WALL GROMMET FOR POWER CONNECTION

Abstract

Provided is a wall grommet, which can be installed through the surfaces of walls to route wiring in the walls' interior spaces. In particular, the wall grommet is configured for running power cords inside walls and presenting the electrical connectors of a power cord in a manner such that power cords are hidden from view. The grommet may comprise a housing, which defines an interior space that is adapted to hold either the female connector or male connector of a power cord. The housing may be configured to enclose and secure the electrical connector of the power cord in the housing.

Claims

1. A power cord rated for use inside walls, comprising: a type NM-B cable terminating with a female receptacle connector on one end and terminating with a male prong connector on another end; wherein the female receptacle connector and male prong connector are integrally formed with the type NM-B cable to form a unitary power cord; wherein each of the female receptacle connector and male prong connector comprises a body defining a front face providing electrical connection points, the body defining a longitudinal axis normal to the front face; wherein the type NM-B cable extends from the body of the female receptacle connector transversely to the longitudinal axis of the female receptacle connector; and wherein the type NM-B cable extends from the body of the male prong connector transversely to the longitudinal axis of the male prong connector.

2. The power cord of claim 1, wherein each of the female receptacle connector and male prong connector further comprises a flange extending from the body along a plane parallel to the front face or perpendicular to the longitudinal axis of the body.

3. The power cord of claim 2, wherein the flange of each of the female receptacle connector and male prong connector is offset from the front face along the longitudinal axis of the body.

4. The power cord of claim 2, wherein the flange of each of the female receptacle connector and male prong connector extends circumferentially around the body.

5. The power cord of claim 1, wherein the type NM-B cable extends from the body of the female receptacle connector at a 90° angle to the longitudinal axis of the female receptacle connector; and wherein the type NM-B cable extends from the body of the male prong connector at a 90° angle to the longitudinal axis of the male prong connector.

6. A power cord rated for use inside walls, comprising: a first electrical connector disposed at a first end of a cable that is rated for use inside walls and a second electrical connector disposed at a second end of the cable; wherein each of the first electrical connector and second electrical connector comprises a body defining a front face providing electrical connection points, the body defining a longitudinal axis normal to the front face; wherein the cable extends from the body of the first electrical connector transversely to the longitudinal axis of the first electrical connector; and wherein the cable extends from the body of the second electrical connector transversely to the longitudinal axis of the second electrical connector.

7. The power cord of claim 6, wherein each of the first electrical connector and second electrical connector further comprises a flange extending from the body along a plane parallel to the front face or perpendicular to the longitudinal axis of the body.

8. The power cord of claim 7, wherein the flange of each of the first electrical connector and second electrical connector is offset from the front face along the longitudinal axis of the body.

9. The power cord of claim 7, wherein the flange of each of the first electrical connector and second electrical connector extends circumferentially around the body

10. The power cord of claim 6, wherein the cable is a type NM-B cable.

11. The power cord of claim 6, wherein the first electrical connector is a female receptacle connector and the second electrical connector is a male prong connector.

12. The power cord of claim 6, wherein the first electrical connector and the second electrical connector are integrally formed with the cable to form a unitary power cord.

13. The power cord of claim 6, wherein the cable extends from the body of the first electrical connector at a 90° angle to the axis normal to the front face of the first electrical connector; and wherein the cable extends from the body of the second electrical connector at a 90° angle to the axis normal to the front face of the second electrical connector.

14. An electrical connector assembly for routing power cords or audio/video cables inside a wall, the assembly comprising: a power cord terminating with a first electrical connector integrally provided at a first end of the power cord and terminating with a second electrical connector integrally provided at a second end of the power cord; wherein the power cord comprises a type of cable that is rated for use inside walls; a first wall grommet comprising a housing configured to be secured to the first electrical connector at the first end of the power cord; and a second wall grommet comprising a housing configured to be secured to the second electrical connector at the second end of the power cord; wherein each of the first wall grommet and second wall grommet is configured to be inserted through a hole in a surface of a wall and mounted in the wall, such that the power cord can be routed through an interior space of the wall.

15. The electrical connector assembly according to claim 14, wherein the housing of the first wall grommet is configured to be secured to the first electrical connector on the first end of the power cord such that the first electrical connector is recessed from the surface of the wall when the housing of the first wall grommet is mounted in the wall; and wherein the housing of the second wall grommet is configured to be secured to the second electrical connector on the second end of the power cord such that the second connector is recessed from the surface of the wall when the housing of the second wall grommet is mounted in the wall.

16. The electrical connector assembly according to claim 15, wherein the housing of each of the first wall grommet and the second wall grommet defines a front opening, a front interior space, a back interior space, and an interior wall separating the front interior space and the back interior space, the interior wall having a vertical portion defining a connector opening that connects the front interior space and the back interior space.

17. The electrical connector assembly according to claim 16, wherein the back interior space defined by the housing of the first wall grommet is configured to accommodate the first electrical connector at the first end of the power cord, such that the first electrical connector at the first end of the power cord is accessible from the front opening and front interior space of the housing through the electrical-connector opening; and wherein the back interior space defined by the housing of the second wall grommet is configured to accommodate the second electrical connector at the second end of the power cord, such that the second electrical connector at the second end of the power cord is accessible from the front opening and front interior space of the housing through the electrical-connector opening.

18. The electrical connector assembly according to claim 17, wherein the housing of each of the first wall grommet and the second wall grommet defines a power cord opening to the back interior space configured to allow the power cord to extend out of the housing transversely to a longitudinal axis of the housing.

19. The electrical connector assembly according to claim 16, wherein the housing of each of the first wall grommet and the second wall grommet further comprises an egress opening providing access to the front interior space of the housing; wherein a portion of the interior wall of each of the first wall grommet and the second wall grommet curves from a back edge of the wire egress opening toward the front interior space and the front opening; and wherein the curved portion of the interior wall and the egress opening of each of the first wall grommet and the second wall grommet are configured such that a cable can be routed from the front opening of the housing of either the first wall grommet or the second wall grommet, through the front interior space of the housing of that wall grommet, out through the egress opening of that wall grommet, and into the interior space of the wall when that housing is mounted in the wall.

20. The electrical connector assembly according to claim 16, wherein each of the first and second electrical connectors comprises a flange configured to engage the interior wall of the housing around the electrical-connector opening; wherein each of the first and second electrical connectors comprises a front face protruding from the flange such that the front face of the electrical connector extends through the electrical-connector opening when the flange engages the interior wall of the housing around the electrical-connector opening.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0007] The foregoing summary, as well as the following detailed description of the preferred embodiments, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, there is shown in the drawings embodiments that are presently preferred, it being understood, however, that the invention is not limited to the specific embodiments disclosed. In the drawings:

[0008] FIG. 1 shows a front perspective view of an exemplary power module of a wall grommet;

[0009] FIG. 2 shows a back perspective view of the power module of FIG. 1;

[0010] FIG. 3 shows a cross sectional view of the power module of FIGS. 1 and 2 taken along cross-sectional line C-C shown in FIGS. 1 and 2;

[0011] FIG. 4 shows a front perspective view of a wall grommet assembled with a female connector;

[0012] FIG. 5 shows an exploded view of the wall grommet of FIG. 4 with a female connector;

[0013] FIG. 6 shows a front perspective view of a wall grommet assembled with a male connector;

[0014] FIG. 7 shows an exploded view of the wall grommet of FIG. 6 with a male connector;

[0015] FIG. 8 shows a wall grommet assembly; and

[0016] FIG. 9 shows a wall grommet kit.

DETAILED DESCRIPTION

[0017] Before the present invention is described in further detail, it is to be understood that the invention is not limited to the particular embodiments described. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to limit the scope of the claims of the present application.

[0018] In accordance with one aspect of the invention, provided is a wall grommet 10, which can be installed through the surface of a wall to route wiring in the wall's interior space. Grommet 10 can be used to route power cords and low-voltage cables for audio and video applications.

[0019] In one embodiment, grommet 10 comprises a power module 100, a back cover 200, a wire egress cover 300 and a trim ring 400. However, it is also contemplated that grommet 10, in another embodiment, may comprise only a power module 100 and a back cover 200. Still in other embodiments, grommet 10 may further optionally comprise a wire egress cover 300 or a trim ring 400.

[0020] As shown in FIGS. 1 and 2, power module 100 comprises a housing 110, which defines an interior space 120 that is adapted to hold either the female connector 510 (also referred to a “female end”) or male connector 520 (also referred to as a “male end”) of a power cord 500. Housing 110 may comprise a tubular wall 130 having a substantially tubular shape that defines a front opening 140 and a back opening 142. Tubular wall 130 extends between the front opening 140 and back opening 142 of housing 110. Also, a wire-egress opening 144 may be provided in tubular wall 130 of housing 110 so that the interior space 120 of housing 110 communicates with a space outside of housing 110, other than through the front and back openings 140, 142. Further, a relief cut 148 may be provided adjacent to back opening 142 for accommodating a power cord 500. As shown in the embodiment illustrated in FIGS. 1 and 2, housing 110 may have an irregular tubular shape. For example, the shape of a cross-section transverse to a longitudinal axis Z may be asymmetric about a horizontal axis X and/or a vertical axis Y. Further, the cross-sections transverse to the longitudinal axis Z may be non-uniform, i.e., the shape of the cross-sections transverse to the longitudinal axis Z may vary along the longitudinal axis Z.

[0021] Additionally, as shown in FIG. 3, housing 110 may comprise an interior wall 150. Interior wall 150 is disposed inside housing 110 and extends from tubular wall 130 across interior space 120 of housing 110 to create a separation in the interior space 120 of housing 110. Interior wall 150 defines a front interior space 122 and a back interior space 124 inside housing 110. A first portion 152 of interior wall 150 preferably extends substantially vertically from the interior of tubular wall 130 and into interior space 120 of housing 110. The first portion 152 of interior wall 150 includes an electrical-connector opening 146 that connects the front interior space 122 and the back interior space 124 of housing 110. The back interior space 124 of housing 110 is adapted to receive the electrical connector 510, 520 of a power cord 500, such that the electrical connector 510, 520 abuts interior wall 150 and the female receptacle or male prongs of electrical connector 510, 520 are accessible through the electrical-connector opening 146.

[0022] As shown in FIGS. 5 and 7, the electrical connector 510, 520 may have a body comprising a flange 512, 522 configured to engage the interior wall 150 of the housing 110 around the electrical-connector opening 146. Further, the body of the electrical connector 510, 520 may further comprise a front face 514, 524 that is configured to be disposed substantially vertically when the electrical connector 510, 520 is disposed inside the housing 110 and the grommet 10 is mounted on a surface of a vertical wall. The body of the electrical connector 510, 520 extends back from the front face 514, 524 generally perpendicularly to the plane of the front face 514, 524. As shown in FIGS. 5 and 7, the power chord 500 of the electrical connector 510, 520 may extend transversely to the body of the electrical connector 510, 520 so that the power chord 500 can be routed vertically inside the wall. The front face 514, 524 of the electrical connector 510, 520, which has the female receptacle or male prongs disposed thereon, may be configured to protrude from the flange 512, 522 such that the front face of the electrical connector 510, 520 extends through the electrical-connector opening 146 when the flange 512, 522 engages the interior wall 150 of the housing 110 around the electrical-connector opening 146.

[0023] The front opening 140 and the front interior space 122 are adapted to provide access to the electrical connector 510, 520 of power cord 500, which is disposed in the back interior space 124 of housing 110, so that the mating connector end of another power cord can be connected to the electrical connector 510, 520 disposed in the back interior space 124 of housing 110. Thus, grommet 10 can be mounted flush on a surface and the electrical connector 510, 520 of power cord 500 may be recessed from the surface. As shown in FIGS. 5-8, grommet 10 is configured such that when grommet 10 is mounted flush on the surface of a vertical wall, the front face 514, 524 of the electrical connector 510, 520 is disposed substantially vertically and parallel to the surface of the vertical wall, and the power cord 500 extends substantially transversely to the longitudinal axis Z of housing 110 and substantially vertically inside the wall.

[0024] Further, as shown in FIG. 3, a second portion 154 of interior wall 150 extends from the interior of the tubular wall 130 at the back edge of the wire-egress opening 144 and slopes/curves up and forward toward front interior space 122 and front opening 140. This particular configuration of the second portion 154 of interior wall 150 guides any wires or cables that are inserted through wire-egress opening 144 toward front interior space 122 and front opening 140. Thus, when grommet 10 is installed in a wall, wires or cables (e.g., low voltage audio/video cables) can be easily fed from the interior space of a wall out trough the wire-egress opening 144 of power module 100. Further, screw posts 156 may disposed on the backside of the second portion 154 of interior wall 150, in the back interior space 124 of housing 110, for engaging fasteners 158, which secure back cover 200 to power module 100.

[0025] Also, as shown in FIGS. 1 and 2, power module 100 may comprise an annular flange 160 that extends outwardly from the front opening 140 of housing 110 and defines a substantially planar surface transverse to the longitudinal axis Z of housing 110. Annular flange 160 comprises a front surface 162 and a back surface 164. When the housing 110 of power module 100 is inserted through an appropriately sized hole in the surface of a wall, the back surface 164 of flange 160 abuts the surface of the wall and prevents power module 100 from falling through the hole. Extending from the front surface 162 through to the back surface 164 of flange 160 are at least two holes 166 adapted to receive and engage fasteners 170 (e.g. screws, nails, etc.) for securing power module 100 to a wall surface. Thus, once power module 100 is inserted through a hole in the surface of a wall, fasteners 170 can be inserted through holes 166 of flange 160 to secure power module 100 to the wall.

[0026] Additionally, as shown in FIGS. 1 and 2, in one embodiment, toggles 172 may be provided in conjunction with fasteners 170 to secure module 100 on the surface of a wall. Toggles 172 comprise bores 174 that are adapted to engage fasteners 170. Toggles 172 may be disposed adjacent to the holes 166 on the back surface 164 of flange 160, such that the bores 174 of toggles 172 are aligned with the holes 166 on the back surface 164 of flange 160. As shown in the embodiment of FIGS. 1 and 2, toggles 172 may be held in mounts 132 provided on an outer surface of housing 110. Toggles 172 and mounts 132 are preferably configured to allow toggles 172 to pivot about a longitudinal axis of bores 174 parallel to longitudinal axis Z. The configuration of toggles 172 and mounts 132 allow toggles 172 to rotate between a dosed position (as shown in FIGS. 4 and 6) to an open position (as shown in FIGS. 1 and 2) when a fastener 170 is rotated in a tightening direction (e.g., clockwise). Likewise, when a fastener 170 is rotated in a loosening direction (e.g., counter clockwise), toggles 172 may rotate from an open position to a closed position. Preferably, mounts 132 include detents 134 that prevent toggles 172 from moving in an opening direction past a certain point, such that toggles 172 are substantially radially aligned with longitudinal axis Z of power module 100. As power module 100 is inserted through a hole in the surface of a wall, toggles 172 may be held in a closed position. Once power module 100 has been inserted through a hole in the surface of a wall and fasteners 170 are tightened, toggles 172 may move into an open position and engage the backside of the wall to secure power module 100 to the wall.

[0027] As shown in FIGS. 5 and 7, grommet 10 further comprises back cover 200 that is adapted to engage housing 110 of power module 100 at the back opening 142. Back cover 200 comprises at least two holes 202 for receiving fasteners 158. The holes 202 are configured to align with the screw posts 156 so that fasteners 158 may be inserted through holes 202 in back cover 200 and engage screw posts 156. Once the electrical connector 510, 520 of power cord 500 is inserted into back interior space 124 of housing 110, electrical connector 510, 520 can be secured in housing 110 by attaching back cover 200 to power module 100 and inserting fasteners 158 through holes 202 and into screw posts 156. Thus, by enclosing the back interior space 124 of housing 110 with back cover 200, an electrical connector 510, 520 can held and secured in the back interior space 124 such that the female receptacle or male prongs of electrical connector 510, 520 can be accessed from the front opening 140 and front interior space through the electrical-connector opening 146.

[0028] Also, as shown in FIGS. 5 and 7, Grommet 10 may further optionally comprise a wire egress cover 300. Wire egress cover 300 preferably includes a planar surface 310 that is shaped to match the shape of a portion of a cross section of the interior space 120 of power module 100 such that the interior space—between the second portion 154 of interior wall 150 and the interior of tubular wall 130—that leads to wire-egress opening 144 can be covered while still allowing wires or cables to be passed through. Wire egress cover may further include arms 320 that extend orthogonally from surface 310. Arms 320 are adapted to fit in the front interior space 122 of housing 110 and engage the interior surface of tubular wall 130 so that wire egress cover 300 may be secured to power module 100. Wire egress cover 300 may also include tabs 330 disposed on the free ends of arms 320. Tabs 330 are configured to engage recesses 136 in the interior surface of tubular wall 130. Wire egress cover 300 may further include a notch 340 cut out to allow wires or cables to be passed through the wire-egress opening 144 when the egress cover 300 is installed.

[0029] Additionally, as shown in FIGS. 5 and 7, grommet 10 may further optionally comprise a trim ring 400. Trim ring 400 includes a substantially planar surface 410 that defines a central opening 420 for allowing access to the interior space 120 of power module 100. Extending orthogonally from surface 410 is a semi-cylindrical wall 430. Semi-cylindrical wall 430 partially encircles central opening 420 on surface 410 and is adapted to extend inwardly into interior space 120 of housing 110. Semi-cylindrical wall 430 is adapted to engage the interior surface of tubular wall 130 so that trim ring 400 may be secured to power module 100. Trim ring 400 is preferably adapted to securely fit on the flange 160 of power module 100 without the need for fasteners. Trim ring 400 is configured to cover fasteners 170 on flange 160 and provide an even finished surface around the front opening 140 of power module 100. Thus, trim ring 400 provides a clean finished appearance to the portion of grommet 10 that is visible after installation in a wall.

[0030] In accordance with another aspect of the invention, as shown in FIG. 8, provided is a wall grommet assembly 600. Wall grommet assembly 600 may comprise two wall grommets 10′, 10″ (as described above) and a power cord 500. Power cord 500 preferably has a female connector 510 on one end and a male connector 520 on the other end. Further, power cord 500 preferably comprises type NM-B cable, or other type of cable that is rated for use inside walls. As shown in FIGS. 4 and 5, grommet 10′ is used in conjunction with the female connector 510 of power cord 500, as shown in FIGS. 4 and 5. As shown in FIGS. 6 and 7, grommet 10″ is used in conjunction with the male connector 520 of power cord 500, as shown in FIGS. 6 and 7. As shown in FIG. 8, wall grommet assembly 600 may be installed by cutting out two holes on the surface of a wall and running power cord 500 inside the wall such that female connector 510 comes out of the wall through one hole and male connector 520 comes out of the wall through the other hole. Then, female connector 510 can be secured in grommet 10′ and male connector 520 can be secured in the other grommet 10″. Grommets 10′, 10″ can then be inserted through their respective holes in the wall and secured to the surface of the wall using fasteners (e.g. screws, nails, etc.) through holes 166 in flange 160. Additionally, other cables (e.g., low-voltage audio/video cables) may be passed through the wire-egress opening 144 of one grommet 10′, through the interior space of the wall, and out through the wire-egress opening 144 of the other grommet 10″. Wire egress covers 300 and trim rings 400 may also be secured on the power modules 100′, 100″, as desired.

[0031] In accordance with yet another aspect of the invention, as shown in FIG. 9, provided is a kit 700 for routing wiring in the interior spaces of walls. In one embodiment the kit 700 comprises a saw 710, a fish stick 720, two grommets 10′, 10″, and a power cord 500. Saw 710 may be any conventional saw that can be used to cutout holes in the surface of walls (e.g., drywall saw). Fish stick 720 comprises a rod 722 with a hook 724 (or other means for holding a cable) on one end. The rod 722 may have a one-piece construction, or it may be provided in multiple sections (as shown) that are connected by connectors 726. The two grommets 10′, 10″ and power cord 500 may be provided in accordance with the preceding descriptions.

[0032] Saw 710 may be used to cut out holes on the surface of a wall. Once two holes are cut out, fish stick 720 may be inserted through one of the holes and into the wall such that the hook 724 on the end of the rod 710 can be accessed through the other hole. One end of the power cord 500 can be secured on the hook 724 and inserted through the hole such that the power cord 500 can be fished through the inside of the wall by pulling out the other end of fish stick 720 through the other hole. Power cord 500 may be fished through the inside of the wall such that one end of the cord comes out of the wall through one hole and the other end of the cord comes out of the wall through the other hole. Then, female connector 510 can be secured in grommet 10′ and male connector 520 can be secured in the other grommet 10″. Grommets 10′, 10″ can then be inserted through their respective holes in the wall and secured to the surface of the wall using fasteners (e.g. screws, nails, etc.) through holes 166 in flange 160. Additionally, other cables (e.g., low-voltage audio/video cables) may be passed through the wire-egress opening 144 of one grommet 10′, through the interior space of the wall, and out through the wire-egress opening 144 of the other grommet 10″. Wire egress covers 300 and/or trim rings 400 may also be secured on the power modules 100′, 100″, as desired.

[0033] While the invention has been described with reference to the preferred embodiments thereof, it will be appreciated by those of ordinary skill in the art that modifications can be made to the structure and elements of the invention without departing from the spirit and scope of the invention as a whole.