Patent Document

CROSS REFERENCE TO RELATED APPLICATIONS 
   This application claims the benefit of priority under 35 U.S.C. § 119(e) of Provisional U.S. patent application Ser. No. 60/439,370 filed on 9 Jan. 2003, the content of which is relied upon and incorporated herein by reference in its entirety. 

   BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   The present invention relates to an electrical wiring device and more particularly to an electrical wiring device suitable for commercial and residential use. 
   2. Background of the Invention 
   Typically, wall mounted conventional electrical devices for use in residential or commercial applications such as offices require a wall plate specifically configured for the electrical device. For example, each switch, receptacle, or hallway light typically employs its own wall plate opening. Installation of multiple devices may require multiple gang wall plates and multiple gang wall boxes. This requires that an electrical installer carry an inventory of an assortment of wall plates and wall boxes, thereby incurring unnecessary cost. 
   Thus, there is a need for a modular electrical device that reduces the need for specialized installation, thereby reducing inventory cost and simplifying the installation process. 
   SUMMARY OF THE INVENTION 
   In one embodiment, the present invention includes a modular electrical device for use in an electric circuit. The modular electrical device includes a wall plate defining a first opening, and a housing configured to be disposed within the first opening. The housing is configured to accommodate a frame member selected from a plurality of frame members. Each frame member is configured to accommodate at least one wiring module. The modular electrical device further includes an electrical wiring module chosen from a plurality of electrical wiring modules. Each of the plurality of electrical wiring modules has a different functional configuration, and each of the plurality of electrical wiring devices being sized to fit in the selected frame member. The modular electrical device further includes a set of terminal contacts selected from a plurality of sets of terminal contacts. Each set of terminal contacts is matched to accommodate one of the plurality of electrical wiring modules. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is front elevation view of the modular electrical device of the present invention. 
       FIG. 2  a perspective view of an one embodiment of an electrical wiring device used in the modular electrical device of the present invention; 
       FIG. 3  a perspective view of an alternative embodiment of an electrical wiring device used in the modular electrical device of the present invention; 
       FIG. 4  a perspective view of an alternative embodiment of an electrical wiring device used in the modular electrical device of the present invention; 
       FIG. 5  a perspective view of an alternative embodiment of an electrical wiring device used in the modular electrical device of the present invention; 
       FIG. 6  a perspective view of an alternative embodiment of an electrical wiring device used in the modular electrical device of the present invention; 
       FIG. 7  a perspective view of an alternative embodiment of an electrical wiring device used in the modular electrical device of the present invention; 
       FIG. 8  a perspective view of an alternative embodiment of an electrical wiring device used in the modular electrical device of the present invention; 
       FIG. 9  a perspective view of an alternative embodiment of an electrical wiring device used in the modular electrical device of the present invention; 
       FIG. 10  is an enlarged fragmentary view of an electrical wiring device of the present invention showing a blank marked with identifying symbols; 
       FIG. 11  is an exploded view of the electrical wiring device  14  shown in  FIG. 2  in accordance with an embodiment of the invention; and 
       FIG. 12  is an exploded view of the electrical wiring device  14  shown in  FIG. 2  in accordance with another embodiment of the invention. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   Reference will now be made in detail to the present embodiments of the invention, examples of which are illustrated in the accompanying drawings. Whenever possible, the same reference numerals will be used throughout the drawings to refer to the same or like parts. 
   One embodiment of the electrical device of the present invention is shown in  FIG. 1  and is designated generally throughout by the reference numeral  10 . The electrical device  10  includes a wall plate  12  and an electrical wiring device  14 . 
   The wall plate includes a single rectangular  16  opening configured to receive any one electrical wiring device  14  from a plurality of differently configured electrical wiring devices. In an alternative embodiment, the opening  16  in the wall plate  12  is sized to accommodate a plurality of electrical wiring devices  14  installed in a single wall box in an abutting relationship to one another. 
   Each of the electrical wiring devices  14  includes a ground strap  15 . The ground strap  15  is made from an electrically conductive metal and is configured for mounting the electrical device  10  into a conventional wall box (not shown). The strap  15  is further configured to receive the housing  17  of the electrical wiring device  14 . The housing  17  includes a body  19 , and a frame  21  that work in cooperation to provide mounting places for the components of the electrical device  10 , such as terminals and electrical switch components. 
   It will be readily apparent to those of ordinary skill in the art that, in view of the teachings disclosed herein, modifications to the described embodiment may be made to incorporate a variety of electrical wiring devices without departing from the scope of the present disclosure. Both the body  19  and frame  21  are made from a non-electrically conductive material, such as, for example plastic and may be made for example, by a molding process, such as, for example an injection molding process. 
   The body  19  is configured to receive a plurality of terminals  23 . The terminals  23  fit into openings in the sides of the body  19 . The openings are configured to securely hold the terminals  23  in predetermined positions that electrically isolate the terminals  23  from one another. Each of the terminals  23  is configured for the coupling of an electrically conductive wire thereto. 
   Turning to  FIG. 2 , one possible electrical wiring device  14  for use in the modular electrical device  10  of the present invention is shown. The electrical wiring device  14  includes two switches  18 ,  20  and two modular blanks  22 . The two switches  18 ,  20  may be either single pole or three-way switches. Thus, the electrical wiring device  14  may include two single pole switches, two three-way switches or a single pole and a three-way switch. The blanks  22  are removably engageable members that aid in alignment of the electrical wiring device  14  within the opening  16  of the wall plate  12  of the modular electrical device  10 .  FIG. 10  shows a detail of the installation of a single blank  22 . As shown in  FIG. 10 , the blank  22  may include identifying symbols  31 . In an alternative embodiment the blanks  22  do not include any identifying markings. 
   Turning to  FIG. 3 , another possible electrical wiring device  14  for use in the modular electrical device  10  of the present invention is shown. The electrical wiring device  14  shown in  FIG. 3  includes three switches  18 ,  24 ,  26  and two blanks  22 . The switches  18 ,  24 ,  26  may be either single pole or three-way switches. Thus, the electrical wiring device may be configured to include three single pole switches, two single pole switches and one three-way switch, one single pole switch and two three-way switches or three three-way switches. The blanks  22  are removably engageable members that aid in alignment of the electrical wiring device  14  within the opening  14  of the wall plate  12  of the modular electrical device  10 . 
   Turning to  FIG. 4 , another possible electrical wiring device  14  for use in the modular electrical device  10  of the present invention is shown. The electrical wiring device  14  shown in  FIG. 4  includes four switches  18 ,  24 ,  26 ,  28  and two blanks  22 . The four switches  18 ,  24 ,  26 ,  28  may be either single pole or three-way switches. Thus, the electrical wiring device may be configured to include four single pole switches, three single pole switches and one three-way switch, two single pole switch and two three-way switches, one single pole and three three-way switches or four three-way switches. The blanks  22  are removably engageable members that aid in alignment of the electrical wiring device  14  within the opening  16  of the wall plate  12  of the modular electrical device  10 . 
   Turning to  FIG. 5 , another possible electrical wiring device  14  for use in the modular electrical deice  10  of the present invention is shown. The electrical wiring device  14  includes a switch  18 , a placard holder  29 , and a single blank  22 . This electrical wiring device is similar to ones described in co-pending U.S. patent application Ser. No. 10/726,137, entitled Electrical Switch with Placard and Remote Use Indicator, which is hereby incorporated by reference in its entirety. The switch  18  may be either a single pole switch or a three-way switch. The placard holder is configured to display a removable media that may include text, tactile indicia, images, or combinations thereof. The single blank  232  is used to align the electrical device  14  within the opening  16  of wall plate  12 . 
   Turning to  FIG. 6 , another possible electrical wiring device  14  for use in the modular electrical device  10  of the present invention is shown. The embodiment of the electrical wiring device  14  shown in  FIG. 6  includes a switch  18 , a receptacle  30  and a single blank  22 . The switch  18  may be either a single pole or a three-way switch. The receptacle may be configured to include ground fault interruption protection. The single blank  22  is used to align the electrical device  14  within the opening  16  of the wall plate  12 . 
   Turning to  FIG. 7 , another possible electrical wiring device  14  for use in the modular electrical device  10  of the present invention is shown. The embodiment of the electrical wiring device  14  shown in  FIG. 7  includes two switches  18 ,  20  mounted in a side-by-side configuration, a receptacle  30  and a single blank  22 . The two switches  18 ,  20  may be either single pole or three-way switches. Thus, the electrical wiring device  14  shown in  FIG. 7  may be configured to include two single pole switches, a single pole switch and a three-way switch or two three-way switches. The receptacle may be configured to include a ground fault circuit interruption (GFCI) protection. The single blank  22  is used to align the electrical device  14  within the opening  16  of the wall plate  12 . 
   Turning to  FIG. 8 , another possible electrical wiring device  14  for use in the modular electrical device  10  of the present invention is shown. The embodiment of the electrical wiring device shown in  FIG. 8  includes a hallway light  32  and a receptacle  30 . The hallway light  32  is configured to provide a predetermined quantity of illumination when electrical power is supplied. The receptacle may be configured to include ground fault circuit interruption (GFCI) or arc fault circuit interrupter (AFCI) protection. 
   Turning to  FIG. 9 , another possible electrical wiring device  14  for use in the modular electrical terminal  10  of the present invention is shown. The embodiment of the electrical wiring device  14  shown in  FIG. 9  includes a hallway light that is sized to substantially fill the opening  16  of the wall plate  12 . The hallway light  32  is configured to provide a predetermined quantity of illumination when electrical power is supplied. 
     FIG. 11  is an exploded view of the electrical wiring device  14  shown in  FIG. 2 . The two switches  18   a  and  20   b  are single pole switches.  FIG. 12  is an exploded view of the electrical device  14  depicted in  FIG. 2 . In that embodiment, switch  18   b  is configured as a single pole switch and the other switch  20   b  is configured as a three-way switch. Reference is also made to U.S. patent application Ser. No. 10/729,566 which is incorporated herein by reference as though fully set forth in its entirety, for a more detailed explanation of these embodiments. 
   Comparing the body  19   a  of  FIG. 11  with the body  19   b  of  FIG. 12  it is evident that body  19   a  is configured to receive four terminals  23  and body  19   b  is configured to receive five terminals  23 . Both body  19   a  and body  19   b  are configured to engage the ground strap  15  in an identical manner. Both body  19   a  and body  19   b  are examples of the different types of frames that may be selected to provide an electrical wiring device  14  with a desired functionality. Both body  19   a  and body  19   b  exhibit the common trait to all of the bodies used in the present invention, namely that they posses a substantially common form factor that allows a them and a complementary frame  21  to engage a specific sized opening in a wall plate  12 . The complimentary frame  21  is also selected depending upon the desired functionality of the electrical wiring device  14 . 
     FIG. 11  and  FIG. 12  illustrate a removable lamp module  50  which has a form factor configured to replace blank  22 . Lamp module  50  is configured to take the place of blank  22  in the various embodiments of the invention as described herein. Lamp module  50  is electrically coupled to terminals  23 . Lamp module  50  may operate as a remote use indicator that emits light when power is applied to the load. Alternatively, lamp module  50  may operate as a locator for device  10  by emitting light even when power is not provided to the load. A locator directs users to the location of the electrical wiring device in a darkened room. Lamp module may also act as a power indicator that emits light when device  10  is electrically energized. Lamp module  50  may include a circuit that provides a continuous emission of light, or a circuit that generates a blinking light. The lamp indicator and module is similar to that described in co-pending U.S. patent application Ser. No. 10/726,173 which is incorporated herein by reference as though fully set forth in its entirety. 
   Whereas the switch in the various embodiments have been characterized as single pole or three way switches, a switch can be in any number of configurations, for example, two single pole switches. 
   Thus, different combinations of frame  21  and body  19  pairs may be assembled to form an almost limitless array of electrical wiring devices to provide a desired functionality. 
   As will be readily appreciated by those skilled in the art, the choice of functionality of the electrical wiring device  14  determines which frame  21  and body  19  are selected. The overriding consideration is that no matter which frame  21  and body  19  are chosen, that when they are combined to form a housing the  17 , the housing exhibits a consistent form factor allowing the housing to be engage the wall plate  12  regardless of the functional design of the electrical wiring device  14 . 
   It will be apparent to those skilled in the art that various modifications and variations can be made to the present invention without departing from the spirit and scope of the invention. Thus, it is intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.

Technology Category: 5