Abstract:
A modular receptacle coupler, including a housing having a first end and an opposite second end and a plurality of conductors disposed substantially within the housing, at least one of the plurality of conductors having an electrical contact proximate the first end and an other electrical contact proximate the second end.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    1. Field of the invention.  
           [0002]    The present invention relates to a modular electrical power distribution system, and, more particularly, to a coupler for modular electrical receptacles.  
           [0003]    2. Description of the related art.  
           [0004]    The modern office environment often consists of a large open area or floor space that is divided into separate and distinct work areas by way of a modular wall panel system. Modular wall panels can be moved about with relative ease, to change an entire office floor plan. Contained in the modular wall panels are modular power distribution systems, which may include a wiring harness or channel that is connected with a modular electrical device such as an electrical outlet. The wiring harness or channel typically includes a plurality of wires, which are associated with line, neutral and ground conductors of the power distribution system.  
           [0005]    Associated with the modular power distribution system and the wiring harness are modular electrical outlets such as the one disclosed in U.S. Pat. No. 5,915,984 (Rupert et al.), which is assigned to the assignee of the present invention. The modular electrical outlet of Rupert et al. interconnects with a connector of the wiring harness of the modular power distribution system to provide power to office appliances, computers, fax machines and associated electrical equipment.  
           [0006]    The distribution of electrical power in a modular power distribution system is accomplished by way of a plurality of connected, electrically pre-wired wiring harnesses that contain a plurality of power, neutral and ground lines. Examples may include ten wire systems that can contain such combinations as six power conductors, two neutral conductors and two ground conductors, which define six different circuits, or may include four power conductors, four neutral conductors and two ground conductors which define four different circuits. Connected to the wiring harness is a modular electrical outlet, which has a connector, associated with one end, as in the aforementioned Rupert et al. patent.  
           [0007]    Often in a modular power distribution system there arises a need to expand the capacity and capability of the electrical outlets. This usually requires re-wiring, running new lines to the distribution system or installing new outlet assemblies.  
           [0008]    What is needed in the art is a relatively easy way to connect modular electrical outlets in series.  
           [0009]    What is further needed in the art is an electrical assembly, which includes a number of conductors to pass electrical power from one modular receptacle to another modular receptacle.  
         SUMMARY OF THE INVENTION  
         [0010]    The present invention provides a modular electrical receptacle coupler having a plurality of conductors, each corresponding conductor associated with a circuit.  
           [0011]    The invention comprises, in one form thereof, a modular receptacle coupler, including a housing having a first end and an opposite second end and a plurality of conductors disposed substantially within the housing, at least one of the plurality of conductors having an electrical contact proximate the first end and an other electrical contact proximate the second end.  
           [0012]    An advantage of the present invention is that modular receptacles may be easily connected in series.  
           [0013]    Another advantage is that a coupler can be installed in the field without requiring an electrician to expand the number of modular receptacles in a modular power distribution system. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0014]    The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become more apparent and the invention will be better understood by reference to the following description of an embodiment of the invention taken in conjunction with the accompanying drawings, wherein:  
         [0015]    [0015]FIG. 1 is a perspective, exploded view of an embodiment of a modular wall panel system including a modular receptacle coupler of the present invention;  
         [0016]    [0016]FIG. 2 is a perspective view of the modular receptacle coupler shown in FIG. 1;  
         [0017]    [0017]FIG. 3 is a cross-sectional view taken along  3 - 3  of the modular receptacle coupler of FIG. 2; and  
         [0018]    [0018]FIG. 4 is an end view of the modular receptacle coupler of FIGS.  1 - 3 . 
     
    
       [0019]    Corresponding reference characters indicate corresponding parts throughout the several views. The exemplification set out herein illustrates one preferred embodiment of the invention, in one form, and such exemplification is not to be construed as limiting the scope of the invention in any manner.  
       DETAILED DESCRIPTION OF THE INVENTION  
       [0020]    Referring now to the drawings, and more particularly to FIG. 1, there is shown an embodiment of the present invention contained in a modular panel system  10 . Modular panel system  10  includes modular panel  12 , wiring channel assembly  14 , wiring harness assembly  16 , modular receptacle  18  and module receptacle coupler  20 . Modular panel system  10  is a typical system used in an office environment allowing the constructing of modules within an open area of an office floor space.  
         [0021]    Wiring channel assembly  14  includes interface connector  22 , receptacle mounting brackets  24  and cover  26 . Interface connector  22  is installed as a part of wiring channel assembly  14  to provide an interface for electrical power between wiring harness assembly  16  and modular receptacle  18 . Receptacle mounting brackets  24  are spaced along wiring channel assembly  14  to physically mount modular receptacles  18  thereto. Receptacle mounting brackets  24  and modular receptacles  18  and  18 ′ are arranged to provide complimentary locking mechanisms to attach modular receptacles  18  and  18 ′ to wiring channel assembly  14 . Cover  26  is removably placed over wiring channel assembly  14  to provide a finished look to the modular panel system  10 . Cover  26  contains holes that allow access to modular receptacles  18  and  18 ′.  
         [0022]    Wiring harness assembly  16  includes first connector  28 , second connector  30  and conductor harness  32 . First connector  28  is electrically connected to conductors contained in conductor harness  32 . First connector  28  is removably connected to interface connector  22  providing electrical power thereto. Second connector  30  interfaces with a power distribution source, either in another modular panel system  10  or a power distribution source contained in, for example, an electrical distribution box. Conductor harness  32  includes a plurality of conductors providing line, neutral and ground connections from an electrical source to modular panel system  10 .  
         [0023]    Now, additionally referring to FIGS.  2 - 4 , there is illustrated a module receptacle coupler  20  that includes housing  34 , a plurality of conductors  36 , non-conductive protrusions  38 , electrical contacts  40  and connectors  42 . Housing  34  is made from a non-conductive material such as plastic and may be injection molded. Housing  34  consists of two parts as shown in FIG. 3, each part being identical.  
         [0024]    Conductors  36  are positioned within housing halves  34  to provide electrical connections from one end of module receptacle coupler  20  to the other end of module receptacle coupler  20 . Non-conductive protrusions  38  are positioned within housing  34  to electrically isolate each of conductors  36  from each other. Non-conductive protrusions  38  may be continuous along the length of conductors  36  or be intermittently positioned to provide the necessary electrical separation. At each end of each conductor  36  is a corresponding electrical contact  40 , which is integral with conductor  36 . Electrical contact  40  provides an electrical interface with connector  46  of modular receptacle  18 . Alternatively, electrical contact  40  may be a separate part yet electrically connected to conductor  46  Electrical contacts  40  are arranged in an order, which is illustrated in FIG. 3, such that an electrical contact  40  of a particular conductor  36 , at one end of modular receptacle coupler  20 , is associated with another electrical contact  40  of the same conductor  36  at the other end of modular receptacle coupler  20 . The order is such that the arrangement on one end of modular receptacle coupler  20  is the mirror image, of the order, on the other end of modular receptacle coupler  20 .  
         [0025]    Connectors  42  are disposed on each end of module receptacle coupler  20 . Connectors  42  electrically separate electrical contacts  40  and secure electrical contacts  40  so that module receptacle coupler  20  can be electrically mated with connector  46  on modular receptacles  18  and  18 ′. Connectors  42  have keying feature  44 , which corresponds to a keying feature on mateable connectors  46  on modular receptacles  18  and  18 ′. The corresponding keying features, of connectors  42  and connectors  46  ensure that modular receptacle  18 ′ will be installed with its face oriented in the same general direction as modular receptacle  18 . As depicted in FIG. 4, connector  42  may have a staggered double column of electrical contacts  40 .  
         [0026]    Module receptacle coupler  20  is configured to convey multiple line voltage circuits on some of conductors  36 , multiple neutral circuits on other conductors  36  and multiple ground circuits on still other conductors  36 . Therein lies one of the advantages of the present invention, that all of the available circuits are serially passed from one modular receptacle  18  to another by way of module receptacle coupler  20 . While the connection of module receptacles  18  and module receptacle couplers  20  is referred to as a serial connection, the electrical circuits within module receptacle  18  and module receptacle coupler  20  are conveyed as parallel circuits.  
         [0027]    To install a module receptacle coupler  20  in modular panel system  10 , which has already been installed in an office environment, cover  26  is removed thereby allowing access to a modular receptacle  18 . Module receptacle coupler  20  is installed by pressing connector  42  onto mating connector  46  of modular receptacle  18 . Modular receptacle  18 ′ is then positioned in a series-like arrangement with another end of module receptacle coupler  20  and pressed together completing the electrical connection between modular receptacle  18  and modular receptacle  18 ′. Modular receptacle  18 ′ is also secured to wiring channel assembly  14  by way of receptacle mounting brackets  24 . Additional modular receptacles  18  or  18 ′ may be added in a series-like fashion with one module receptacle coupler  20  installed between each successive modular receptacle  18 . This arrangement allows for an expansion of the number of outlets available in modular panel system  10 .  
         [0028]    Although module receptacle coupler  20  has been described as being assembled using conductor housing halves  34 , alternatively, module receptacle coupler  20  may be made as one injection molded assembly. In addition, although conductors  36  have been shown and described as single solid metal conductors, conductors  36  may be wires with terminals on each end thereof or any other type of electrical conductor to which electrical contacts  40  may be electrically connected.  
         [0029]    While this invention has been described as having a preferred design, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims.