Abstract:
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. 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.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
   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.” 

   BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   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. 
   2. Description of Related Art 
   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. 
   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. 
   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. 
   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. 
   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. 
   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. 
   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. 
   BRIEF SUMMARY OF THE INVENTION 
   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. 
   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. 
   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. 
   A primary advantage of the present invention to significantly reduce the time required to install electrical devices in a building after wallboard application. 
   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. 
   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. 
   Yet another advantage of the present invention is to enable a safer installation of electrical devices during building construction or remodeling. 
   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. 
   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. 

   
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
     The drawings constitute a part of this specification and include exemplary embodiments of the invention, which may be embodied in various forms. It is to be understood that in some instances various aspects of the invention may be shown exaggerated or enlarged to facilitate an understanding of the invention. 
       FIGS. 1A-1C  illustrate a single-gang module in one embodiment of the invention, wherein  FIG. 1A  is a front view,  FIG. 1B  is a left side view, and  FIG. 1C  is a rear view. 
       FIG. 2  illustrates a cross-section of the embodiment of  FIGS. 1A-1C , as seen from a front viewpoint. 
       FIG. 3  is an exploded view of the assembly of a single pole switch with the single-gang module of  FIGS. 1A-1C  and with an electrical box. 
       FIGS. 4A-4B  illustrate a single pole switch according to one embodiment of the invention, wherein  FIG. 4A  is a right side view and  FIG. 4B  is a rear view. 
       FIGS. 5A-5B  illustrate the single-gang module of  FIGS. 1A-1C , wherein  FIG. 5A  is a front view and  FIG. 5B  is a rear view. 
       FIGS. 6A-6H  show a three-way switch assembly, wherein  FIG. 6A  is a right view of a switch according to one embodiment of the present invention,  FIG. 6B  is a rear view of the switch of  FIG. 6A ,  FIG. 6C  is a front view of a single-gang module according to an embodiment of the present invention,  FIG. 6D  is a rear view of the module of  FIG. 6C ,  FIG. 6E  is a rear view of a single-gang module according to an embodiment of the present invention,  FIG. 6F  is a front view of the module of  FIG. 6E ,  FIG. 6G  is a rear view of a switch having the same construction as  FIG. 6B , and  FIG. 6H  is a right side view of the switch of  FIG. 6G . 
       FIGS. 7A-7B  illustrate a single receptacle according to one embodiment of the present invention, wherein  FIG. 7A  is a front view and  FIG. 7B  is a rear view, and  FIGS. 7C-7D  illustrate the single gang module of  FIGS. 1A-1C , wherein  FIG. 7C  is a front view and  FIG. 7D  is a rear view. 
       FIGS. 8A-8B  illustrate a duplex receptacle according to one embodiment of the present invention, wherein  FIG. 8A  is a front view and  FIG. 8B  is a rear view, and  FIGS. 8C-8D  illustrate the single gang module of  FIGS. 1A-1C , wherein  FIG. 8C  is a front view and  FIG. 8D  is a rear view. 
       FIG. 9  is an exploded view of the assembly of a duplex receptacle with the single-gang module of  FIGS. 1A-1C  and with an electrical box. 
       FIGS. 10A-10B  illustrate a half switch receptacle according to one embodiment of the present invention, wherein  FIG. 10A  is a front view and  FIG. 10B  is a rear view, and  FIGS. 10C-10D  illustrate the single gang module of  FIGS. 1A-1C , wherein  FIG. 10C  is a front view and  FIG. 10D  is a rear view. 
       FIGS. 11A-11B  illustrate a single pole/receptacle according to one embodiment of the present invention, wherein  FIG. 11A  is a front view and  FIG. 11B  is a rear view, and  FIGS. 11C-11D  illustrate the single gang module of  FIGS. 1A-1C , wherein  FIG. 11C  is a front view and  FIG. 11D  is a rear view. 
       FIGS. 12A-12L  show a four-way switch assembly, wherein  FIG. 12A  is a right view of a switch according to one embodiment of the present invention,  FIG. 12B  is a rear view of the switch of  FIG. 12A ,  FIG. 12C  is a front view of a single-gang module according to an embodiment of the present invention,  FIG. 12D  is a rear view of the module of  FIG. 12C ,  FIG. 12E  is a rear view of a single-gang module according to an embodiment of the present invention,  FIG. 12F  is a front view of the module of  FIG. 12E ,  FIG. 12G  is a rear view of a switch according to a different embodiment of the present invention,  FIG. 12H  is a left side view of the switch of  FIG. 12G ,  FIG. 12I  is a rear view of a single-gang module according to an embodiment of the present invention,  FIG. 12J  is a front view of the module of  FIG. 12I ,  FIG. 12K  is a rear view of the same switch as in  FIG. 12B  but in an upside-down position, and  FIG. 12L  is a right side view of the switch of  FIG. 12K . 
       FIGS. 13A-13D  illustrate a two-gang electrical module according to on embodiment of the present invention, wherein  FIG. 13A  is a front view,  FIG. 13B  is a right side view,  FIG. 13C  is a rear view, and  FIG. 13D  illustrates a cross-section of the module of  FIGS. 13A-13C  as seen from a front viewpoint. 
       FIGS. 14A-14D  illustrate a three-gang electrical module according to on embodiment of the present invention, wherein  FIG. 14A  is a front view,  FIG. 14B  is a right side view,  FIG. 14C  is a rear view, and  FIG. 14D  illustrates a cross-section of the module of  FIGS. 13A-13C  as seen from a front viewpoint. 
       FIGS. 15A-15D  illustrate a four-gang electrical module according to on embodiment of the present invention, wherein  FIG. 15A  is a front view,  FIG. 15B  is a right side view,  FIG. 15C  is a rear view, and  FIG. 15D  illustrates a cross-section of the module of  FIGS. 15A-15C  as seen from a front viewpoint. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   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. 
   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. 
   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&#39;s screwdriver during installation. 
   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. 
   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 . 
   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. 
   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. 
   The following Table I exemplifies how a few, exemplary electrical devices that may connect to the different slots illustrated in  FIG. 1 . 
   
     
       
             
             
             
           
         
             
                 
               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 
             
             
                 
                 
             
           
        
       
     
   
   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 . 
   The operation of universal electrical module  10  may be better understood upon reference to  FIGS. 3 ,  4 A-B, and  5 A-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. 
   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 . 
   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 . 
     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 . 
   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 . 
   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. 
     FIGS. 7A-7D ,  8 A- 8 D,  9 ,  10 A- 10 D, and  11 A- 11 D 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. 
   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 . 
   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. 
   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 . 
   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 ,  14 A- 14 D, and  15 A- 15 D, 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. 
   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. 
     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. 
   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. 
   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. 
   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.