Abstract:
A modular electrical wiring component comprises includes a wiring module having a wiring portion for coupling to a source of electrical power and a user-accessible portion configured to accept and provide electrical power to a functional module that provides a selected electrical distribution function, wherein the wiring module is configured to accept the functional module without access to the wiring portion. The modular electrical wiring component also comprises includes an adjustable plaster ring configured to couple to the wiring module and to an electrical junction box, wherein the adjustable plaster ring provides a variable distance between the electrical junction box and the wiring module.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
     Notice: More than one reissue application has been filed for the reissue of U.S. Pat. No. 7,572,977. The reissue applications include the present application, which is a continuation reissue application of reissue application Ser. No. 13/208,260, filed Aug. 11, 2011, both of which are broadening reissues of U.S. Pat. No. 7,572,977.  
     This applicationU.S. Pat. No. 7,572,977 is a continuation of co-pending U.S. application Ser. No. 10/924,555 filed Aug. 24, 2004 and entitled “Universal Electrical Wiring Component,” now U.S. Pat. No. 7,312,396, issued on Dec. 25, 2007, which claims priority from U.S. Provisional Application No. 60/552,546 filed Mar. 13, 2004 and entitled “Modular Integrated Wiring System,” both of which are incorporated by reference in their entirety. 
    
    
     BACKGROUND OF THE INVENTION 
     Conventional AC electrical systems are comprised of a junction box and an electrical device, such as an outlet or switch, installed within the box. During a rough-in phase of construction, power cables are routed through building framing to junction boxes mounted at predetermined electrical distribution locations. The power cables are fed through openings in the rear or sides of the junction boxes and folded back inside, unterminated, so as to be out of the way until the next phase. During a makeup phase, wall panels are installed and painted, and electrical devices are installed into the boxes. After conductors are wired to an electrical device, it and the attached conductors are pushed into the electrical box and the device is attached to the top and bottom of the box. During a trim phase, face plates are mounted over the open-end of the junction boxes, completing the conventional electrical wiring process. 
     SUMMARY OF THE INVENTION 
     Conventional electrical wiring installation is a logistical nightmare of schedules, inventory, design changes and rework to correct design and installation errors and product defects. Prefabricated units having brackets with pre-mounted junction boxes and pre-wired outlets and switches installed within the boxes are sometimes utilized in an effort to save installation time. These units are manufactured per contractor specification and delivered to the job site. An electrician attaches a particular unit at a specific location and attaches a corresponding power cable to a standard connector. 
     Such prefabricated electrical systems, however, do not solve all of the logistical problems associated with electrical wiring system design and installation and create additional ones. Each prefabricated unit is typically specified as to mounting height, plaster ring depth, support arm length and electrical device type, to name a few, and are given unique part numbers. Each part number represents a different stock keeping unit (SKU) for the distributor and contractor. The contractor must sort each SKU to corresponding installation locations at the job site. If an SKU malfunctions, there is typically no replacement part, and the SKU has to be returned to the manufacturer. Each prefabricated part is custom made so there is much room for mistakes to be made in the specification and assembly process. If an electrician opens the SKU to fix a problem inside, the product warranty may be void. 
     A universal electrical wiring component advantageously combines an adjustable, modular mount with modular electrical devices to reduce installation costs over conventional wiring in much the same manner as a typical prefabricated system. Because a universal electrical wiring component is modular, a limited number of such components can be combined and configured as a substitute for many conventional assemblies. This significantly reduces the number of SKUs and associated inventory and planning headaches. Because a universal wiring component is adjustable, it greatly reduces specification requirements and eliminates the possibility of assembly errors associated with custom prefabricated parts. A universal electrical wiring component also advantageously accommodates design changes including the location and the type of an electrical distribution point and the function and color of an installed electrical device. Testing of the wiring system can be accomplished at the rough-in phase while walls are open rather than the trim-out phase. Trim-out can be completed without touching a wire. Devices can finish flush with the wall every time. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a front view of a modular integrated wiring system utilizing various embodiments of a universal electrical wiring component; 
         FIG. 2  is a front perspective exploded view of a universal electrical wiring component having modular electrical devices combined with an adjustable, modular mount; 
         FIG. 3  is a front perspective view of a floor bracket electrical wiring component; 
         FIG. 4  is a front perspective view of a stud bracket electrical wiring component; 
         FIG. 5  is a front perspective view of a box bracket electrical wiring component; 
         FIG. 6  is a front perspective view of an extended box bracket electrical wiring component; 
         FIG. 7  is an exploded perspective view of a junction box assembly; 
         FIG. 8  is an exploded perspective view of a floor bracket assembly; 
         FIG. 9  is an exploded perspective view of a stud bracket assembly; 
         FIG. 10  is an exploded perspective view of a box bracket assembly; 
         FIG. 11  is an exploded perspective view of an extended BOX bracket assembly; 
         FIG. 12  is an exploded perspective view of an adjustable plaster ring; 
         FIG. 13  is a perspective view of a junction box; and 
         FIGS. 14A-D  are top, perspective, front and side views, respectively, of a support arm. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       FIG. 1  illustrates a modular integrated wiring system  100  utilizing universal electrical wiring component embodiments  300 - 600 . A floor bracket component  300 , a stud bracket component  400 , a box bracket component  500  and an extended box bracket  600  are included, providing adaptability for different electrical power distribution designs. Each wiring component  300 - 600  provides mounting flexibility by adjusting to various wall dimensions, stud configurations, and electrical distribution point locations. Specifically, each component  300 - 600  has an adjustable depth into the wall, guaranteeing a flush finish with the wall surface at every electrical distribution point. In addition, the floor bracket component  300  provides an adjustable height. The stud bracket component  400  can be positioned at any height and provides an adjustable distance between studs. The box bracket component  500  can be positioned at any height, and the extended box bracket component  600  can be positioned at any height and at various locations between studs. Further, each wiring component  300 - 600  accommodates a variety of functional modules, including various outlets, switches, GFCI devices, and motion detectors to name few. Advantageously, the color of the functional modules and even some functionality can be readily changed at anytime without rewiring, as described below. The resulting modular integrated wiring system  100  has the labor saving advantages of prefabrication with the design and installation flexibility of individually configured and wired components. 
     A universal electrical wiring component combining modular electrical devices and an adjustable, modular mount is described with respect to  FIG. 2 , below. A floor bracket component  300  is described in further detail with respect to  FIG. 3 , below. A stud bracket component  400  is described in further detail with respect to  FIG. 4 , below. A box bracket component  500  is described in further detail with respect to  FIG. 5 , below, and an extended box bracket component  600  is described in further detail with respect to  FIG. 6 , below. Adjustable mounts are described in detail with respect to  FIGS. 7-11 , below. 
       FIG. 2  further illustrates a universal electrical wiring component  200  having an adjustable mount  205  combined with a wiring module  201 . The adjustable mount  205  includes a bracket  207  and a box assembly  700 . The bracket  207  can be, for example, a vertically adjustable floor bracket  800  ( FIG. 8 ), a horizontally adjustable stud bracket  900  ( FIG. 9 ), a box bracket  1000  ( FIG. 10 ), or an extended box bracket  1100  ( FIG. 11 ). The box assembly  700  is mounted to the bracket  207  and the wiring module  201  is mounted in the box assembly  700 . The wiring module  201  may be a regular wiring module  210  or a GFCI wiring module  220 . The adjustable mount  205  is configured to position the wiring module  201  at any of various locations within a building wall. The wiring module  201  is configured to connect to a source of electrical power and to removably accept a functional module  203 . Advantageously, the combination of adjustable mount and wiring module form a universal electrical wiring component that can implement a variety of electrical distribution points of an electrical system. For example, a universal electrical wiring component can accept various outlet modules  250 - 260  and can be adjusted to implement a wall outlet. As another example, a universal electrical wiring component can accept various switch modules  240  and can be adjusted to implement a switch outlet. A universal electrical wiring component  200  may be, for example, a floor bracket component  300  ( FIG. 3 ), a stud bracket component  400  ( FIG. 4 ), a box bracket component  500  ( FIG. 5 ) or an extended box bracket component  600  ( FIG. 6 ). A cover  204  may be used to protect a wiring module  201  from damage prior to functional module installation. 
       FIG. 3  illustrates a floor bracket component  300  having a wiring module  201  and an adjustable mount comprising a box assembly  700  and a floor bracket  800 . In this embodiment, the floor bracket  800  provides the wiring module  201  an adjustable height from the floor and the box assembly  700  provides the wiring module  201  an adjustable distance from the box assembly  700  for a flush position with a wall surface. 
       FIG. 4  illustrates a stud bracket component  400  having a wiring module  201  and an adjustable mount comprising a box assembly  700  and a stud bracket  900 . In this embodiment, the stud bracket  900  provides the wiring module  201  an adjustable distance between studs and the box assembly  700  provides the wiring module  201  an adjustable distance from the box assembly  700  for a flush position with a wall surface. 
       FIG. 5  illustrates a box bracket component  500  having a wiring module  201  and an adjustable mount comprising a box assembly  700  and a box bracket  1000 . In this embodiment, the box bracket  1000  allows positioning of the wiring module  201  along a vertical stud. Also, the box assembly  700  provides the wiring module  201  an adjustable distance from the box assembly  700  for a flush position with a wall surface. 
       FIG. 6  illustrates an extended box bracket component  600  having a wiring module  201  and an adjustable mount comprising a box assembly  700  and an extended box bracket  1100 . In this embodiment, the extended box bracket  1100  allows vertical positioning of the wiring module  201  along a stud and horizontal positioning between studs. Also, the box assembly  700  provides the wiring module  201  an adjustable distance from the box assembly  700  for a flush position with a wall surface. 
       FIG. 7  illustrates a box assembly  700  having a junction box  1300 , an adjustable plaster ring  1200  and a support arm  1400 . The plaster ring  1200  removably attaches to the junction box  1300  and a wiring module  201  ( FIG. 2 ) attaches to the plaster ring  1200 . The plaster ring provides the wiring module  201  ( FIG. 2 ) with an adjustable distance from the junction box  1300 , as described in detail with respect to  FIG. 12 . The junction box  1300  advantageously has an attached ground wire that can be quickly connected to a wiring module  201  ( FIG. 2 ). The plaster ring  1200  has slotted fastener apertures so that the plaster ring  1200  along with an attached wiring module can be removed from, and reattached to, the junction box  1300  by merely loosening and tightening, respectively, the fasteners. The support arm  1400  attaches to the back of the junction box to provide support against an inside wall surface, as described in further detail with respect to  FIGS. 14A-D , below. 
       FIG. 8  illustrates a floor bracket  800  having an open front  801  and ruled sides  810 . The floor bracket  800  has tabs  820  for attaching the bracket  800  to one or both of a floor joist or a wall stud. Side grooves  830  allow fasteners to attach the junction box  1300  at an adjustable height from the floor. Conduit supports  840  are adapted for attachment to conduits running to the junction box  1300 . The plaster ring  1200  is attached to the box  1300  through the open front  801  so that the plaster ring  1100  can be removed from the box  1130  without removing the box  1300  from the bracket  800 . 
       FIG. 9  illustrates a stud bracket  900  having a horizontal bar  901  and ends  903 . The ends  903  are folded perpendicularly to the bar  901  and adapted to secure the bracket  900  horizontally between wall studs. The bar  901  has grooves  910  and a slot  920  that extend horizontally to proximate both ends  903  of the bracket  900 . The grooves  910  are adapted to slideably retain corresponding box tongues  1312  ( FIG. 13 ). The slot  920  is centered between the grooves  910  and accommodates a fastener that secures the junction box  1300  to the bracket  900  while allowing the box to slideably adjust in position along the bar  901 . The plaster ring  1200  is attached to the box  1300  and can be removed from the box  1300  without removing the box  1300  from the bracket  900 . 
       FIG. 10  illustrates a box bracket  1000  having a stud mounting face  1001  and a box mounting face  1003 . The stud mounting face  1001  is disposed perpendicular to the box mounting face  1003  and is adapted to fasten to a wall stud. Either side of the junction box  1300  attaches to the box mounting face  1003 . The box mounting face  1003  has a keyhole slots  1011  allowing the junction box  1300  to fasten and unfasten to the bracket  1000  without removing the fasteners  1020 . The stud mounting face  1001  has a plurality of mounting holes  1110  to accommodate fasteners that allow the junction box  1300  to be positioned along a stud. 
       FIG. 11  illustrates an extended box bracket  1100  having an extended stud mounting face  1101  and a box mounting face  1103 . The box mounting face  1103  is disposed perpendicular to the extended stud mounting face  1101  and is adapted to fasten to the junction box  1300 . The extended stud mounting face  1101  is adapted to fasten to a wall stud. The extended stud mounting face  1101  has a plurality of mounting holes  1110  spaced along the length of the bracket  1100  to accommodate fasteners that allows the junction box  1300  to be position vertically along a stud and horizontally between studs. 
       FIG. 12  further illustrates an adjustable plaster ring  1200  having a base ring  1210 , an insert ring  1220  and adjusting screws  1230 . The insert ring  1220  is slideably retained by the base ring  1210  and secured to the base ring  1210  by the adjusting screws  1230 . The insert ring  1220  is adapted to mount a wiring module and to adjust the wiring module position relative to the base ring  1210  in response to turning of the screws  1230 . The base ring  1210  has keyhole slots  1214  adapted to accommodate fasteners that attach the plaster ring  1200  to a junction box. The keyhole slot  1214  allows the plaster ring  1200  to fasten and unfasten to the junction box without removing the fasteners. 
       FIG. 13  further illustrates a junction box  1300  having a ground wire  1310 , a tongue  1312  and knockouts  1314 . The ground wire  1310 , being pre-wired to the box, advantageously saves a fabrication step on the job site. Further, the ground wire  1310  is configured to insert into a push-wire connector on a pre-wired wiring module, providing a plug-in function module with a path to ground. The tongue  1312  stabilizes the box within a groove on a stud bracket, if used. The knockouts  1314  provide attachment points for power cable conduits. 
       FIGS. 14A-D  further illustrate a support arm  1400  adapted to attach to a back face of the junction box  1300  ( FIG. 13 ) and provide support against an inside wall surface. In particular, the support arm  1400  has an attachment section  1401  and a support section  1402  extending generally perpendicularly from one end of the attachment section  1401 . The attachment section is generally planar having an inside face  1404  that is disposed against the junction box  1300  and an opposite outside face  1405  that is disposed distal the junction box  1300 . The support section  1402  has a support face  1407  that is disposed against an inside wall surface. The attachment section  1401  has an adjustment slot  1410 , a fastener hole  1420 , and a plurality of bending slots  1430  distributed along and extending perpendicularly across the adjustment slot  1410 . The attachment section  1401  is configured to bend along one of the bending slots  1430  so as to provide a variable length support extending generally normal to the junction box back face. The support arm  1400  is held to the box  1300  with a fastener that is slideable along the adjustment slot  1410 , providing an adjustable support arm position. 
     A universal electrical wiring component has been disclosed in detail in connection with various embodiments. These embodiments are disclosed by way of examples only and are not to limit the scope of the claims that follow. One of ordinary skill in the art will appreciate many variations and modifications.