Patent Publication Number: US-2009235515-A1

Title: Plug and Play Utility Control Modules

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     The present application is a continuation of U.S. patent application Ser. No. 11/683,335, Attorney Docket No. 58732-369501, filing date: Mar. 7, 2007, entitled “PLUG AND PLAY UTILITY CONTROL MODULES” and related to U.S. patent application Ser. No. 11/683,304, Attorney Docket No. 66816/P012 U.S. Ser. No. 10/609,934, filing date: Mar. 7, 2007 entitled “SYSTEMS AND METHODS FOR LINKING UTILITY CONTROL DEVICES”; U.S. patent application Ser. No. 11/683,327, Attorney Docket No. 66816/P013 U.S. Ser. No. 10/609,935, filing date: Mar. 7, 2007 entitled “SYSTEM AND METHOD FOR INFRASTRUCTURE REPORTING”; U.S. patent application Ser. No. 11/683,298, Attorney Docket No. 66816-P014 U.S. Pat. No. 1,061,4006, filing date: Mar. 7, 2007 entitled “LIGHT SWITCH USED AS A COMMUNICATION DEVICE”; U.S. patent application Ser. No. 11/683,308, Attorney Docket No. 66816-P015 U.S. Pat. No. 1,061,4005, filing date: Mar. 7, 2007 entitled “SYSTEM AND METHOD FOR PREMISES MONITORING USING WEIGHT DETECTION”; U.S. patent application Ser. No. 11/683,326, Attorney Docket No. 66816-P016 U.S. Pat. No. 1,061,4296, filing date: Mar. 7, 2007 entitled “ANTICIPATORY UTILITY CONTROL DEVICE”; and patent application Ser. No. 11/683,354, Attorney Docket No. 66816-P018 U.S. Pat. No. 1,070,1603, filing date: Mar. 7, 2007 entitled “SYSTEM AND METHOD FOR SUBSTITUTING DATA IN RESPONSES TO MULTIMEDIA INQUIRIES”; the disclosures of which are hereby incorporated in their entirety herein by reference. 
    
    
     TECHNICAL FIELD 
     This disclosure relates to utility control devices and more particularly to such devices that are modular and used in a plug and play manner. 
     BACKGROUND OF THE INVENTION 
     Utility control devices, such as light switches, dimmers, sockets and the like, are in common use today in various environments, such as homes, offices and factories. While great advances have been made in materials and in the manufacture of these devices, the actual manner in which the devices are wired into circuits has not changed significantly over the years since their first introduction into construction. Thus, electrical power is distributed throughout a premises by running individual wires from a power source to a load with branches run to locations where switches are to be wired into the circuit. These switches, as is well-known, are used to control power to fixed lights, to power outlets (wall sockets) and to a myriad of other devices. Typically, in the United States, this wiring carries 110 Volts, 60 cycle AC and in some countries 220 Volts 50 cycle AC. The wiring terminates in a metal or polymer box (utility box) and then a switch or other device is manually connected to the wires in the utility box. The electrical device is then fastened into the utility box and a face plate covers the device and covers any exposed wiring. 
     The plate serves the function of making the device less obtrusive to a decorated room as well as serving to keep fingers out of harms way, i.e., avoiding electrocution. The electrocution issue, along with fire hazard issues also arise when a person desires to change a switch, either because an existing device fails, or because it is desired to place another type of device in its place. 
     In addition to the above-discussed dangers of changing an electrical power control device, a further problem exists because the wires are pre-run to each outlet box. For example, if a person desires to convert a switch box to a socket (assuming the height and position of the box were otherwise acceptable) it would often be impossible since the wiring to the box often only contains the switched leg (for example only the black wire leg) of the circuit and not both legs (black and white wires) of the AC circuit. 
     Recently, as shown in one or more of the above-identified patent applications, there has been a desire to consolidate a number of operations into a single location. These operations have historically been performed by individual controls dedicated to each function. For example, a typical home has a controller for the thermostat, one for an alarm system and a number of controllers for each light in the home. When designing a home (or office or any other space) one of the challenges facing the designer is where to place all of these controls. This has often resulted in a number of switches being placed together for controlling a number of similar functions. Rearranging the location of one or more of these switches after construction is finished is at best a difficult process typically only performed by experienced and expensive skilled labor. It is common for the labor costs to be many times the cost of the device itself. 
     BRIEF SUMMARY OF THE INVENTION 
     A utility control device, such as a light socket, a switch or a plug socket, is designed with universal terminals so that when plugged into a pre-wired utility box (box socket), the terminals will make the proper electrical connections with the premises wiring. In one embodiment, a “shell” is inserted into a common utility box. The shell would then be wired to the building wiring on the “back-side” of the shell and when the shell is installed within the utility box the wiring is sandwiched inside the box and behind the shell and therefore not easily seen. A standard socket is positioned within the shell and provides a quick no-wiring required connection to the mating terminals on the actual device, for example a light-switch, or plug, or thermostat, or any other device normally installed and wired as a permanent fixture. Systems and methods are disclosed for arranging the premises power grid such that any device type can be “plugged” into the shells that are pre-wired inside the utility boxes. In one embodiment, the grid is constructed exactly as it has always been with each box pre-established for a particular type of control but with a plug/play adapter. In another embodiment, the grid is universally wired and each device instructs the system as to its type and as to its intended use. In operation, such a universal plan would allow a device, for example, to “announce” what light, or set of lights, it will control. The system can handle power wiring as well as control wiring. 
     The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter which form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims. The novel features which are believed to be characteristic of the invention, both as to its organization and method of operation, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       For a more complete understanding of the present invention, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which: 
         FIG. 1  shows one embodiment of an illustrative plug and play utility box mounted to a construction stud; 
         FIG. 2  illustrates one example of the use of plug and play utility boxes in a premises environment; 
         FIGS. 3 ,  4 ,  5 , and  6  show embodiments of schematics illustrating the plug and play nature of the wiring connections among permanently mounted utility boxes; and 
         FIG. 7  shows one embodiment of a system having universal control. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       FIG. 1  shows one embodiment  10  of an illustrative plug and play system using shell  11  inserted into a utility box, such as box  100 . While not necessary, it is anticipated that many such utility boxes will be permanently fastened to studs, such as stud  140 , or to other structural supports of a premises. Ideally, each box  100  would have a depth d no greater than (and presumably slightly less than) width w of the stud to which it is attached. The utility boxes can be constructed from any material, such as for example, metal or plastic. Such boxes would typically be mass-produced and sold in bulk. Shell  11  would have a depth less than “d” so as to form area  130  behind shell  11  and in front of back  103  of box  100 . The wiring, such as wiring  14  and  15 , that interconnects the boxes can be individual wires or preformed cables which are plugged into connector  12  or, when the shell is used, connected to connector(s)  12  ( 120 ) within space  130 . This wiring typically would be added by an electrician after the box is fastened to a particular structural member with the utility wires entering the rear of box  100  and held in place, for example, by clamps  131 . When shell  11  is mated and secured within box  100  this wiring is hidden from view and away from fingers and tools. Shell  11  can be secured within box  11  in any well known manner, such as, for example, snaps, clips, screws, force fit and the like. 
     One or more connectors  12 - 120 , are positioned within shell  11  (or directly within box  100  when the shell is not used) such that contacts  13  of each such connector are open into area  102  of shell  11 . This then allows a control device (not shown in  FIG. 1 ) to become mated, both electrically and physically, within box  100 . Slots  101  of box  100  serve, if desired, to hold the mated control device within the utility box by mating with tabs on an inserted control device. 
     As will be discussed, the user then simply pushes in (or pulls out) a control device when desired such that user need not touch the electrical connections within the utility box and does not require an electrician to install or remove the device. These connections (electrical and/or control, and/or communications) are made by the plug on the control device mating with socket  12  or  120 . Connector  12  ( 120 ) can be designed to snap in and out of shell  11  (or housing  100 ) which also serves to facilitate wiring to the connector. Note that while the connector is shown on the back wall of the shell, one or more connectors can be placed on any interior surface of the box and any surface of the shell, if desired. 
       FIG. 2  illustrates the use of plug and play shell  11 - 1  shown without utility box  100 - 1  for simplicity. The utility box(es) would be mounted in a premises environment together with a control device, such as switch  300  about to be mated into shell  11 - 1 . Also shown is a ceiling fixture having shell  11 - 2  with light socket  301  mated therewith. Light  302  is about to be screwed into socket  301 . 
     Device  300  is a switch (in this case a single-pole single-throw switch) contained within housing  21 . Housing  21  (as is housing  301 ) has a physical design such that it fits within open area  102  of shell  11 - 1  (or within shell  11 - 2 ). The rear surface of housing  21  contains connector  22  having contacts  23  adapted for mating both physically and electrically with connector  12 . Connector  22  is rigidly mounted to the rear surface of housing  21  as is connector  230  (if present). 
     The front portion of housing  21  is covered by, for example, face plate  201 . Tabs  202  mate with slots  101  and are used to hold housing  21  firmly in position with respect to shell  11 - 1 . Note that the utility box can be designed to allow housing  22  to mate with it so that shell  11  need not be sturdy enough to hold the housing. This also allows the shell to be optimal, perhaps being used as in a retro fit situation. Shell  11  can be made of any material and typically would be of a plastic non-conductive material. 
       FIG. 3  shows one embodiment of a schematic, such as schematic  30 , illustrating the plug and play nature of the wiring connections among shells  11 - 1 ,  11 - 2 ,  11 - 3  mounted within utility boxes. Terminals W, B, S 1 , S 2 , and S 3 , as well as other terminals are connected to wiring  14  and optionally  15  as shown. Thus, all the similarly lettered terminals are electrically common. Assume that the W terminal is connected to the white wire of the power grid while the B terminal is connected to the black wire of the grid. In this example, a 110V AC grid is assumed, but any power grid can be used. 
     Switch  300  is shown connected to contacts  23 - 1  and  23 - 2  of connector  22  (shown in  FIG. 2 ) such that when switch  300  is mated with connector  12  ( FIG. 2 ) of a junction box, such as shell  11 - 1 , terminal  23 - 1  is electrically connected to terminal B of connector  12  while terminal  23 - 2  is electrically connected to terminal S 1  of connector  12 . 
     Lamp  302  (or more precisely, device  301 ,  FIG. 2  into which lamp  302  can be mounted) has its terminal  23 - 3  connected to terminal W of connector  12  in shell  11 - 2  while terminal  23 - 4  is connected to terminal S 3 . Note that bridge connector  320  is used (if desired) to cross-connect terminal S 3  to terminal S 1 . The same electrical effect could be achieved by connecting terminal  23 - 4  directly to terminal S 1 . However, to do so would require wiring changes to cable  14  by a user that may not be desired. Note that while bridge  320  is shown, the respective connections can be changed by slipping pins into various locations within the base of connector  22  of device  301  so as to effect the desired cross-connect arrangement. 
     In operation, when a user operates switch  300 , electrical current flows from the black wire of the power grid (terminal B shell  11 - 1 ) through switch  300  and via terminal S 1  of shell  11 - 1  to terminal S 1  of shell- 2  through cross connect bridge  320  to terminal S 3  of shell  11 - 2  to device  301 . The other side of device  301  is connected to the white wire of the power grid via terminal W of shell  11 - 2 . This causes lamp  302  to go on and off following the switch operation of switch  300 . 
       FIG. 4  shows the situation where it is desired to convert the switch operation of lamp  302  into a so called three-way circuit such that lamp  302  can be turned on or off from two different locations. The conversion starts with the removal of plug and play device  301  from shell  11 - 2 . Cross-connect bridge  320  is then removed which essentially removes the jumper between terminals S 1  and S 3 . This can be done by moving pins (either on the bridge or on the device) or simply by cutting the bridge jumper on bridge  320 , or by not using a bridge at all. 
     A three-way switch device, such as device  400 - 2 , is plugged into shell  11 - 3 . Device  400 - 2  is wired so that terminal  23 - 1  connects to terminal B. However, bridge  402  blocks the connection to terminal B and instead connects terminal  23 - 1  to terminal S 3 . This connection, as discussed above, can be made directly at the switch if desired without using the bridge. In such a situation, terminal  23 - 1  would be connected to terminal S 3 . 
     Switch  300  is removed from shell  11 - 1  and replaced by three-way switch  400 - 1  which is wired as shown. This conversion then has the effect of allowing lamp  302  to be operated on or off from either switch  400 - 1  or  400 - 2  using the plug/play concepts described herein. Note that this conversion of functional operation occurred without the need for touching main wiring  14  or  15  and thus would not normally require the use of an electrician. 
       FIG. 5  shows how shell  11 - 3  can be converted from a switch to an outlet. This is accomplished by removing the switch simply by pulling the switch out of shell  11 - 3  and inserting in its place outlet  501  which is pre-wired such that the outlet connects to the black and white wires (B &amp; W terminals) of shell  11 - 3  via terminals  23 - 3  and  23 - 2 . 
       FIG. 6  shows the situation where device  501  becomes a switched outlet simply by inserting bridge  620  between outlet  501  and the connector of shell  11 - 3 . In this manner switch  300  controls the on-off state of outlet  501 , in a plug and play manner all without any changes to the power wiring of the premises. Note that while only a few different functions have been discussed herein, any number of different functions can be interchanged, such as, outlet socket, light socket, dimmer, motion detection switch, light-intensity detection switch, touch screen controller, telephone, alarm controller, etc. 
       FIG. 7  illustrates system  70  having universal control such that processor/communicator  71 - 1  associated with connector  230 - 1  in box  700 - 1  sends messages to one or more other processors, such as processor/communicator  71 -N in box  700 -N, to inform the system as to what type of device is plugged into box  700 - 1 . Processor/communicator  71 -N can be a control processor that then sends control signals to other devices, or processor/communicator  71 -N can be a processor in each device for self control of the associated device. 
     The electrical signals among processors can be any type of signals, including wireless signals and light signals, but advantageously, these signals would be transmitted on one of the wires (such as the power line) interconnecting the boxes or, as shown, the signals can be transmitted on a set of control lines. The signals can be general broadcast signals or can be coded for transmission reception by one or more selected (by address, location, etc.) other devices. Note that optics can be used and thus the terms electrical and wiring include optics and optical cables. 
     Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the disclosure of the present invention, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized according to the present invention. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps.