Abstract:
An electrical box assembly for providing electrical service and signal line hookups to a television or home entertainment center. The electrical box assembly can be recessed within the wall to make it unobtrusive and out of the way. The box assembly includes an integral electrical box for housing line voltage connections and connection points for several low voltage openings. The low voltage connection points are capable of accepting standard jacks for broadband cable, direct TV, surround sound cabling, or phone systems. The electrical box assembly enables easy consolidation of all the various electrical and signal hookups for TV or home entertainment systems.

Description:
FIELD OF THE INVENTION 
   This invention relates to electrical box assemblies for mounting components for high and low voltage devices and specifically to a flat panel TV box assembly that can be easily installed on an interior wall of a building and provide electrical services and cable TV connections to a television, computer, or home stereo system. 
   BACKGROUND OF THE INVENTION 
   With the proliferation of high definition televisions and various auxiliary devices, such as digital videodisc players, game stations, and surround sound systems, there is a need to manage the connections between these devices to ensure there is adequate power and also to manage the myriad of cables and cords that accompany such systems. Additionally, many electrical boxes for both high and low voltage components mount the components flush with the wall, which makes the plugs or connectors that mate with the wall-mounted components susceptible to damage, such as when devices, such as vacuum cleaners or other household hazards brush against the plugs or connectors. 
   What is needed therefore is an electrical box assembly that provides connection points for both high and low voltage components, provides isolation of high voltage connections from low voltage connections, provides features for managing the plethora of cables and wiring associated with modern television systems, and recesses the end connector of cords or cables to protect the plug ends of cords or end connectors of cables from undesirable contact with household appliances or household occupants. 
   SUMMARY OF THE INVENTION 
   The invention is an electrical box assembly that provides electrical service including line voltage and signal line hookups for a television or home entertainment center. The electrical box assembly can be recessed within the wall to make it unobtrusive and out of the way. The box assembly includes an integral electrical box for housing line voltage connections and connection points for several low voltage openings. The low voltage connection points are capable of accepting standard jacks for broadband cable, direct TV, surround sound cabling, or phone systems. The electrical box assembly enables easy consolidation of all the various electrical and signal hookups for TV or home entertainment systems. 
   OBJECTS AND ADVANTAGES 
   The electrical box assembly of the present invention includes several advantages over the prior art, including:
         (1) Connection points are provided for mounting both high and low voltage components. An electrical box, integral with the box member of the assembly, is provided for housing and isolating high voltage components, such as a duplex receptacle to provide line voltage to a TV or other electrical device. Connection points are also provided for mounting several low voltage components, such as a coupling plate for a coaxial cable.   (2) The electrical box assembly includes a backward projecting box portion that mounts within a wall, thereby recessing electrical devices within the wall to render them unobtrusive and out of the way. By recessing the electrical devices, the plug ends of cords or end connectors of cables are advantageously protected from undesirable contact with household appliances, household occupants, or other hazards.   (3) The electrical box assembly provides features for managing the plethora of cables and wiring associated with modern television systems, including integral loops for bundling and tying-off wires and cables, thereby providing a clean installation that is unobtrusive and minimizes excessive wires and cables running between the wall and the television, speaker system, or other components of a home entertainment system. The loops are positioned against the back wall of the box member, thereby positioning the wires and cables along the back wall of the assembly and advantageously recessing them behind the wall surface and away from household hazards.       

   These and other objects and advantages of the present invention will be better understood by reading the following description along with reference to the drawings. 

   
     DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a perspective view of the preferred embodiment of a flat panel TV box assembly according to the present invention. 
       FIG. 2  is a perspective view of a box member that forms a portion of the flat panel TV box assembly of  FIG. 1.9 )  FIG. 3  is a front view of the box member of  FIG. 2 . 
       FIG. 4  is a bottom view of the box member of  FIG. 3 . 
       FIG. 4A  is a side view of the box member of  FIG. 3 . 
       FIG. 5  is a perspective view of a frame member that forms a portion of the flat panel TV box assembly of  FIG. 1 . 
       FIG. 6  is a front view of the frame member of  FIG. 5 . 
       FIG. 7  is a sectional view of the frame member taken along line  7 - 7  of  FIG. 6 . 
       FIG. 8  is a front view of the flat panel TV box assembly of  FIG. 1 . 
       FIG. 9  is a bottom view of the flat panel TV box assembly of  FIG. 8 . 
       FIG. 10  is a side view of the flat panel TV box assembly of  FIG. 8 . 
       FIG. 11  is an exploded perspective view of the flat panel TV box assembly of the present invention including some high and low voltage components in alignment with the box assembly to be installed therein. 
       FIG. 12  is a side view of the flat panel TV box assembly with a portion of the frame member and box member cut away to show a duplex power receptacle and an electrical cord plugged therein. 
       FIG. 13  is a perspective view of a flat panel TV box assembly according to the present invention installed in a wall and with high and low voltage components installed therein. 
       FIG. 14  is a perspective view of a second embodiment of a flat panel TV box assembly according to the present invention. 
   

   TABLE OF NOMENCLATURE 
   The following is a listing of part numbers used in the drawings along with a brief description: 
   
     
       
             
             
             
           
         
             
                 
                 
             
             
                 
               Part Number 
               Description 
             
             
                 
                 
             
           
           
             
                 
               20 
               electrical box assembly 
             
             
                 
               22 
               box member 
             
             
                 
               24 
               frame member 
             
             
                 
               26 
               electrical box 
             
             
                 
               28 
               open area 
             
             
                 
               30 
               connection point 
             
             
                 
               30A 
               vertically oriented connection point 
             
             
                 
               30B 
               horizontally oriented connection point 
             
             
                 
               32 
               peripheral wall of box member 
             
             
                 
               34 
               back wall of box member 
             
             
                 
               36 
               sidewalls of electrical box 
             
             
                 
               38 
               side of open area 
             
             
                 
               40 
               sidewall portion of peripheral wall 
             
             
                 
               42 
               aperture in sidewall of box member 
             
             
                 
               44 
               inner edge of peripheral wall 
             
             
                 
               46 
               juncture of peripheral wall and back wall 
             
             
                 
               48 
               outer edge of peripheral wall 
             
             
                 
               50 
               bottom wall 
             
             
                 
               52 
               loop member 
             
             
                 
               54 
               boss of electrical box 
             
             
                 
               56 
               threaded bore 
             
             
                 
               58 
               rear wall of electrical box 
             
             
                 
               60 
               high voltage enclosure 
             
             
                 
               62 
               boss on peripheral wall of box member 
             
             
                 
               63 
               flared portion on sidewalls of peripheral wall 
             
             
                 
               64 
               peripheral flange of frame member 
             
             
                 
               65 
               transverse flange of frame member 
             
             
                 
               68 
               guide member 
             
             
                 
               69 
               inner edge of transverse flange 
             
             
                 
               70 
               aperture in transverse flange 
             
             
                 
               72 
               attachment arrangement 
             
             
                 
               74 
               fastener for securing frame to box member 
             
             
                 
               76 
               aperture for low voltage component 
             
             
                 
               78 
               hole 
             
             
                 
               80 
               sheet rock 
             
             
                 
               82 
               wall 
             
             
                 
               84 
               stud 
             
             
                 
               86 
               mounting arrangement 
             
             
                 
               87 
               fastener 
             
             
                 
               88 
               mounting fastener 
             
             
                 
               89 
               apertures in transverse flange 
             
             
                 
               90 
               duplex receptacle 
             
             
                 
               92 
               fastener 
             
             
                 
               94 
               cover plate 
             
             
                 
               96 
               CATV connector plate 
             
             
                 
               98 
               fastener 
             
             
                 
               99 
               outer edge of electrical box assembly 
             
             
                 
               100 
               plug end 
             
             
                 
               102 
               electrical cord 
             
             
                 
               104 
               horizontally oriented CATV connector 
             
             
                 
               106 
               vertically oriented CATV connector 
             
             
                 
               108 
               telephone jack 
             
             
                 
               110 
               depressed area 
             
             
                 
               112 
               removable wall portion or knockout 
             
             
                 
               114 
               push-in electrical connector 
             
             
                 
               120 
               electrical box assembly, second embodiment 
             
             
                 
               122 
               one-piece box member 
             
             
                 
               124 
               peripheral wall 
             
             
                 
               126 
               flange 
             
             
                 
               128 
               mounting arrangement 
             
             
                 
               130 
               bottom wall 
             
             
                 
               D1 
               depth of peripheral wall 
             
             
                 
                 
             
           
        
       
     
   
   DETAILED DESCRIPTION OF THE INVENTION 
     FIG. 1  depicts a preferred embodiment of an electrical box assembly  20  according to the present invention. The recessed electrical box assembly  20  includes a box member  22  and a frame member  24 . The box member  22  includes an electrical box  26  for accommodating high voltage components (not shown) and open areas  28  having connection points  30  for accommodating low voltage components (not shown). 
   With reference to  FIG. 2 , a preferred embodiment of the box member  22  includes a forward extending peripheral wall  32  and a back wall  34 . The electrical box  26  includes sidewalls  36  and is integral with the back wall  34  of the box member  22 . The connection points  30  are provided on the back wall  34  of the box member  22  typically on opposing sides  38  of the open areas  28 . The peripheral wall  32  of the box member  22  includes sidewalls  40  and apertures  42  are provided in the sidewalls  40 . The peripheral wall  32  of the box member  22  includes an inner edge  44  at a juncture  46  with the back wall  34  of the box member  22  and an outer edge  48  with the apertures  42  in the peripheral wall  32  adjacent or very close to the inner edge  44 . The peripheral wall  32  of the box member  22  includes a bottom wall  50  and loop members  52  in linear alignment along the bottom wall  50 . The loop members  52  extend across the juncture  46  of the bottom wall  50  and the back wall  34 . The electrical box  26  includes bosses  54  that are integral with the sidewalls  36  of the electrical box  26 . 
   Referring to  FIGS. 3-4A , threaded bores  56  are provided in the bosses  54  of the electrical box  26 . The electrical box  26  includes a rear wall  58  that closes the rear of the electrical box and provides a high voltage enclosure  60  therein. As shown at the cutaway portion of the peripheral wall  32  in  FIG. 4 , the peripheral wall  32  of the box member  22  includes a depth D 1  as measured from the inner edge  44  to the outer edge  48 . The box member  22  includes a plurality of bosses  62  extending inward from the peripheral wall  32 . The peripheral wall  32  of the box member  22  further includes a flared portion  63  near the outer edge  48  at both the top and bottom ends of the peripheral wall  32 . As shown in  FIG. 3 , the connection points  30  for the low voltage components may include connection points  30 A aligned for vertical connection of the low voltage components and connection points  30 B aligned for horizontal connection of the low voltage components. 
   With reference to  FIGS. 5-7 , a preferred embodiment of the frame member  24  includes a rearward extending peripheral flange  64  and a transversely extending flange  66 . A plurality of guide members  68  is provided on the peripheral flange  64 , with each guide member  68  positioned along the inner edge  69  of the transverse flange  66  of the frame member  24 . The transverse flange  66  of the frame member  24  includes apertures  70  therein. 
   Referring to  FIGS. 8 and 9 , there is shown an attachment arrangement  72  for securing the frame member  24  to the box member  22  to create the recessed electrical box assembly  20  of the present invention. The attachment arrangement  72  includes fasteners  74  which are secured through each guide member  68  on the peripheral flange  64  of the frame member  24  into a corresponding boss  62  (see  FIG. 2 ) on the peripheral wall  32  of the box member  22 . To secure the frame member  24  to the box member  22 , the peripheral flange  64  of the frame member  24  is aligned with the peripheral wall  32  of the box member  22 . With the frame member  24  thus aligned with the box member  22 , each guide member  68  in the frame  24  is aligned with a corresponding boss  62  in the box member  22 . As shown in  FIG. 8 , the connection points  30  for low voltage components (not shown) include apertures  76  on opposing sides  38  of the open areas  28  in the back wall  34  of the box member  22 . 
   As shown in  FIG. 10 , after the frame member  24  is secured to the box member  22  to form electrical box assembly  20 , the electrical box  26  projects from the back-wall  34  of the box member  22  and the sidewalls  36  and rear wall  58  of the electrical box  26 . The sidewalls  36  and rear wall  58  of the electrical box  26  thereby create a high voltage enclosure  60  that isolates any high voltage wiring or components therein (not shown) from nearby low voltage components. 
   For operation of the electrical box assembly  20  of the present invention, reference is made to  FIG. 11 . An installer first cuts a hole  78  in the sheet rock  80  or similar wall covering on a wall  82  thereby exposing a stud  84 . The box member  22  is inserted into the hole  78  until the transverse flange  66  is flush with the surrounding wall  82 . The electrical box assembly  20  includes a mounting arrangement  86  for securing the box member  22  to the stud  84  and thereby positioning the back wall  34  of the box member substantially within the wall  82 . The mounting arrangement  86  for securing the box member  22  to the stud  84  includes mounting fasteners  88  that are secured through the apertures  42  in the peripheral wall  32  and into the stud  84  thereby securing the box member  22  to the stud  84 . After the box member  22  is secured to the stud  84 , the frame member  24  is secured to the box member  22  by tightening the fasteners  74  of the attachment arrangement  72  through the guide members  68  of the frame  24  and into the bosses  62  on the peripheral wall  32  of the box member  22 . As an alternative to fastening the frame  24  to the box member  22  with the attachment arrangement, the frame  24  may be secured directly to the wall  82  by driving fasteners  87  through alternative apertures  89  in the transverse flange  66  into the wall  82 . A high voltage component such as the duplex power receptacle  90  can be secured to the electrical box  26  by fasteners  92  and a cover plate  94  attached thereto. Low voltage components such as the CATV connector plate  96  can then be secured with fasteners  98  to the connection points  30  surrounding the open areas  28 . 
   Referring to  FIG. 12 , after the electrical box assembly  20  is secured to the wall  82  and electrical components installed therein, all electrical components, such as the duplex receptacle  90  shown, are recessed within the wall  82  by at least the depth D 1  of the peripheral wall  32  of the box member  22 . Preferably the electrical components are recessed from the outer edge  99  of the electrical box assembly  20  by between 1 and 2 inches. Most preferably, the electrical components are recessed from the outer edge  99  of the electrical box assembly  20  by at least 1.5 inches. With the electrical box assembly  20  recessed within the wall  82  as shown, the plug ends  100  of cords  102  or connector ends of low voltage cables (not shown) are protected from being dislodged by contact from vacuum cleaners or similar hazards. 
   With reference to  FIG. 13  there is shown a completed installation of an electrical box assembly  20  of the present invention in a wall  82 . The electrical box assembly  20  includes a duplex receptacle  90  and cover plate  94 , a horizontally oriented CATV connector  104 , a vertically oriented CATV connector  106 , and a horizontally oriented telephone jack  108 . 
   As shown in  FIG. 4  or  9 , the electrical box  26  of the present invention may include a depressed area  110  in one of the sidewalls  36  and a knockout or removable wall portion  112  therein in the depressed area  110 . The depressed area  110  in the sidewall  36  enables the use of electrical fittings or connectors such as the Black Button™ push-in connector  114  for connecting non-metallic cable to electrical boxes, which is available from Arlington Industries of Scranton, Pa. The depressed area  110  permits use of the connectors  114  without projecting from the sidewall  36  and interfering with placement of the electrical box assembly  20  in locations where space is tightly restricted. 
   With reference to  FIG. 14  there is shown a second embodiment of the electrical box assembly  120  of the present invention. The second embodiment of the electrical box assembly  120  is a one-piece electrical box assembly wherein the box member  122  includes a forward extending peripheral wall  124  and a transverse flange  126  all provided in one piece. The box member  122  includes a back wall  34  and one or more openings  28  in the back wall  34 . One or more of the openings  28  in the back wall  34  of the box member  122  may include an electrical box  26 . The electrical box  26  includes sidewalls  36  integral with and extending rearward from the back wall  34  of the box member  122 . The openings  28  in the back wall  34  of the one-piece box member  122  include connection points  30  for securing the electrical components (not shown) thereto. A mounting arrangement  128  is provided for securing the box member  122  to a wall in such a manner that the installed electrical components (not shown) are recessed within the wall. The peripheral wall  124  of the box member  122  includes a bottom wall  130  and loop members  52  in linear alignment along the bottom wall  130 . 
   The electrical box assembly  20  of the present invention could be constructed of metal or plastic but most preferably the box member  22  of the present invention is molded in one piece of plastic and the frame member  24  is also molded in one piece of plastic. Suitable plastics include polycarbonate and polyvinylchloride. 
   Having thus described the invention with reference to a preferred embodiment, it is to be understood that the invention is not so limited by the description herein but is defined as follows by the appended claims.