WO2004057716A1 - Solid wire modular electrical system for office areas - Google Patents

Abstract

A modular multi-component power distribution system is provided having a plurality of modular components which are configurable into a bus-bar based system, a flexible cable base system and a hybrid configuration wherein the bus-bar and flexible cable components are interconnected together. The components allow for configuration of the power distribution system into a variety of office systems including wall panel systems, desking or freestanding furniture systems and raised flooring systems either individually or in various combinations.

Description

SOLID WIRE MODULAR ELECTRICAL SYSTEM FOR OFFICE AREAS

FIELD OF THE INVENTION [0001] The invention relates to a modular electrical system for supplying power through an office area and more particularly, to an electrical power distribution system incorporating multiple modular components which are selectively configurable into a bus-bar based system and/or a cable based system.

BACKGROUND OF THE INVENTION

[0002] In office buildings, large open areas are often finished off to define an office environment configured for the specific needs of a business. This may be accomplished through combinations of different building systems such as raised floor systems, ceiling systems, wall panel systems, and desking or other furniture systems .

[0003] For example, space-dividing wall panel systems often are provided to subdivide a large office space into multiple, individual workstations. Each workstation includes various pieces of office equipment including computers, telephones and lighting wherein such equipment requires connection to power distribution systems as well as data distribution systems.

[0004] Such space-dividing wall systems include individual upright wall panels which are serially connected together to form the walls of the various workstations. Typically, such wall panels are provided with raceways extending therethrough in which power and communication cabling are laid.

[0005] While such wall panel systems perform the general function of sub-dividing a larger office area, a wide variety of wall panel systems are commercially available wherein the specific construction of these various wall panel systems differs from one system manufacturer to another. Further, each manufacturer also may manufacture and sell a variety of different wall panel systems as part of their product line. [0006] In addition to wall panel systems, it is known to provide freestanding furniture systems such as arrangements of desks wherein each desk is adapted to support power and/or communication cabling systems thereon such as by raceways or cable hangers built onto the desks. As such, these desk systems may be used by themselves or if desired, in combination with wall panel systems .

[0007] Still further, the main office area typically includes a hard floor surface, such as a concrete surface cover by a suitable floor covering, wherein the above- described wall panel systems and desk systems are used directly thereon. To further enhance and simplify the routing of power and communication systems throughout the office area, it is known to provide raised floor systems which define a main floor area that is spaced above and overlies the pre-existing base floor of the office area. The raised floor area is covered with removable floor tiles and supports various furniture components thereon such as the desk systems and wall panel systems discussed above. A clearance space between the base floor and the raised floor tiles defines a raceway-like area wherein the floor tiles may be removed to permit the laying of power and communication cabling systems therein. [0008] It is desirable therefore to provide data communication systems and power distribution systems which have significant flexibility for use with any or all of the above-described furniture systems. [0009] As to power distribution systems, various power distribution systems are already in use. However, known power distribution systems may possess structural limitations which restrict the flexibility that such systems have for use with the various furniture systems discussed above. Accordingly, it is an object of the invention to provide an improved power distribution system which has significant flexibility and adaptability for use with a wide variety of building systems and, furthermore, has the capability to readily transition between the various building systems located in the office area.

[0010] The invention relates to a power distribution system comprising modular electrical components which are readily connectable together in multiple configurations depending upon the specific environment in which the power system will be used. The modular components include a solid wire power distribution assembly which forms a solid wire bus, a receptacle and flexible connector cables .

[0011] These modular components may be configured into a bus-bar based power system which is particularly suitable for use in raceways of wall panel systems or desk systems, or even a flexible cable based system for use by itself in wall panel, desk and raised floor systems. When transitioning between different building systems, for example, between the raceways of a raised floor system and a wall panel system supported thereon, a portion of the power system may be configured into a cable based system comprising flexible interconnected cables which may be used in a raised floor, wherein the flexible cables of the cable based system are then connected to a bus-bar based system that may supply power throughout the wall panel system.

[0012] The modular power system has significant flexibility and adaptability for use in most any combination of the above-described wall panel, raised floor, or desking system as well as other types of furniture systems, ceiling applications and the like. [0013] Other objects and purposes of the invention, and variations thereof, will be apparent upon reading the following specification and inspecting the accompanying drawings .

BRIEF DESCRIPTION OF DRAWINGS

[0014] Figure 1 is a perspective view of a space- dividing wall panel system having modular components of the inventive power distribution system arranged in a bus-bar based configuration.

[0015] Figure 2 is a perspective view of the wall panels arranged in a three-way T-connection having a busbar based configuration disposed in wall panel raceways.

[0016] Figure 3 illustrates the wall panels of Figure 2 reconfigured in a two-way, linear connection with the existing power system components modified to accommodate this connection.

[0017] Figure 4 is a perspective view illustrating an off-modular wall panel arrangement and a bus-bar based electrical system in one configuration.

[0018] Figure 5 is a perspective view of the bus-bar based configuration in a modified configuration during off-modular adjustment of the wall panels.

[0019] Figure 6 is a perspective view of a fixed raceway cover having two receptacle ports formed therein.

[0020] Figure 7 is a perspective view of a further fixed raceway cover having a single receptacle port formed therein.

[0021] Figure 8 is a perspective view of a further fixed raceway cover having four receptacle ports therein.

[0022] Figure 9 is a perspective view of a further raceway cover having removable receptacle ports therein. [0023] Figure 10 is a perspective view of an adjustable raceway cover adapted to accommodate a single receptacle .

[0024] Figure 11 is a perspective view of an adjustable raceway cover adapted to accommodate two single receptacles or a single double-width receptacle. [0025] Figure 12 is a perspective view of a bus-bar like power distribution assembly in combination with multiple receptacles and connector cables. [0026] Figure 13 is a perspective view of the components of the power system including a power distribution assembly, flexible branching connectors and multiple receptacles.

[0027] Figure 14 is a perspective view of a standard flex connector.

[0028] Figure 15 is a perspective view of an extended length flex connector.

[0029] Figure 16 is a perspective view of an in-feed cable.

[0030] Figure 17 is a perspective view of a standard branching connector.

[0031] Figure 18 is a perspective view of an extended length branching connector.

[0032] Figure 19 is a perspective view of a receptacle being connected to a branching connector. [0033] Figure 20 is a perspective view of a pair of branching connectors being joined with a receptacle. [0034] Figure 21 is a perspective view of a pair of branching connectors being joined together. [0035] Figure 22 is a perspective view of two branching connectors and an in-feed cable being interconnected together.

[0036] Figure 23 is a perspective view of the power distribution system defining a bus-bar based configuration for use in a desking system. [0037] Figure 24 is a perspective view illustrating a flexible cable based system installed in a space-dividing beam system.

[0038] Figure 25 is a perspective view illustrating the modular power distribution system and a data distribution system installed in a raised-floor system. [0039] Figure 26 is a perspective view illustrating the power distribution system installed in a raised-floor system and a wall panel system supported thereon. [0040] Figure 27 is a perspective view illustrating a desk arrangement positioned on a raised floor system having the power distribution system and a data distribution system provided therein.

[0041] Figure 28 is a perspective view illustrating the power distribution system in a raised floor system having receptacles accessible through a floor-mounted outlet box.

[0042] Figure 29 is a perspective view of a power distribution assembly having receptacles illustrated in phantom outline.

[0043] Figure 30 is an enlarged front view of one end of the power distribution assembly.

[0044] Figure 31 is a front view illustrating the power distribution assembly interconnected with a connector plug of a flex connector.

[0045] Figure 32A is an end elevational view of the power distribution assembly and connector plug. [0046] Figure 32B is an end view of the power distribution assembly and connector plug of Figure 32A plugged together.

[0047] Figure 33 is a perspective view of a ten-wire power distribution assembly.

[0048] Figure 34 diagrammatically illustrates a first ten-wire circuit configuration for the power distribution assembly. [0049] Figure 35 diagrammatically illustrates a second ten-wire circuit configuration.

[0050] Figure 36 diagrammatically illustrates a third ten-wire circuit configuration.

[0051] Figure 37 is a perspective view of a six-wire power distribution assembly.

[0052] Figure 38 diagrammatically illustrates a first six-wire circuit configuration.

[0053] Figure 39 diagrammatically illustrates a second six-wire circuit configuration.

[0054] Figure 40 diagrammatically illustrates a third six-wire circuit configuration.

[0055] Figure 41 is a block diagram of a manufacturing process for forming a power distribution assembly. [0056] Figure 42 is a diagrammatic end view of extrusion profiles for step 1 of the manufacturing process.

[0057] Figure 43 is a diagrammatic end view of the extrusion profiles during step 2 of the manufacturing process.

[0058] Figure 44 is a diagrammatic end view of the extrusion profiles during step 4 of the process. [0059] Figure 45 is a diagrammatic end view of the completed PDA housing during step 5 of the manufacturing process .

[0060] Figure 46 is an end view illustrating one connector plug of a flex connector.

[0061] Figure 47 is a front view of the connector plug.

[0062] Figure 48 is a rear perspective view of the interior of a plug housing for the connector plug. [0063] Figure 49 is a rear perspective view of a plug housing assembly illustrating the plug housing having electrical contacts disposed therein. [0064] Figure 50 is an enlarged perspective view of the plug housing assembly.

[0065] Figure 51 is a perspective view of an electrical contact.

[0066] Figure 52 is a side view of the electrical contact.

[0067] Figure 53 is a side cross-sectional view of a pair of connector plugs joined together. [0068] Figure 54 is a perspective view of the pair of the joined connector plugs of Figure 53. [0069] Figure 55 is a perspective view of a plug housing for a branching connector.

[0070] Figure 56 is a plan view of the branching connector plug housing.

[0071] Figure 57 is a plan view of the branching plug housing having wires illustrated therein. [0072] Figure 58 is a perspective view of a receptacle.

[0073] Figure 59 is an exploded view of the receptacle illustrating a plurality of face plates for the receptacle housing.

[0074] Figure 60 is a rear perspective view of a second type of receptacle.

[0075] Figure 61 is a front view of the receptacle of Figure 60.

[0076] Figure 62 is a front view of the receptacle having the receptacle housing removed therefrom. [0077] Figure 63 is a perspective view of the base plate of the receptacle.

[0078] Figure 64 is a perspective view of a slidable contact assembly.

[0079] Figure 65 is a perspective view of a rotatable ground contact assembly. [0080] Figure 66 is a front view of a power distribution assembly of a further power distribution system.

[0081] Figure 67A is an enlarged front view of an end of the PDA.

[0082] Figure 67B is a front view of Figure 66 illustrating conductors extending therethrough. [0083] Figure 68 is a perspective view of two flex connectors connected to the PDA.

[0084] Figure 69 is a rear perspective view of the flex connectors and PDA of Figure 69. [0085] Figure 70 is a front perspective view of a connector plug for the flex connector.

[0086] Figure 71 is a rear view of the connector plug. [0087] Figure 72 is an end cross section of the connector plug.

[0088] Figure 73 is a plan view of a plug housing. [0089] Figure 74 is a bottom view of the plug housing. [0090] Figure 75 is a perspective view of the plug housing.

[0091] Figure 76 is a perspective view of an electrical contact.

[0092] Figure 77 is a bottom view of the electrical contact .

[0093] Figure 78 is a rear view of the electrical contact .

[0094] Figure 79 is a plan view of a cover for the plug housing.

[0095] Figure 80 is a perspective view of two flex connectors interconnected together. [0096] Figure 81 is an end view thereof. [0097] Figure 82 is a cross-sectional end view. DETAILED DESCRIPTION

I . System Overview

[0098] Referring to Figure 1, components of a modular multi-component power distribution system 10 are illustrated in use within a wall panel system 12. The wall panel system 12 is used to subdivide an open office area 14 into individual subdivided areas 15 such as for walkways, individual work stations and the like. [0099] Generally, the wall panel system 12 includes a plurality of individual space-dividing wall panels 17 that are disposed in load bearing relation on a floor surface 18. Each wall panel 17 includes a horizontally elongate raceway 19 which in the illustrated arrangement is located at the base of the wall panel 17 as indicated by reference arrow 20 but which also may be located at other heights such as beltline height as indicated by reference arrow 21. The position of the raceways 19 at beltline and/or base height or at any other location within the wall panel is known and further disclosure as to the position of the raceways is not required herein. [00100] Each raceway 19 defines a longitudinal passage extending between the opposite ends of each respective wall panel 17 and opens sidewardly in communication with the raceways 19 of each serially adjacent wall panel 17. As such, the serially aligned raceways 19 allow for the passage of cabling along the lengths of the interconnected wall panels 17.

[00101] As seen in Figure 1, one of the wall panels 17A is interconnected with a pair of additional wall panels 17 through a three-way connection 25. In the specific three-way connection of Figure 1, the serially adjacent wall panels 17 are separated by a vertically elongate gap 26 wherein one of the sides of the gap 26 is defined by the end of the wall panel 17A oriented perpendicular to the serially-adjacent wall panels 17. If desired, a further wall panel (not illustrated) could be positioned adjacent to the gap 26 on the side opposite to the perpendicularly positioned wall panel 17A to form a four- way connection.

[00102] Referring to Figure 2, the wall panel system 12 illustrates the wall panels 17 and 17A oriented in the three-way connection 25 with the gap 26 formed therebetween. Each wall panel 17 includes a vertically enlarged panel body 28 which is supported on the floor 18 by a pair of support legs or glides 29 which project downwardly and are disposed in load bearing relation with the floor 18. The panel body 28 thereby is spaced vertically from the floor 18 such that the open area disposed therebetween defines the raceway 19. [00103] The raceway 19 for each wall panel 17 extends horizontally between the support legs 29 so as to open horizontally from the opposite ends. As such, the opposite ends of the multiple raceways 19 defined by the panels 17 and 17A are in open communication with each other to allow cabling to be routed between the individual wall panels 17 and 17A.

[00104] As generally illustrated in Figure 1, each wall panel 17 also includes a raceway cover 31 which encloses the opposite side faces of the raceway 19 while still defining an opening 32 at each opposite end of the panel 17 or 17A. While the raceway covers 31 are omitted in Figure 2, the raceway covers 31 are mounted to the panel body 28 by cover connector brackets 33 which project downwardly. The raceway covers 31 are adapted to be snap-connected to the brackets 33 in a conventional manner.

[00105] Furthermore as to Figures 1 and 2, the modular power distribution system 10 is illustrated therein in an exemplary configuration. As will be understood from the following discussion, the power distribution system 10 is formed of multiple components which provide a high degree of flexibility to allow the power distribution system 10 to be adapted for use in multiple building systems and furniture configurations.

[00106] As seen in Figure 1, a number of the components of the power distribution system 10 are illustrated including a distribution assembly 35 (herein "PDA") which is formed as a sold wire bus-bar, a flex-type connector 36, a flexible in-feed cable 37 and a plurality of receptacles 38. These components are configured in a bus-bar based configuration. As seen in Figure 2, the power distribution system 10 further includes flexible branching cables 39 which may perform a function similar to the flex connectors 36 but also may be used as the base component for forming a flexible cable based configuration, for example, as illustrated in Figure 24. [00107] In the bus-bar based configuration, a PDA 35 is suspended within the raceway 19 of each wall panel 17 or 17A. The PDA 35 is functionally similar to a bus bar as illustrated in Figures 29 and 30. As will be described in further detail herein, the PDA 35 has an extruded construction formed by an insulative casing 40 which has a plurality of parallel, vertically spaced apart electrical conductors 41 which are embedded within the casing 40 and extend longitudinally along the entire length thereof. The conductors 41 define multiple electrical circuits for distribution throughout the office area 14 wherein the conductors 41 define multiple circuits of line, neutral and ground wires. [00108] To provide access to the conductors 41 and permit the connection of system components thereto, the casing 40 is formed with a pre-defined pattern of plug openings 43 wherein the plug openings 43 have portions of the conductors 41 exposed therein. The plug openings 43 are grouped into multiple groups of openings 43 wherein each group 44 is defined by a pair of vertical rows 45 of vertically spaced apart openings 43. Each opening group 44 is adapted to be connected to one of the aforementioned system components, namely a flex connector 36, an in-feed cable 37 or a receptacle 38. [00109] More specifically, two opening groups 44 are provided at each of the opposite ends 46 and 47 of the casing 40. Each end pair 47 of groupings 44 is intended to be connected to one of the flex connectors 36, the in- feed cable 37 or the branching connector 39 which allows for the construction of an electrical power distribution system extending throughout the office area 14 which comprises multiple electrical circuits. [00110] Each PDA 35 further includes at least one interior pair 48 of groupings 44 to which receptacles 38 may be connected. As seen in phantom outline in Figure 29, one of the opening groups 44 in an interior pair 48 allows for a receptacle 38 to be plugged into and connected to one face 50 of the casing 40 while the other group 44 of the same interior pair 48 allows for another receptacle 38 to be plugged into the opposite casing face 51. As such, during installation, the receptacles 38 may be positioned on any of the PDAs 35 on either side thereof to supply power to specific work areas. As seen in Figure 29, the illustrated PDA 35 is provided with a second interior grouping pair 48 which provides an additional pair of mounting locations for a further receptacle 38 (not illustrated) .

[00111] The following provides an overview of the individual components of the power distribution system 10, particularly as to the general structure and function of these components. [00112] Referring to Figure 12, a PDA 35-1 is illustrated which is formed the same as the PDA 35 (Figure 29) except that the PDA 35-1 includes three interior grouping pairs 48 between the end grouping pairs 47. This specific PDA 35-1 is illustrated in the endmost wall panel 17 of Figure 1. Additional PDAs 35-2 are illustrated in the remaining wall panels 17 of Figure 1. These PDAs 35-2 have the same basic construction as the PDAs 35 and 35-1 except that a single interior grouping pair 48 is provided thereon between the end grouping pairs 47.

[00113] In Figure 1, the PDAs 35-1 and 35-2 are affixed to a bottom edge 53 of the panel body 28 so as to be suspended downwardly therefrom within the raceway 19. Each PDA 35-1 and 35-2 extends longitudinally along a substantial length of the panel body 28 and in the illustrated embodiment is disposed longitudinally between the raceway cover brackets 33. The PDAs 35-1 and 35-2 are relatively rigid and axially elongate so as to provide fixed mounting locations for the receptacles 38. Since the PDAs 35-1 and 35-2 are rigidly connected to the frame structure of the respective wall panel 17, each PDA 35-1 and 35-2 therefore is movable in unison with the wall panel 17 during initial assembly and subsequent reconfiguration of the wall panel 17. The PDAs 35-1 and 35-2 are adapted to be enclosed within the raceways 19 by the raceway cover 31.

[00114] By the use of multiple PDAs 35, multiple mounting locations are provided for the receptacles 38 to allow the receptacles 38 to be positioned in any work station 15 at a location which is most desirable for use by an office worker. In this regard, the receptacles 38 can be readily connected to one of the groupings 44 of the interior grouping pairs 48 not only at different longitudinal positions along a series of PDAs 35, but also on opposite sides of the individual PDAs 35. [00115] As to the receptacles 38 (Figure 12), these components generally have a receptacle housing 55 through which a plurality of three-prong outlets 56 are arranged. The outlets 56 open forwardly for access from the work station 15, and when mounted to a PDA 35, the receptacles 38 project through the raceway cover 31 as described in further detail herein.

[00116] To rigidly support the receptacle 38 on the PDA 35 and also electrically connect the receptacle 38 to the conductors 41 encased within the PDA 35, each receptacle 38 includes two aligned rows of posts 57 which project rearwardly from a back face 58 of the receptacle housing 55. The posts 57 are aligned horizontally and vertically with each other to define two aligned vertical rows of the posts 57. Each post 57 is adapted to be tight- fittingly inserted within a respective one of the plug openings 43 formed in a PDA 35. Further, each post 57 has an exposed electrical contact that is adapted to electrically connect to and abut against a respective one of the conductors 41 which is exposed within the plug opening 43. Due to the tight fitting engagement of the posts 57 within the plug openings 43, the cooperating plug parts of the posts 57 and the openings 43 not only allow for electrical connection of the receptacle 38 to the conductors 41 but also provide mechanical support to the receptacle 38.

[00117] The posts 57 also are readily disengaged from the grouping 44 to which the receptacle 38 is connected to allow for relocation of the receptacle 38 at a different location on one PDA 35 or a different location on a different PDA 35. To prevent inadvertent disengagement of the receptacle 38, locking parts are provided thereon such as hook-like locking flanges 59 (Figure 10) which are adapted to snap over and grip onto the upper and lower edges 61 and 62 of the PDA 35. [00118] The posts 57 are located at a longitudinally offset position on the receptacle backface 58, preferably near one end thereof. As such, the receptacle 38 can be mounted to one casing face 50 (Figure 29) by insertion of the post 57 in one grouping 44 of an interior grouping pair 48. The same receptacle 38 can be positioned on the opposite casing face 51 merely by rotating the receptacle 38 one hundred eighty degrees about a vertical axis such that the posts 57 engage the other grouping 44 of the same interior grouping pair 48. Since the receptacle 38 mounts to a different grouping 44 depending on which side of the PDA 35 that the receptacle 38 is mounted, two receptacles 38 can be mounted in back-to-back relation as seen in Figure 29 so that receptacles 38 are aligned with each other.

[00119] In addition to the above components, the power distribution system 10 further includes components for interconnecting each PDA 35 with an adjacent one of the PDAs 35 so as to define continuous electrical circuits extending throughout the office area 14. In a wall panel based arrangement such as in Figures 1, 4 and 5, the primary component is the flex connector 36 which connects serially between a pair of PDAs 35.

[00120] Referring to Figure 14, the flex connector 36 includes a bendable conductor body 65 which terminates at its opposite ends in connector plugs or terminal units 66. The conductor body 65 is relatively rigid in the vertical direction but is bendable in the horizontal direction. The conductor body 65 is formed of an extruded insulative cover 67 in which a plurality of flexible electrical conductor wires extend. The conductor body 65 is mechanically interconnected with the connector plug 66 wherein the conductor wires therein electrically connect to electrical contacts in the connector plugs 66.

[00121] Each connector plug 66 includes an outer terminal or plug housing 67 having an interior face 69 and an exterior face 70. The interior face 69 includes a plurality of plug posts 71 which are arranged in two vertical rows of horizontally aligned posts in the same arrangement as the receptacle posts 57 described above. The posts 71 are adapted to be inserted into the openings of a corresponding one of the opening groups 44 in the PDA 35. The posts 71 when engaged with a grouping 44 of plug openings 43 electrically connects the flex connector 36 to the PDA 35 and when the opposite ends of the flex connector 36 are joined to a pair of PDAs 35, the electrical circuits extend continuously from one PDA 35 to a serially adjacent PDA.

[00122] In addition to the posts 71 on the interior face 69, the exterior face 70 of each connector plug 66 includes a further grouping 73 of plug openings 7 . The plug openings 74 in each grouping 73 are arranged in two vertical rows wherein each individual plug opening 74 is horizontally aligned with an adjacent opening 74 in an adjacent row thereof. Each contact post 71 includes an exposed contact adapted to be engaged with a conductor of another component of the power distribution system 10 such as the PDA 35. The plug opening 74 also provides access to the same contact of the post 71. Thus, the electrical circuit completed between the connector plug 66 and a system component such as the PDA 35 may be further branched off or extended by plugging an additional system component into the grouping 73 of openings 74.

[00123] In a general sense, each connector plug 66 therefore has a first type of connector part, namely the posts 71 which define male connector parts, and a second type of connector part, namely the openings 74 which define female connector parts . The first and second types of connector parts thereby are different types which are configured to mate with each other. The male connector parts on the connector plug 66 connect to the female connector parts on another system component, while the female connector parts on the same connector plug 66 allow for the connection of another system component thereto through the male connector parts on the other system component. As such, each connector plug 66 has male connector parts and female connector parts which allows for stacking of multiple system components together.

[00124] When interconnecting PDAs ^"35 together, the flex connector 36 preferably is connected between two PDAs 35 by connecting each end of the flex connector 36 to one of the groupings 44 on a respective PDA 35. [00125] Preferably as to the length of the flex connector 36, the length thereof is such that when two serially adjacent wall panels 17 abut against each other as seen in Figure 1, the left connector plug 66 plugs into a right, endmost grouping 44 as indicated by reference arrow 76 on one PDA 35, while the right connector plug 66 plugs into a right grouping of a second, serially adjacent PDA 35.

[00126] Preferably, the spacing between the groupings 44 on each end grouping pair 47 of the PDAs 35 is dimensioned such that for a three-way connection as seen in Figure 1, the same flex connector 36 is usable therewith. For a three-way connection, a serially adjacent pair of wall panels 17 are spaced apart from each other to define the gap 26 which gap has a width which corresponds to the thickness of the return wall panel 17A oriented perpendicular thereto. The spacing of the groupings 44 in each end group pair 47 corresponds to the spacing of the gap 26. Thus, in a three-way connection, the left connector plug 66 of a flex connector 36 is plugged into the right endmost grouping 44 of one PDA 35 as identified by reference arrow 79, and also plugs into the left endmost grouping 44 of a serially adjacent PDA 35-1 as indicated by reference arrow 80.

[00127] Accordingly, the same standard flex connector 36 may be used at the junction between each pair of wall panels 17, whether a two-way in-line connection, a three- way connection, or a four-way connection. Further, for the return wall 17A which is oriented perpendicular to a wall panel 17 in the three-way connection, a PDA 36 may be bent at a right angle and plugged in appropriate groupings 44 in the same manner as in the two-way connection described above, as indicated by reference arrows 79 and 81.

[00128] Referring to Figure 15, an alternate flex connector 36-1 may be provided which is formed with a conductor body 84 which has a longer length as compared to the flex connector 36 of Figure 14. The connector ends include connector plugs 83 which are identical to the connector plugs 66 described above. [00129] As to the in-feed cable 37 illustrated in Figures 1 and 16, a length of flexible multi-conductor cabling 86 is provided which has a first end 87 which connects to a power supply. The cabling 86 defines a plurality of electrical circuits and has a cable plug 88 at the free end 89 thereof.

[00130] The cable plug 88 includes a plug housing 90 which connects to the cabling end 89 by a collar 91. The housing 90 further has an interior face 92 from which projects a plurality of contact posts 93. The contact posts 93 are formed the same as the above-described posts 71 in the flex connector 36. The posts 93 have exposed contacts which are adapted to electrically connect to the conductors in the PDA 35. For the in-feed cable 37, however, the electrical circuits are supplied to the flex connector 36 as generally illustrated in Figure 1 and they supply electrical power to the PDA 35 when connected thereto. It will be understood that the in-feed cable 37 also may supply the electrical circuits to any of the other system components including the flex connector 36 or the branching connector 39.

[00131] The in-feed plug housing 90 includes a grouping of plug openings 94 which define female connector parts that are adapted to connect, for example, to the posts 57 of the receptacle 38 or to the posts 71 of the flex connector 36. The openings 94 are arranged in the same configuration of two parallel vertical rows wherein each individual opening 94 aligns horizontally with an adjacent opening 94. The cable plug 88 also includes a pair of locking flanges 95 which snap-lockingly engage with another system component, such as to the upper and lower edges 60 and 61 of the PDA 35 to which the in-feed cable 37 is connected.

[00132] Referring to Figure 17, a branching connector 39 is illustrated. The branching connector 39 has an intermediate cable 95 which is flexible and includes a plurality of conductor wires adapted to carry the circuits therethrough. The opposite ends of the intermediate cable 95 has connector plugs 97 connected thereto which connector plugs 97 are formed identical to the cable plug 88 of the in-feed cable 37. Each connector plug 97 has a configuration of contact posts 99 arranged in two vertical, sidewardly aligned rows like the other connector plugs described above. Also, plug openings 100 are arranged in the same pattern of sidewardly aligned rows and align respectively with the posts 99. [00133] In Figure 18, an alternative branching connector 39-1 is illustrated. The branching connector 39-1 has the identical connector plugs 97 at the opposite ends thereof with the intermediate cable 96-1 having a substantially longer length than the cable 96. The extended length cable 96-1 may be formed of any length but preferably has a large length so as to span large distances without the necessity of using multiple branching connectors 39.

[00134] Generally with the above-described components, a wide variety of cabling configurations may be constructed in order to accommodate the specific structural limitations of different building systems such as furniture, wall and floor systems. The following describes exemplary applications for the power distribution system 10. In many figures, the components are illustrated disconnected for clarity, it being understood that they physically connect together in use, for example, as illustrated in Figures 25, 26, 27, 28, 31 and 32B.

II. System Applications

[00135] Referring to Figure 2, the wall panels 17 and 17A are arranged in a three-way configuration. In this arrangement, PDAs 35 are suspended from the wall panels 17 and 17A within the raceways 19. These PDAs 35 are joined together by system connectors such as the branching connector 39. The branching connector 39 has the same modular length as the flex connector 36 described above relative to Figure 1. Therefore, in a three-way panel arrangement, the connector plugs 97 of the branching connector 39 connect to the endmost opening groupings 44 of two PDAs 35-2 as indicated by reference arrows 105 and 106. [00136] Should the return wall 17A be removed such as during redesign of an office area 14, the remaining serially-aligned wall panels 17 may be slid together as indicated by reference arrows 107 in Figure 3. While the PDAs 35-2 are now located closer together, the same branching connector 39 may be used.

[00137] In particular, the left connector plug 97 connects to the endmost PDA grouping 44 of one PDA 35 as indicated by reference arrow 108, while the right connector plug 97 connects to the right grouping 44 of the end grouping pair 48 as indicated by reference arrow 109. When installed, the branching connector 39 spans two serially-adjacent raceways 19 by extending over one facing side of the support leg 29.

[00138] As can be seen, the combination of PDAs 35 and branching connectors 39 provides significant flexibility in wall panel systems. Such flexibility may also be provided by the use of flex connectors 36 instead. [00139] In a further wall panel application, Figure 4 illustrates a pair of serially-aligned wall panels 17 disposed in end-to-end relation. A pair of additional return wall panels 17B are mounted on opposite sides of the wall panels 17 in perpendicular relation thereto. Each wall panel 17 or 17B includes a PDA 35 mounted within the raceway 19 thereof. [00140] One of the return wall panels 17B is diagrammatically illustrated as being slidable along a face of the wall panels 17 through multiple off-modular positions as indicated by reference arrow 111. In the position in Figure 4, the PDA 35 of the wall panel 17B is electrically connected to an adjacent PDA 35 by a flex connector 36. The connector plug 66 connects to the return wall PDA 35 by insertion into the right opening grouping 44 as indicated by reference arrow 111, while the opposite end connector plug 66 plugs into the endmost grouping 44 on the adjacent PDA 35 as indicated by reference arrow 112.

[00141] A further flex connector 36 is provided at the end of the wall panel 17 to supply the electrical circuits thereto. A further flex connector 36 connects the other return wall panel 17B to the left wall panel 17 similar to the connection between the front wall panel 17B and the right wall panel 17 described above.

[00142] Referring to Figure 5, the system components allow the return wall panel 17B to be slid to a new off modular position. In particular, the supply flex connector 35 on the left and connects directly to the endmost PDA grouping 44 as indicated by reference arrow 114. Directly adjacent thereto, the flex connector 36 for the return wall 17B is connected to the right grouping 44 of the end grouping pair 47 as indicated by reference arrow 115. The opposite end of this flex connector 36 remains connected to the right end pair grouping 44 of the return wall PDA 35 as indicated by reference arrow 116.

[00143] Once the system components are installed in the wall panels 17 and 17B, a suitable number of receptacles 38 are mounted to the PDAs 35, and the components are enclosed by the raceway covers 31, which are depicted in Figures 4 and 5 as being transparent for illustrative purposes. The receptacles 38, however, remain accessible through the raceway covers 31 so that electrical equipment, such as computers and the like, may be connected thereto.

[00144] Figures 6-9 illustrate four variations of raceway covers 31. In particular, the raceway cover 31-1 of Figure 6 has a bottom wall 118 and a pair of side walls 119 projecting upwardly therefrom. The side walls 119 snap onto the cover brackets 33 wherein the side walls 119 enclose the respective raceway 19 while the opposite open ends 120 thereof remain open to permit cabling to extend from one wall panel 17 to the next. The side walls 119 further include fixed receptacle openings 121 on the opposite side walls 119 through which the receptacles 38 may project.

[00145] As to Figure 7, the raceway cover 31-2 therein has a single, central receptacle opening 122 on each side wall, while the cover 31-3 of Figure 8 has four (4) such openings 123 through the opposite sides. In Figure 9, the openings 124 of the cover 31-4 are provided on each side and defined by perforated knockouts. Figure 10 illustrates a cover 31-5 which has a slidable door 126 which permits the size of the opening 127 to be adjusted, for example, to accommodate a single receptacle 38. The cover 31-6 of Figure 11 has a door 128 which allows the size of the opening 129 to be adjusted to accommodate one or more single receptacles 38 or a double width receptacle 38-1.

[00146] Referring to Figure 13, the system components also may be combined with a short PDA 35-3 interconnecting two branching connectors 39. The PDA 35- 3 differs in that the length thereof is relatively short and only three groupings 44 of plug openings 43 are provided thereon. The end groupings 44 may be connected to the branching connectors 39 to electrically and mechanically connect all of these components together. One receptacle 38-1 may be mounted on the back face 131 of the PDA 35-3 by connection to the middle grouping 44. Another receptacle 38-2 may be mounted to the front face 132. Since only one receptacle 38 may be mounted directly within a single grouping 44, the second receptacle 38-2 could be mounted to the connector plug 97 on either of the branching connectors 39 by plugging the receptacle posts 57 within the group of openings 94 on the connector plug 97. [00147] While the above configurations use a PDA 35 therewith, the in-feed cable 37, the receptacles 38 and the branching connector 39 may be used independently of the PDA 35. For example, in Figure 19, the receptacle 38 may be connected to a connector plug which may be a cable plug 88 of an in-feed cable 37 or a connector plug 97 of a branching connector 39. In particular, the contact posts 57 may be plugged into the openings 94 or 100 to mechanically and electrically connect the receptacle 38 thereto. The locking flanges 59 on the receptacle 38 removably engage the cable plug 88 or connector plug 97 to prevent inadvertent disengagement of the receptacle 38.

[00148] As to Figure 20, the connector plug 97 of two adjacent branching connectors 39 may be connected together in stacked relation by engaging the male connector parts, namely the posts 99, of one connector plug 97 with the female connector parts, namely the group of openings 100, of the other connector plug 97. A receptacle 38 may be connected to or stacked on the upper connector plug 97 by engaging its male connector parts, namely the contact posts 57 with the female connector parts, i.e. the openings 100, of the connector plug 97. Therefore, the branching connectors 39 are interconnected to define an elongate cabling assembly while the connector plugs 97 define a receptacle mounting location.

[00149] In Figure 21, the components may include the in-feed cable 37 and an extended branching cable 39-1 wherein the respective cable plug 88 and connector plug 97 are interconnected together by plugging of the posts 99 into the openings 94.

[00150] As to Figure 22, an alternate arrangement of components may be stacked together. In particular, the in-feed cable 37 has live electrical circuits supplied to the cable plug 88 which circuits are accessible through the openings 94. Two additional branching connectors 39 are connected thereto. Since the connector plug 97 and cable plug 88 are all non-handed, one branching connector 39 may be oriented so as to extend to the left in one downstream direction, while the other branching connector 39 extends to the right in an opposite downstream direction. Each branching connector 39 is connected to the in-feed cable 37 due to the interconnection of the posts 99 and openings 100.

[00151] Referring to Figures 23-28, the power distribution system 10 is usable in multiple different wall, furniture and floor systems, either individually or in combinations of such systems. Figures 23-28 illustrate representative installations for such wall, furniture and floor systems, and it will be understood that the inventive power distribution system 10 has significant flexibility not only for use as illustrated but also for use in a variety of configurations. [00152] In Figure 23, a desking system 135 is illustrated, which comprises a plurality of individual desks 136. Each desk 136 includes a work surface 137 which is supported by a pair of legs 138. [00153] Most of the desks 136 are positioned in end-to- end relation although one desk identified by reference numeral 136-1 is oriented transverse thereto. This desk 136-1 has a PDA 35 suspended from an underside of the work surface 137 wherein an in-feed cable 37 is connected to the PDA 35.

[00154] Additional desks 136-2 and 136-3 also have PDAs 35 suspended therefrom. The PDA 35 on the desk 136-1 is connected to the PDA 35 on the desk 136-2 which in turn is connected to the PDA 35 on the desk 136-3 by three extended branching connectors 39-1. The first two branching connectors 39-1 are connected serially together and bent around the corner defined between the desks 136- 1 and 136-2. The third branching connector 39-1 spans or extends entirely across the desk 136-4 which is disposed between the desks 136-2 and 136-3. Another branching connector 39 is connected to the end of the PDA 35 on the end desk 136-3 and provides electrical power to other locations in the office area 114.

[00155] To provide outlets for the individual offices, a plurality of receptacles 38 are provided. As seen on the desks 136-2 and 136-3, a receptacle 38 may be connected to any PDA 35, on either face thereof. As such, the receptacles 38 are located below the work surface 137 and are therefore hidden from sight.

[00156] Also, a receptacle 38 may be connected to the system in a tethered configuration. In particular, a branching connector 39 is connected between the receptacle 38 and the junction 139 of the two serially- connected branching connectors 39. As such, the receptacle 38 may be positioned at a selected location under the worksurface 137 of the desk 136-5, and therefore is not confined to a specific location dictated by the position of the PDA 35.

[00157] In Figure 24, a post-and-beam space-dividing system 143 is illustrated. This system 143 is defined by vertical posts 144 which serve as legs for horizontal beams 145. The posts 144 and beams 145 are hollow so as to define vertical and horizontal raceways. The posts 144 further include a utility port 146 which is adapted to accommodate a receptacle 38 and a faceplate 148 therefor.

[00158] The power distribution system 10 is configured in Figure 24 in a cable based arrangement which does not use any PDAs therein. Rather, the system 10 is constructed solely of branching connectors 39, receptacles 38 and an in-feed cable 37. The in-feed cable 37 is fished through the post 144 and partially along the length of a beam 145. Branching connectors 39 are connected serially thereto so as to extend along the length of the beams 145. At the cable junction 150, two downstream branching connectors 39 are connected to and extend away from an upstream branching connector 39 generally in a Y configuration.

[00159] Also at the junction 150, another branching connector 39 is provided to define a jumper or tether for supplying electrical circuits to the receptacle 38 located in the post 144 at location 151. [00160] At the end post 144 at location 152, another branching connector 39 is fished through the beam 145 and post 144, the free end of which is connected to the receptacle 38.

[00161] In a more comprehensive application, as illustrated in Figure 25, it is known to first outfit an office space 14 with a raised floor system 155. Raised floor systems are well known, and typically include removable floor tiles 156 which enclose a raceway space 157 defined vertically between the floor tiles 156 and the base floor surface 158.

[00162] The office space 14 also may include a power closet 160 and a telecommunications closet 161 which supply the entire office space or building. As such, a modular telecommunications cabling system 162 runs from the telecommunications closet 161 in multiple cable runs 163, 164, 165 and 166. Also multiple cable runs 167, 168, 169 and 170 of the power cabling are provided. [00163] In this example, the power cable runs 167-170 are defined by a cable based arrangement of serially connected branching connectors 39. Generally, the telecommunication runs 163 and 164 and the power runs 167 and 168 extend through the raceway space 157 and supply data and power circuits to an open floor space 175. [00164] The data run 165 and the power run 169 extend below and supply a wall panel system 176 disposed on top of the raised floor system 155. The remaining data run 166 and power run 170 supply a desk system 177 and additional freestanding furniture components, namely a side chair 178 and a table 179.

[00165] Referring more particularly to Figure 26, the wall panel system 176 includes a plurality of wall panels 181 wherein one of the wall panels 181 defines a return wall 182. As described previously, each wall panel 181 has a raceway 183 extending longitudinally along the bottom edge thereof. The power distribution system 10 is configured for this application in a hybrid arrangement of a bus-bar based arrangement for the wall panels 181 and a cable based arrangement for the raised floor system 155.

[00166] In the floor raceway 157, a plurality of branching connectors 39 are connected serially together, with a further branching connector 39 being connected thereto at the cable junction 184 and extending out of the floor raceway 157 through an access opening 185 formed by removal of a floor tile. This branching connector 39 extends into a panel raceway 183 at location 186.

[00167] In the wall panel raceways 183, each panel 181 has a PDA 35 suspended therefrom wherein serially- adjacent PDAs 35 are connected together by a branching connector 39. Further, the branching connector 39 extending from the floor is connected to the panel raceway cable components by connecting the end of this branching connector 39 to one of the branching connectors 39 connecting the PDAs 35 together at location 186. [00168] Referring to Figure 27, the power run 170 and the data run 166 are exposed through an access opening 190 created in the raised floor system 155 by removal of a floor tile. This access opening 190 is located adjacent to a desking system 177, which desking system includes a desk 191 and a chair 192 disposed adjacent thereto. The desk 191 has a receptacle housing 193 mounted near a front edge of a worksurface 194. The housing 193 includes a power receptacle 38, as well as a multi-port data receptacle 195. A branching connector 39 has one end connected to a junction 196 defined between two branching connectors 39. The connector port 97 is connected at the cable junction 196 in stacked relation. The upper end of the cable 39 is connected to the receptacle 38 in substantially the same manner as that illustrated in Figure 19.

[00169] Referring to Figure 28, the side chair 178 and the table 179 are illustrated with a laptop computer 198 and a telephone 199 disposed thereon. In this arrangement, the data run 166 and power run 170 are connected to a floor-mounted junction box 200. The junction box 200 includes an access door 201, which closes flush with the floor tiles 156. The junction box

200 further includes a data run 202 and a power receptacle 38.

[00170] The power run 170 has two branching connectors 39 interconnected together to define a junction 204, to which is connected a further branching connector 39, which extends upwardly and is connected to the power receptacle 38 in the junction box 200.

III. System Components

[00171] More particularly, as to the PDA 35, Figure 29 illustrates one configuration for a power distribution assembly having end grouping pairs 47 and two interior grouping pairs 48. The two interior grouping pairs 48 provide two different mounting locations for receptacles

38 wherein one opening group 44 of an interior pair 48 permits mounting of the receptacle 38 on one side of the PDA 35, while the other opening group 44 of the same interior pair 48 permits the receptacle 38 to be mounted to the opposite side thereof. As discussed above, the plug openings 43 of each group 44 are arranged in two vertical rows 45, which rows 45 are aligned horizontally with each other. In other words, each plug opening 43 is aligned horizontally with another plug opening 43 in side-by-side relation.

[00172] The plug openings 43 have a rectangular shape and project through the entire thickness of the PDA casing 40 so as to open from the opposite casing faces 50 and 51. This allows a system component such as any of the connector plugs 83 or 97, or cable plug 88, to be plugged therein through either one face 50 or the other face 51, as illustrated in Figures 29 and 32A. Each opening 43 is defined vertically by an upper edge 203 and a lower edge 204.

[00173] The casing 40 is defined by casing halves 205 and 206, which are interconnected together in facing relation to define an interface 207 therebetween. The conductors 41 are sandwiched between the casing halves 205 and 206, as illustrated in Figure 32A and furthermore, extend longitudinally along the entire length of the PDA 35.

[00174] More specifically, as to the conductors 41, the construction of the PDA 35 illustrated in Figure 29 has 10 conductors or wires 41 and is thereby referenced as a ten-wire configuration. The conductors 41 are arranged in vertically spaced relation wherein each pair of conductors 41 has a vertical spacing which corresponds to the vertical size of the opening 43 as defined between the upper and lower edges 203 and 204.

[00175] As illustrated in Figure 32A, each opening 43 provides access to an exposed portion of a pair of conductors 41. Specifically, each of the upper and lower edges 203 and 204 has one of the conductors 41 projecting vertically into the open area of the opening 43. The conductors 41 are specifically identified by reference numerals 211-220, with conductors 211, 212 and 215-220 being 12-gauge conventional conductor wire formed of. The conductors 213 and 214 in this illustrated construction are formed of 10-gauge wire to provide a higher capacity, particularly where the conductors 213 and 214 are configured for use as a neutral wire which serves multiple circuits. A more detailed discussion of the assignment of ground, neutral and line wires is discussed in further detail hereinafter. It will be understood that all of the wires may be formed of the same wire gauge, or that different gauges and compositions of wires could be used.

[00176] Referring to Figure 30, each of the conductors such as conductors 219 and 220, which are illustrated in phantom outline, extend along the casing 40 with horizontally spaced apart portions of each conductor being exposed along multiple openings 43. For example, four vertical rows 45 of openings 43 are illustrated, which define the end grouping pairs 44. The four lowermost openings 43 of the rows 45 are horizontally aligned with each other such that each conductor 219 and 220 extends across all of the horizontally aligned openings 43. Each conductor 219 and 220 has portions thereof which are accessible from the openings 43, specifically along the upper and lower edges 203 and 204 thereof. Thus, each opening 43 has an exposed conductor portion of the conductor 219 along the upper edge 203 and a conductor portion of the conductor 220 exposed along the lower edge 204.

[00177] In view of the foregoing, each vertical row 45 of openings 43 provides access to all of the conductors 211 to 220, and as such, the two rows 45 of each opening group 44 provide two different access locations for each conductor. Generally, each horizontally aligned pair of posts has the electrical contacts thereof facing in opposite vertical directions such that, when one of the system components, such as the flex connector, branching connector or receptacle is plugged into an opening group 44, only one of the exposed conductor portions of the conductors 211 and 212 for a single opening 43 is connected to a port .

[00178] More particularly as to Figures 31 and 32A, the connector plug 66 of a flex connector 36 is illustrated therein. The plug 66 includes the grouping 73 of openings 74 in the exterior face 70. Each opening 74 has an electrical contact 225 or 226 accessible therethrough to permit connection of another system component to the flex connector 36 if desired. As illustrated, the contacts 225 and 226 are located at alternating positions for each horizontally aligned pair of openings 74. In other words, contacts 225 of one vertical row 227 are located vertically on one side of the openings 74, while the contacts 226 of an associated second row 228 of openings 74 are positioned on the opposite vertical side of these openings 74.

[00179] Referring to Figure 32A, posts 71 project from the interior face 69 of the connector plug 66. While two rows of posts 71 are provided which align with the openings 74 illustrated in Figure 31, only one row of posts 71 is seen in the end view of Figure 32A. In this visible row of posts 71, the above-described electrical contacts 225 project downwardly therefrom. The contacts 226 for the adjacent row of posts can also be seen and these project upwardly.

[00180] As such, when the posts 71 are plugged into the PDA openings 43 as illustrated in Figure 32B, the contact 225 in the uppermost left opening 43 mechanically contacts the conductor 212 to complete an electrical circuit therebetween. Further, the sidewardly adjacent contact 226 contacts the conductor 211 in the uppermost right opening 43. In this manner, all of the contacts 225 and 226 contact all of the conductors 211 to 220. [00181] With this arrangement, the flex connector 36 and the in-feed cable 37 in the identical manner plug into and thereby electrically connect to all of the conductors 211 to 212. The receptacles 38 connect through a similar connection but connect to less than all of the conductors 211 to 220 as will be described herein. [00182] Referring to Figure 33, a PDA 35-2 is illustrated which has an end pair 47 of opening groups 44 and a single interior pair 48 of opening groups 44. The PDA 35-2 has a ten-wire configuration which corresponds to the ten-wire configuration of Figure 32A. [00183] As described below, the actual circuits defined by the ten conductors 211-220 can be readily varied depending upon the arrangement of circuits defined in the in-feed cable 37, wherein in-feed arrangement is defined by and can be varied by the connection of the in-feed cable 37 to the wiring closet 160 (Figure 25) . [00184] More particularly, the circuit configuration of Figure 34 has the ten solid-wire conductors 211-220 configured into four dedicated circuits of one line and one neutral, plus a ground and an isolated ground. Specifically, conductor 211 defines a ground, while conductor 212 serves as an isolated ground. Conductors

213, 215, 217 and 219 serve as line 1, line 2, line 3 and line 4 of the four dedicated circuits, while conductors

214, 216, 218 and 220 serve as neutral 1, neutral

2, neutral 3 and neutral 4. Notably, circuit 1 which comprises line 1 (213) and neutral 1 (214) is a higher capacity circuit since conductors 213 and 214 are 10 gauge wire rather than 12 gauge wire.

[00185] Since the flex connector 36 and branching connector 39 connect to all conductors 211 to 220 when plugged in the PDA 35, the same circuit configuration is distributed throughout all of the PDAs 35 or any flex connectors 36 or branching connectors 39 connected thereto as in Figures 1-5, 12 and 13. It will be understood that the front view of Figure 34 illustrates the line, neutral and ground conductors and that this diagram also applies to the openings 74 of the flex connectors 36 or the openings 94 of the branching connectors 39. Furthermore, this diagram also applies to the arrangement of circuits in the system application of Figure 24. While the following discussion of circuits is directed primarily to the PDA 35, this discussion of the arrangement of the circuit and the connection of receptacles 38 thereto also applies to the other system components .

[00186] Figure 34 further includes a diagrammatic representation of a receptacle 38 and in particular, a variation of a receptacle identified by reference numeral 38-1. The receptacle 38-1 is illustrated in greater detail in Figures 60-65.

[00187] Generally as to Figure 34, the receptacle 38-1 has an upper post 57-1 which includes an electrical contact 230 exposed on one side thereof similar to the contacts 225 or 226 described above. The post 57-1 further is rotatable as indicated by reference arrow 231 to reorient the contact 230 from an upward facing orientation as illustrated in solid outline to a downward facing orientation as indicated in phantom outline. Accordingly, the post 57-1 fits into the upper right PDA opening 43 wherein the contact 230 either contacts the ground conductor 211 or the isolated ground conductor 212 which thereby defines to what type of ground that the receptacle 38-1 is connected to.

[00188] The receptacle 38-1 also includes a pair of movable posts 57-2 which move in unison along a vertical path 232. The posts include respective contacts 233 and 234 which face upwardly and downwardly in opposite directions so as to engage the conductors of a horizontally aligned pair of openings. For example, at the upper end of the slide path 232, the contacts 233 and 234 engage the conductors 213 and 214 so that the receptacle 38-1 is connected to circuit 1 or more particularly, to line 1 and neutral 1. The posts 57-2 can be slid downwardly to alternately connect to any of line 2/neutral 2, line 3/neutral 3 or line 4/neutral 4. [00189] In Figure 35, an alternate circuit arrangement is illustrated for the same PDA 35-2. This arrangement comprises two neutrals wherein three lines share each neutral. Specifically, conductors 211 and 212 serve as ground and isolated ground, while the heavy gauge conductors 213 and 214 serve as neutral 1 and neutral 2. Conductors 215, 217 and 219 serve as lines 1, 2 and 3 which share neutral 1, while conductors 216, 218 and 220 serve as lines 4, 5 and 6 which share neutral 2. [00190] A modified receptacle 38-2 is diagrammatically illustrated. This receptacle 38-2 has four fixed posts 57 formed the same as posts 57 described herein. The upper pair of posts 57 are provided with an electrical contact 236 either in an upward facing position illustrated in solid lines to connect to the ground conductor 211 or a downward facing position such as illustrated in phantom outline to connect to the isolated ground conductor 212. Alternatively, a rotatable post 57-1 could also be used.

[00191] The second pair of posts 57 also are prewired with an electrical contact 237 either in an upward facing orientation for connection to neutral 1, or a downward facing position for neutral 2. A slidable pair of posts 57-3 and 57-4 are provided which are similar to the posts 57-2 and slid vertically along slide path 239. In this arrangement, a contact 238 may be provided in the post 57-3 to selectively connect to any one of the line 1 conductor 215, the line 2 conductor 217 or the line 3 conductor 219. Alternatively, the contact 238 may be installed in the post 57-4 to connect to any one of the line 4 conductor 216, the line 5 conductor 218 or the line 6 conductor 220.

[00192] Referring to Figure 36, a further circuit arrangement is illustrated wherein three shared circuits and 2 dedicated circuits are provided. Specifically, conductors 211 and 212 define a common ground and an isolated ground, while line 1, line 2 and line 3 conductors 215, 217 and 219 are associated with neutral 1 conductor 213. Further, the two dedicated circuits are defined by neutral 2 conductor 214 which is associated with line 4 conductor 216 and neutral 3 conductor which is associated with line 5 conductor 220. [00193] The receptacle 38 is diagrammatically illustrated. This receptacle 38 has two vertical rows of fixed posts 57 which are prewired during manufacture depending upon the specific circuits that the receptacle 38 is being connected to. For example, either contact 240 or contact 241 is provided depending upon the type of ground connection required. Also, contact 242 could be provided in combination with another contact 243 for use of one of the shared circuits. In the illustrated arrangement, contact 242 connects to neutral 1 conductor 213 while contact 243 connects to line 1 conductor 215, although contact 243 could be repositioned for connection to conductor 217. Alternatively, two alternate contacts 244 and 245 could be provided to connect to one of the two dedicated circuits. As illustrated, contacts 244 and 245 connect respectively to neutral 2 conductor 214 and line 4 conductor 216.

[00194] Referring to Figures 37-40, the PDA 35-3 therein is formed in a six-wire configuration. The PDA 35-3 has end opening groups 247 and intermediate receptacle groups 248. The PDA 35-3 is formed substantially the same as the PDA 35-2 except that only six conductors 251-256 are provided. Otherwise, the position of the conductors 251-256 in the openings 250 is structurally and functionally the same as the conductors 211-220 in openings 43.

[00195] As to Figure 38, the conductors 251-256 serve as a ground, an isolated ground and two dedicated circuits. The receptacle 38-3 could have a variety of constructions. For example, post 257-1 has contact 258 therein and could be rotatable so that contact 258 connects to either of ground conductors 251 or 253. In this arrangement, posts 257-2 have contacts 259 and 260 and are slidable for connection to either circuit 1, i.e. line l/neutral 1, or circuit 2, i.e. line 2/neutral 2. [00196] Alternatively, all of posts 257-1 and 257-2 as well as posts 257-3 and 257-4 could be fixed posts like in the receptacle 38. As such, contact 261 could be provided instead of contact 258, while contacts 262 and 263 could be provided instead of contacts 259 and 260 so as to connect to circuit 2, i.e. line 2/neutral 2. [00197] Figure 39 illustrates a variation of a two dedicated circuit arrangement where neutral 1 conductor 255 is 10 gauge wire instead of 12 gauge wire. In this arrangement, the posts 257-5 are fixed and prewired with either contact 264 or 265 to define the ground type, and contacts 266/267 for line l/neutral 1, or contacts 268/269 for line 2/neutral 2. [00198] Figure 40 illustrates a configuration with three shared circuits in which conductors 251 and 253 define ground wires, while conductor 255 serves as a neutral and conductors 252, 253 and 254 serve as line wires 1, 2 and 3. The ground is selected by providing contacts 270 or 271 in one of the posts 257-5, and the neutral is selected by providing contact 272. The line is selected by providing contact 273 for line 1 or alternatively contacts 274 or 275 for lines 2 or 3 respectively.

[00199] It will be understood that the above-described ten-wire and six-wire arrangements can be modified depending upon how the ground, neutral and line connections are supplied to the PDA by an in-feed cable 37. Further, different numbers of conductors may be provided using the same structural and functional features of the inventive power distribution system. [00200] Referring to Figures 41-45, the manufacturing process for forming the PDAs is readily adaptable to forming the PDAs with different numbers of conductors, such the ten-wire and six-wire systems. Further, the different patterns of openings in these two systems can be readily modified through the manufacturing process to form different numbers of openings and different layouts thereof .

[00201] Generally in this process, the PDAs 35 are formed in a continuous length with the pattern of openings 43 being punched depending upon the specific type of PDA being formed, i.e. depending upon the number of opening groups 44 being provided. Thereafter, the length of PDA material is cut to the specific length required. This provides an improved manufacturing process with increased efficiency which thereby reduces the costs associated with the power distribution system 10. [00202] More specifically, Figure 41 illustrates the multiple steps involved in the process with Figures 42-45 structurally illustrating process steps 1, 2, 4 and 5 respectively.

[00203] Referring to Figures 41 and 42 which relate to process step 1, this first step involves extruding a profile 280 for the PDA 35 in a continuous extrusion process. The PDA profile 280 is formed of an insulative, relatively rigid material such as plastic. This initial profile 280 may have different configurations including a single common profile 280-1 which is used in pairs to define both halves of the casing 40. This would require two extrusion processes or a single process from which two halves would be formed.

[00204] The profile 280-2 could also be formed having two mirror image profile halves 281 which are joined together by a flexible web 282 that defines a hinge about which the profile halves 281 are folded together. The following discussion is directed to profile 280-2 although it is understood that providing two profiles 280-1 is substantially the same as profile 280-2 except that web 282 is not present. Thus, the following discussion of profile 280-2 also applies to profile 280-1.

[00205] The profile 280-3 could be formed which has two different half profiles 284 and 285 which also are joined by a flexible web 286. One profile half 285 has a greater thickness.

[00206] In Step 2, wire or conductor grooves are formed into the profile 280 for accommodating conductors 41. Referring to Figure 43, the two profile halves 281 have inside faces 287 into which are formed partial-depth grooves 288. The grooves 288 extend longitudinally and are parallel to each other. These same grooves 288 would also be machined into the face 289 of the profile 289. [00207] While the grooves 288 are configured to accommodate half the thickness of a conductor 41, full- depth grooves 290 are provided in parallel relation in the interior face 291 of the profile half 285. The depth of the grooves 290 accommodates the entire thickness of a conductor conductors 41, such that the interior face 292 of the profile half 284 does not require grooves to be machined therein. Further, the grooves 290 have features therein such as a narrow width opening which allows the conductors to be positively secured therein such as by a snap fit.

[00208] Step 2 is optional in that the grooves could be formed during extrusion, rather than by a separate machining process .

[00209] In Step 3, the pattern of openings 43 or 250 are punched into the two profiles which make up the PDA. The number of opening groups 44 and the specific arrangement of openings 43 such as in two vertical rows may be varied. For example, groups 44 may be punched to form a PDA 35, which has two interior pairs 48 of groups 44, or a PDA 35-2 which has a single interior pair 48.

[00210] In Step 4, the conductors 41 are positioned in the open profile, for example in the grooves 288 of profile 280-2. The empty profile half 281 is hence positioned for folding. For profile 280-3, the conductors 41 are fitted into the grooves 290 with the profile half 284 positioned for folding generally in the direction of arrow 292. In Step 4, the conductors 41 are formed as a continuous length of solid conductor wire which is laid continuously into the groves 288 or 290.

[00211] In Step 5, the profile halves are then folded one onto the other at which time the two halves are sealed together to form the finished profile of the PDA. However, the profile still has a continuous length. [00212] In Step 6, the finished profile is cut to length by severing sections from the finished profile to form a finished PDA 35. The finished length of the PDA 35 corresponds to the specific pattern of opening groups 44 punched therein. Thus, any of the PDAs 35, 35-1 or 35-2 may be formed from the same process by varying the pattern of groups 44 and severing the finished profile at the length corresponding to the specific pattern applied thereto. This severing steps cuts through the insulative material as well as the conductors 41. With this manufacturing process, the PDAs 35 may be cost- effectively produced primarily by extruding the components in a continuous operation. [00213] Turning to the specific construction of the flex connector 36, the plug housing 67 of the connector plug 66 is formed by a housing base 300 and a cover 301 as seen in Figure 46. The base 300 has a side wall 302 and an end wall 303 which connects to the conductor body 65.

[00214] The end wall 303 has an open slot 304 which includes a plurality of conductor seats 305 formed as a half-circle to receive the individual conductors or wires of the conductor body 65. The base 300 includes a first interior wall 306 which includes deep conductor seats 307 and shallow conductor seats 308. A second interior wall 310 includes further conductor seats 311 for those conductors extending to this point .

[00215] The base 300 further includes the posts 71 projecting from the interior face 69 in two vertical rows. Referring to Figure 53, each post 71 has a wall 312 which is open on one side 313 to allow the electrical contact 225 or 226 to project therethrough. The posts 71 in one row are reverse oriented or formed identical but opposite to the other row. As such the open sides 313 open upwardly for one row of posts 71 and open downwardly for the other row of posts 71.

[00216] The post 71 is hollow and receives the contact 225 or 226 therein. Each post 71 opens into the interior of the base 300 and has a mounting flange 314 projecting upwardly from the bottom wall 315. The flanges 314 for one vertical row of posts 71 are reverse oriented relative to the flanges 314 for the other row of posts 71. The flanges 314 include guide slots 315 and a locator block 316.

[00217] Each mounting flange 314 includes one of the contacts 225 or 226 therein. The contacts 225 and 226 are identical to each other but identified by different reference numerals for reference purposes. Thus, the following description of contact 225 applies equally to contact 226.

[00218] Referring to Figures 51 and 52, the contact 225 has a mounting plate 320 at one end which is formed with a locator window 321 and a channel 322 therein. An upper end 323 of the contact 225 has a semi-cylindrical conductor mount 324, the interior surface 325 of which is adapted to have a conductor affixed thereto. The outer surface 326 defines an electrical contact surface. [00219] A lower end 327 has an offset connector section 328 and a support leg 329 projecting downwardly therefrom in cantilevered relation. The support leg 329 has a rectangular opening 330 from which projects an electrical contact finger 331.

[00220] Referring to Figures 49, 50 and 53, each contact 225 or 226 is fixedly mounted to one of the mounting flanges 314 by inserting the lower contact end 327 downwardly into the post 71. The lower end 327 slides through the slots 315 until the locator block 316 snaps into the locater window 321 on the contact. The lower end 327 projects into the post 71 wherein the support leg 329 abuts against an inside surface thereof and the contact finger 331 projects through the open side 313 of the post 71.

[00221] Further, the conductor mount 324 projects from the mounting flange 314 for connection to the individual wires of the conductor body 65 such as by soldering. As such, the conductors are electrically connected to the contact 225 whereby contact between the contact finger 331 and a respective PDA conductor such as seen in Figure 32B completes an electrical circuit therebetween. [00222] Also, the contact surface 326 faces upwardly and sidewardly. To provide access thereto, the cover 301 has the openings 74 formed therein as seen in Figure 47. The openings 74 are arranged in two vertical rows and open downwardly directly above the contact surface 326 as seen in Figures 47 and 53 such that the contacts 225 and 226 are accessible through the openings 74. [00223] Therefore, one connector plug 66 may be plugged into another connector plug 66 for example as seen in Figures 20-24. As such the contact finger 331 of the outer plug 66 abuttingly contacts the contact surface 326 of the contact 225 or 226 of the inner plug 66. This thereby completes the electrical connection therebetween. [00224] Referring to Figures 55-57, a variation of one of the plugs 97-1 for a branching connector 39-1 is illustrated. This plug 97-1 is formed identical to the plug 97 except that the cable fitting 340 is oriented at a right angle as compared to the cable fitting 341 (Figure 17) of the plug 97. This plug 97-1 extends vertically from a PDA 35 as seen in phantom outline in Figure 31 which is more suitable for use in a raised floor application since the branching connector 39-1 does not require bending.

[00225] The plug 97-1 has a housing base 342 and a cover (not illustrated) constructed similar to the cover , „_nΛ 04/057716

301 discussed above. The base 342 is functionally the same as the base 300 in that posts 99 project downwardly therefrom, and mounting flanges 344 project into the base interior 345. The posts 99 and flanges 344 are formed identical to the posts 71 and mounting flanges 314 described above and thus, a detailed discussion is not required.

[00226] Generally, the posts 99 and flanges 344 are arranged in two vertical rows wherein the posts 99 of each row are horizontally aligned with the posts 99 of the adjacent row. As seen in Figure 57, contacts 225 and 226 are supported in the mounting flanges 344 while conductor wires 345 extend into the housing base 342. The free end 346 of each wire 345 fits in the conductor mount 324 and is mechanically and electrically connected thereto such as by soldering. The housing base 342 also includes a cable fitting 346 in which the cable 95-1 is fixed when the cover is secured in place. [00227] In Figures 58 and 59, one version of a receptacle 38 is illustrated. This receptacle 38 has a base plate 350 and an interchangeable receptacle cover 351. Generally, the base plate 350 is formed with two vertical rows of fixed posts 57 projecting rearwardly therefrom which posts 57 open inwardly into the receptacle interior. The posts 57 may be formed with mounting flanges 59 like those described above. [00228] The receptacle 38 also includes a conductor strap unit 352 comprising an insulative housing 353, a plurality of elongate, conductive straps 354 received in the housing 353 and electrical contacts 355, 356 and 357 which are connected to the straps 354 by wires 358. [00229] The conductive straps 354 are accessible through the receptacle cover 351 through the line and neutral openings 360 and the ground openings 361 formed in the cover 351. Three straps 354 are provided corresponding to line, neutral and ground and are connected to the contacts 355, 356 and 357. The receptacle 38 is pre-wired by inserting the contacts 355- 357 into appropriate openings of the post 57. For example, the contacts 355-357 may be inserted into the post 57 so as to define the contacts 240, 242 and 243 of Figure 36. The positions of these contacts 355-357 can be varied to pre-wire the receptacle for connection to a selected circuit being carried by a PDA 35-2 or another type of PDA.

[00230] Alternate receptacle covers 351 may be provided such as 351-1, 351-2, 351-3 and 351-4. With these different receptacle covers, the identical arrangement of the base plate 350 and the conductor strap unit 352 is used.

[00231] Referring to Figures 60-65, a receptacle 38-1 is illustrated which includes a rotatable ground unit and a slideable circuit selector. In particular, the receptacle 38-1 includes a base plate 365 and a cover 366. The base plate 355 includes the rotatable post 57-1 which is rotatable as indicated by reference arrow 231. Also, the base plate 365 includes a window 366A, to which is slideably mounted the posts 57-2. One post 57-2 has an upward opening open side 367 through which the contact 233 is accessible. The other post 57-2 opens downwardly in the opposite orientation and has the contact 234 accessible therethrough.

[00232] Referring to Figures 61 and 62, the receptacle 38-1 includes a conductor strap unit 367 which comprises an insulative housing 368 in which is mounted three conductive straps 369, 370 and 371. Strap 370 is a ground strap while straps 369 and 371 correspond to line and neutral. The straps 369-371 have mounting terminals 372 at the ends thereof, which connect to wires 373 and 374. These wires 373 and 374 have the contacts 230, 233 and 234 connected thereto.

[00233] Referring to Figure 64, a slide block 375 is illustrated, which has two guide flanges 376 on the opposite sides thereof, and the post 57-2 projecting therefrom. The post 57-2 has the contacts 233 and 234 projecting in opposite directions. The contacts 233 and 234 respectively include mounting terminals 377 and 378 on the inner ends thereof. These mounting terminals 377 and 378 are connected respectively to the wires 373 and 374. The slide block 375 also includes an indicator flange 380. The base plate 365 is formed with guide slots 381 along the opposite side edges of the window 366A, wherein the guide flanges 376 slide within the slots 381 in a vertical direction. Additionally, the indicator flange 380 is located proximate to visual indicators 383 on the receptacle cover 366. The indicators correspond to the vertical position so the slide block 375 which corresponds to the specific circuit being connected to. In other words, the slide block 375 is moveable between four positions in which circuits 1-4 may be engaged, as illustrated in Figure 34. [00234] As for the rotatable post 57-1, this post has the contact 230 accessible therethrough. Referring to Figure 65, the rotatable post 57-1 has a rotation collar 385 and a toothed portion 386 along at least a portion of the circumference thereof. The toothed portion 386 engages a driven gear 387, which driven gear 387 (Figure 61) has an indicator pin 388 projecting coaxially therefrom. The indicator pin 388 has an indicator arrow 389 thereon, which points at surface indicia on the cover 366 so as to indicate whether the post 57-1 is engaged with the ground or the isolated ground. By rotating the post 57-1 in the direction of arrow 231, the post 57-1 drives the driven gear 387 to rotate the indicator post 388.

[00235] The receptacle 38-1 thereby has a rotatable ground and a slideable contact assembly, which allows for ready selection of the ground and circuit to which the receptacle 38-1 is connected. This adjustment may be in the field and may even be re-adjusted at a later date. [00236] Referring to Figures 66-83, a further power distribution system 400 is illustrated therein, which system uses similar components and manufacturing techniques. In particular, the power distribution system 400 includes a power distribution assembly 401, which is formed with the same manufacturing process as that described herein. In particular, the PDA 401 includes an insulated casing 402, which is formed with multiple groups 403 and 404 of openings 405.

[00237] Referring to Figure 67A, each opening group 403 includes a first vertical row 406 of the apertures 405 and a second vertical row 407 of additional apertures 405. The row 406 of apertures 405 is at a higher elevation relative to the second row 407. [00238] The adjacent group 404 of openings is formed similar to the group 403 in that group 404 includes a row 407 of apertures and another row 406 of apertures 405. However, the row 406 is located to the right of row 407 in group 404, which is opposite to the orientation of the rows 406 and 407 in the group 403. Thus, groups 403 and 404 are similar except that the higher elevation row 406 is located on different sides of their respective lower elevation rows 407.

[00239] With respect to the individual openings 405 of each row 406 or 407, each vertically adjacent pair of openings 405 is separated by a bridge or land of insulative material 410 which extends laterally across and vertically separates each vertically adjacent pair of openings 405. The openings 405 are formed in the same manner as the openings described previously in that during the extrusion process of the PDA 401, the individual openings 405 are punched into the insulative material of the casing 402.

[00240] Referring to Figure 67B, the casing 402 of the PDA 401 is formed internally with a plurality of parallel grooves extending along the entire length of the PDA 401, in which a plurality of conductors 411 are received. Each conductor 411 extends the entire length of the PDA and extends below the bridge 410 disposed between an adjacent pair of openings 405. The conductor 411 for each pair of openings 405 is accessible therethrough and may be accessed through each of said openings 405. [00241] Referring again to Figure 66, the PDA 401 is formed with a set of three opening groups at each opposite end which are associated with each other and used to electrically connect serially adjacent PDAs 401 together through a flex connector 415 (Figures 68 and 69) . Additionally, intermediate pairs of groups are associate with each other for the mounting of receptacles .

[00242] Specifically, the PDA 401 includes two intermediate grouping pairs 416 which each comprise an opening group 403 and an opening group 404. On the left end of the PDA 401, a group set 417 is provided on the left end 418 of the PDA 401. The group set 417 comprises a spaced apart pair of groups 403 with a group 404 disposed therebetween. The opposite right end 419 of the PDA 401 includes a further group set 420 which comprises a spaced apart pair of groups 404 having another opening group 403 disposed centrally therebetween. [00243] More particularly, each PDA 415 includes a pair of connector plugs 422 and 423 at the opposite ends thereof, which are joined together by a bendable conductor body 424, which includes electrical conductors extending therethrough.

[00244] The plug 422 includes^" a group 426 of openings 427, which group 426 is defined by two vertical rows 428 and 429 of openings 427. The row 428 is at a higher elevation relative to the row 429 such that the opening group 426 has substantially the same configuration as the PDA opening group 403.

[00245] The plug 423 as illustrated in Figure 70 similarly includes a group 430 of openings 431, which are arranged in two vertical rows 432 and 433, with row 432 being at a higher elevation. As such, the opening group 430 on the right end connector plug 423 is structurally and functionally similar to the opening group 403 described above.

[00246] The group set 417 and the group set 420 allow the flex connector 415 to be used on different sides of the PDA 401. Specifically, when the flex connector 415 is on the front PDA side 435, the plug 423 may be connected to either of the groups 403 in the group set 417. The plug 422 on the opposite end thereof would then be connected to the opening group 403 in the group set 420 on the serially adjacent PDA 401.

[00247] If the flex connector 415 is flipped over and used on the opposite side of the PDA 401, the opening groups 426 and 430 would be oriented in an opposite orientation which corresponds to the opening groups 404. As such, the flex connector 415 would have the plug 423 connected to the opening group 404 of the group set 417, while the opposite end plug 422 would be connected to either of the opening groups 404 in the group set 420 on a serially adjacent PDA 401. Use of three opening groups 403 and 404 for each group set 417 or 420 allows two adjacent PDAs 401 to be positioned at two different modular distances from each other, which distances correspond to the thickness of the wall panel in a three- way connection such that the power distribution system 400 is usable in either a two-way connection such as in Figure 3, or a three-way connection such as in Figure 2. [00248] Specifically, as to the connector plugs 422 and 423, these components are formed substantially the same as each other and thus, while the following discussion is directed more specifically to the connector plug 423, this discussion also applies to the plug 422. [00249] Referring to Figure 70, the connector plug 423 includes a plug housing 440 defined by a housing base 441 and a housing cover 442. The plug housing 440 generally includes the opening group 430 formed in the cover 442 and also includes a plurality of contact posts 443 which project from an inside face 444 of the housing base 441. More particularly as to the cover 442, the cover 442 is illustrated in Figures 70 and 79. It is formed flat with the two rows 432 and 443 of openings 431 formed therein. Openings 431 are vertically spaced apart and generally arranged in pairs, wherein each pair of openings 431 is separated by a bridge or land 445. Additionally, locking flanges 446 project vertically from the upper and lower edges of the cover 442.

[00250] Referring to Figure 71, the base 442 has a peripheral side wall 448 and a main wall 449 from which the individual posts 443 project. The posts 443 are arranged in two vertical rows 450 and 451 having the same relative spacing as the openings 431 and specifically the vertical rows 432 and 433 thereof. The posts 443 are arranged in pairs of such posts 443 which are substantially identical to each other but arranged as mirror images in vertically spaced relation. The pairs of posts 443 are vertically spaced apart so as to fit within a corresponding pair of openings. For example, the posts 443 may fit into the openings 405 of the PDA 401 with the material bridge 410 being received between the posts 443. Alternatively, when one flex connector 415 is connected to another such as illustrated in Figures 68 and 69, the posts 443 would fit within the openings 427 of the connector plug 422, with a material bridge 455 being slideably received between the associated pair of posts 443.

[00251] More particularly, as to Figures 71-75, each post 443 has a rectangular opening 455 adjacent to an inside face thereof on the interior of the base 441. Each associated pair of openings 445 is separated by a rib 456.

[00252] Additionally, each rib 456 extends and terminates at a support block 457.

[00253] Referring to Figure 76, a generally U-shaped contact body 460 is mounted on each support rib 456. The front end of each contact body 460 fits within the support block 457 and is restrained from movement thereby. The contact body 460 is illustrated in further detail in Figures 76-78 and is formed from a U-shaped barrel or spine section 461 having an enlarged semi- cylindrical conductor seat 462 at one end thereof. The conductor seat 462 is adapted to receive a conductor wire therein and which seat 462 is soldered to the free end of the wire. Additionally, a pair of contact prongs 463 and 464 project downwardly from the barrel 461. Each pair of prongs 463 and 464 comprises a narrow prong 465 and a wide prong 466 which are separated from each other by a gap 467. The prongs 465 and 466 are configured to mechanically control distortion of the contact body 460 during soldering of wire to the wire seat 462. When fitted into the housing base 441, each pair of prongs 463 and 464 is inserted through a corresponding one of the openings 455 and is supported by the post 443 as seen in Figures 71 and 72. ,„„„, , 04/057716

[00254] When assembled together, the barrel portion 461 of each contact body is exposed within the interior and when the cover 442 is mounted in place, the barrel portions 461 are accessible through the openings 431 in the cover 442. Therefore, when joining two flex connectors 415 together such as in Figure 80, the flex connectors can be electrically interconnected by engagement of the posts 443 therein. More particularly, Figure 82 illustrates a connector plug 423 connected to the connector plug 422 of the other flex connector 415. For the flex connector 422, the prongs 443 thereof are exposed with the contact body 460 positioned for use. Additionally, the posts 443 of the plug 423 fit into a pair of openings 427. This allows the pairs of prongs 463 and 464 to resiliently fit over the barrel 461 of the lower contact body 460. Thus, the two plugs 422 and 443 are electrically connected together. [00255] Referring to Figures 70, 71 and 80, each connector plug 422 or 423 includes latching devices 450 on the upper and lower edges thereof . As seen in Figures 80 and 81, each latching device comprises a T-shaped guide rail 451 and the locking flange 446 which is disposed parallel to but spaced sidewardly from the guide rail 451. Further, a slideable latch 452 is slideably connected to the rail 451 so as to be movable therealong. The latch 452 includes a groove 453 which fits over the guide rail 451. The latch 452 further includes a locking flange 454 which slides over and lockingly engages the flange 446 to prevent separation of the two plugs 422 and 423. When the two plugs 422 and 423 are fitted together, the latch 452 is then slid along the guide rail 451 until the flange 454 slides over and engages the flange 446. Thus, all of the components can be positively locked together. [00256] Referring to Figure 68, the same latch 452 also may be used to engage one of two locking ribs 456 or 457 which extend along both of the opposite side edges of the PDA 401.

[00257] In addition to the foregoing, each plug 422 or 423 may be fitted to the PDA 401 by insertion of the posts 443 into the openings 405. The prongs 463 and 464 spread apart as they pass over the bridge 410 between the openings 405 and then resiliently spring back together into contact with the respective conductor 411. [00258] The system 400 functions similar to the above described power distribution system 10 such that further discussion of the system components such as a branch connector or a receptacle is not required. [00259] Other objects and purposes of the invention, and variations thereof, will be apparent upon reading the following specification and inspecting the accompanying drawings .

Claims

What is claimed is:

1. A power distribution system for horizontal raceways comprising: elongate power distribution modules having a plurality of conductors extending horizontally therethrough which are either common, neutral or ground conductors to define a plurality of electrical circuits carried through said power distribution module; a first one of said power distribution modules including one or more groups of openings wherein each group of openings provides access to said electrical conductors therein; and at least a second one of said power distribution modules including at least one group of openings on a front module face thereof providing access to said conductors therein, and further including electrical contacts electrically connected to said conductors and each having a projecting contact part projecting from a back module face thereof opposite said front module face, said projecting contact parts being engagable with said exposed conductors of said first power distribution module through said group of openings thereof to electrically connect said conductors of said first and second power distribution modules.

2. The power distribution system according to Claim 1, wherein a third one of said power distribution modules includes electrical contacts electrically connected to said conductors and each having a projecting contact part projecting from a back module face thereof, wherein said projecting contact parts of said third power distribution module are engagable with said group of _^ openings of said first power distribution module or said group of openings of said second power distribution module to electrically connect said conductors of said third power distribution module with said conductors of said first and second power distribution modules.

3. The power distribution system according to Claim 2, wherein said third power distribution module includes at least one group of openings providing access to said conductors therein, said power distribution system further including a receptacle having receptacle contacts projecting from a back receptacle face thereof which are engagable with any of said groups of openings of said first, second and third power distribution modules wherein said receptacle includes plug openings on an exterior receptacle face thereof which permit electrical connection of a plug of electrical equipment with said receptacle contacts.

4. The power distribution system according to Claim 3, wherein said first power distribution module includes a plurality of said groups of said openings wherein said second power distribution module is engagable with any one of said opening groups and said receptacle is engagable with any one of said opening groups of said first power distribution module and said second power distribution module.

5. The power distribution system according to Claim 1, wherein said electrical contacts of said second power distribution module have interior contact parts which are exposed through said group of openings thereof through said front module face .

6. A power distribution system for building raceways comprising: a main power distribution module having an extruded insulative housing formed in two longitudinal housing halves which said housing halves are joined together and have a uniform cross-section along the length thereof, said main distribution module including a plurality of elongate conductor wires which are confined between said housing halves wherein at least one of said housing halves include groups of openings which open sidewardly through said housing half to expose portions of said conductor wires; and a secondary power distribution module having a plurality of electrical conductors therein and a plurality of electrical contacts which project from a back face of said secondary power distribution module and are insertable within a respective one of said groups of openings of said main power distribution module for engagement with said exposed portions of said conductor wires .

7. The power distribution system according to Claim 6, wherein said main power distribution module has opposite side faces which are planar and disposed in parallel relation along the length of said main power distribution module.

8. The power distribution system according to Claim 7, wherein said housing halves are hinged along a longitudinal edge thereof and foldable together to confine said conductor wires therebetween.

9. A method of forming a main power distribution module for a power distribution system used in building raceways, method comprising the steps of: providing a plurality of electrically conductive conductor wires; forming a length of module extrusion into a module housing by extruding an insulative material into two housing halves having a uniform cross section along a longitudinal length thereof wherein said cross section of at least one of said housing halves has a plurality of internal parallel grooves extending along the entire length thereof; forming a plurality of groups of openings within said housing which said openings are aligned with said grooves ; positioning said conductor wires within said grooves wherein said conductors have portions thereof exposed through said openings; and joining said housing halves together to confine said conductor wires within said grooves between said housing halves wherein said conductor wires are enclosed by said housing halves.

10. The method according to Claim 9, wherein the length of said module extrusion permits formation of a plurality of said module housings, the method including the step of severing said module extrusion along a length thereof to define said main distribution module wherein said length depends upon said groups of openings defined therein.

11. The method according to Claim 9, wherein said housing halves are hingedly connected along a longitudinal side edge thereof, said method further comprising the step of folding said housing halves together for said confining of said conductor wires within said grooves between said housing halves.

12. The method according to Claim 9, wherein said method further includes the step of punching said housing halves after said extrusion step to form said groups of openings .

13. A power distribution system for installation in building raceways comprising: a first power distribution module having a plurality of electrical conductors extending therethrough that define a plurality of circuits which include common, neutral and ground conductors, said first power distribution module including first access parts having a first configuration which define a group of openings providing access to said conductors of said first power distribution module; a second power distribution module having a plurality of electrical conductors therein, and having second access parts having a second configuration that defines openings providing access to said conductors, said second access parts being adapted for mating engagement with said first access parts to electrically connect said conductors of said first and second distribution modules, said second distribution module further including additional first access parts formed with said first configuration to provide access to said conductors of said second power distribution module; and a third power distribution module having electrical conductors extending longitudinally therethrough and including additional second access parts which define openings and are formed with said second configuration to permit mating engagement with said corresponding first access parts of said second distribution module; wherein said first configuration is one of a female configuration and a male configuration and said second configuration is the other of said female configuration and said male configuration.

14. The power distribution system according to Claim 13, wherein said third power distribution module further includes a group of openings defined by additional second access parts having said second configuration.

15. The power distribution system according to Claim 14, wherein said first power distribution module extends longitudinally and has a plurality of said first access parts with said first configuration along the length thereof to permit engagement of said second access parts of said second power distribution module with any of said groups of openings .

16. The power distribution system according to Claim 15, wherein said second power distribution module has electrical contacts which includes first and second sections thereof that are exposed respectively through said first and second access parts thereon.

17. The power distribution system according to Claim 16, wherein said first and second access parts on said second power distribution module are disposed on opposite side faces thereof which face sidewardly in opposite directions and said electrical contacts extend sidewardly such that opposite ends thereof are exposed through said groups of said openings on said opposite side faces.

18. A power distribution system comprising: a main power distribution module having a plurality of conductors extending longitudinally therethrough which define a plurality of electrical circuits having common, neutral and ground wires, at least one side face of said 04/057716

main power distribution module including a group of openings which exposes portions of said conductors; and a plurality of secondary power distribution modules which are engagable with each other and with said main power distribution module, each of said secondary power distribution modules including a plurality of conductors extending therethrough which said conductors include electrical contacts disposed within said secondary power distribution module, said secondary power distribution module further including a group of male projections which enclose but permit access to first portions of said electrical contacts and are insertable within said openings of said main power distribution module to engage said electrical contacts with said conductors of said main power distribution module, said secondary power distribution module further including a group of female openings on an opposite face thereof which expose second portions of said electrical contact to permit engagement with said male connector parts of another of said secondary power distribution modules.

19. The power distribution system according to Claim 18, wherein a receptacle is provided which includes male projections having exposed electrical contacts therein wherein said male projections are engagable with said female openings of any of said main and said secondary power distribution modules to complete an electrical connection therebetween.

20. A power distribution system for building raceways comprising: a main power distribution module having a plurality of parallel electrical conductors extending longitudinally through an insulative housing, said housing including at least one group of openings which 04/057716

provides access to all of said conductors, said group of openings being defined by a plurality of vertical rows of openings which are arranged in parallel, side-by-side relation wherein each adjacent pair of individual openings are horizontally aligned with each other such that each said pair provides access to one said conductor along upper edges thereof and a second said conductor along lower edges thereof; and a secondary power distribution module comprising a plurality of electrical conductors contained within a housing and electrical contacts which project from a back face of said secondary power distribution module, said contacts being arranged in two vertical rows corresponding to said vertical rows of said openings of said main distribution module wherein each sidewardly adjacent pair of said contacts faces in opposite vertical directions, said contacts being engagable with said openings wherein one of each said pair of said contacts engages said first conductor in one said opening and the other of said pair of contacts engages said second conductor in the sidewardly adjacent one of said openings .

21. The power distribution system according to Claim 20, wherein said contacts on said secondary power distribution module are enclosed by insulative posts wherein said contacts are exposed on only one side of said posts with said contacts of each sidewardly adjacent pair thereof being exposed in said opposite directions.