accommodate the head when the electrical receptacle is engaged in the first connector or the second connector.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to electrical distribution harnesses for modular wall panels, and, more particularly, to a method and a device for mounting electrical receptacles to the electrical distribution harness of the modular wall panel.

2. Description of the Related Art

Electrical distribution harnesses are located in modular wall panels to provide electrical power to a user located in a space defined by the wall panels. The electrical power can be used to power lighting, computers and other office machines in an office environment, or can be used to power lighting, tools and other equipment in a laboratory or industrial setting.

The electrical distribution harnesses are hidden within the modular wall panel, typically near to or attached to a frame of the modular wall panel, and provide user access to the electricity via receptacles, such as standard duplex receptacles.

The receptacle components need to electrically connect to the electrical distribution harness. Mechanical forces are applied to the receptacle, and therefore to the electrical distribution harness via the receptacle, when plugging and unplugging a power cord and the like. A stable mechanical connection is required for the receptacle to ensure that the receptacle does not work itself loose from the electrical distribution harness after multiple power cord plugging and unplugging cycles. A stable mechanical connection is also required for the electrical distribution harness to ensure that the electrical distribution harness does not work itself loose from the modular wall panel after multiple power cord plugging and unplugging cycles.

A method of mounting a receptacle to an electrical distribution harness is known whereby a receptacle retaining element is part of the electrical distribution harness and includes legs that connect to the modular wall panel. The receptacle electrically connects to an electrical port on the harness and mechanically mounts into the receptacle retaining element.

Wall panels may be made thinner to save space and to reduce the material content therein, yet an electrical receptacle needs to accommodate electrical plugs engaged therein. The thinner wall panels present issues when dealing with electrical interconnections that require a minimum amount of space.

What is needed in the art is a device and method that allows a receptacle of an electrical distribution harness to be connected in a reliable and cost effective manner, and at the same time, have a profile compatible with the smaller space constraints of modular wall panels.

SUMMARY OF THE INVENTION

The present invention provides a device and method to hold a receptacle module to an electrical distribution harness.

The invention comprises, in one form thereof, an electrical receptacle for use with an electrical distribution harness. The electrical distribution harness including a first connector and a second connector, a plurality of electrical conductors electrically connecting the first connector and the second connector, a conduit member at least partially enclosing the plurality of electrical conductors between the first connector and the second connector, at least one fastener element having a head, and at least one structural member connected to the conduit member by way of the fastener element, the head projecting above a surface of the structural member. The electrical receptacle including a housing with at least one recess and a connector extending from the housing. The electrical receptacle being electrically connectable to the first connector or the second connector of the harness. The recess being configured to accommodate the head when the electrical receptacle is engaged in the first connector or the second connector.

An advantage of the present invention is that it provides a device and method that mechanically allows an electrical receptacle to engage an electrical distribution harness in a reliable and cost effective manner.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to the drawings, and more particularly toFIG. 1, there is shown a modular wall panel assembly10which generally includes a modular wall panel12, an electrical distribution harness14and an electrical receptacle16.

Electrical distribution harness14includes electrical connectors18and20with a plurality of conductors22extending therebetween. Conductors22are routed in a conduit24that serves to define a channel extending from and electrically connected with electrical connectors18and20. The number of conductors22can vary from application to application, but will generally include ground, neutral and line conductors, or some combination and/or multiples thereof. Isolated circuit conductors and/or isolated grounds can be included. Conductors22electrically interconnect terminals in electrical connectors20with corresponding terminals in electrical receptacle16. Electrical connectors20are inwardly facing connectors, and electrical connectors18are outwardly facing connectors. Electrical connectors18are configured to connect with another connector such as an end connector that is typically connected to a source of electrical power, another electrical distribution harness and/or a jumper cable (all not shown).

Electrical distribution harness14also includes structural members26that are connected to conduit member24by way of fasteners28, which may be in the form of rivets28. Structural members26are used to position and physically connect electrical distribution harness14to wall panel12. Although fasteners28extend through conduit24only the protruding head is shown inFIG. 1. For the sake of simplicity, the heads of fasteners28will be referred to as heads28, which protrude above structural members26by a height42.

An electrical receptacle16is connected to one of electrical connectors20. In the embodiment shown, multiple electrical receptacles16can be connected to electrical connectors20with only one electrical receptacle16shown on one side of harness14. Electrical distribution harness14is substantially symmetrical with the side not shown inFIG. 1being substantially similar to the side that is shown. This allows electrical receptacles to be positioned on each side and at multiple locations on each side of electrical distribution harness14.

Electrical receptacle16includes a faceplate30, openings32therein, connectors34, and recesses36. Openings32are positioned to accommodate the insertion of electrical plugs therethrough to interact with electrical connections therein. As can be seen inFIG. 3, there is a ground plug opening on the side opposite faceplate30to accommodate the length of the ground plug of an electrical plug. The ground plug typically extends further than the flat blades that convey current flow to an electrical load. The opening on the back of electrical receptacle16is one accommodation in the present invention to account for a lower profile electrical assembly in wall panel assembly10.

Recesses36are shaped with a depth44to accommodate the positioning of heads28. Depth44is generally equal to or deeper than height42. Recesses36have a longitudinal direction that corresponds to an insertion direction38of electrical receptacle16with electrical distribution harness14. This arrangement allows for electrical receptacle16to be oriented so that connector34aligns with connector20and electrical receptacle16is slid in direction38to engage the connectors. The length of recesses36is configured to allow electrical receptacle16to be slidingly inserted into any of connectors20with heads28being in an off center location in recesses36when electrical receptacle16, having been slid relative to harness14, is fully engaged with a connector20. Structural members26extend in a longitudinal direction40, which is substantially perpendicular to direction38.

In a similar fashion recesses48are positioned to provide clearance for the passing of the heads of rivets46by the housing of electrical receptacle16, as electrical receptacle16is slid into a connector20. The heads of rivets46extend above the surface of conduit24and would, without the accommodation of recesses48, interfere with the insertion of connector34into connector20. The planes of the bottom of recesses48may be coplanar with each other, yet are offset from the plane of the bottom of recesses36. The depth of recesses48may be substantially similar to depth44of recesses36. Recesses48are located on the hood of connector34, which is thinner than those typically used in the industry to allow for an overall thinner assembly and to accommodate the clearances of harness assembly14.

Further, electrical receptacle16is assembled using snap latches50and52to hold the front and back of the assembly together. Latch50includes latch arms that are visible on the outside of electrical receptacle16. In contrast latches52latch internally, with the opening shown at52being an access, that can allow for the disengagement of latches52, which along with the disengagement of latches50, allow for the disassembly of the front and back of the assembly.