Abstract:
An electrical box ( 100 ) for mounting between adjacent studs of a structural wall and having side panels ( 102, 103 ) defining spaced apart stress relief regions ( 182 ) each encompassing a mounting hole ( 184 ) and outwardly deflectable in response to actuation of a fastener through the hole ( 184 ) into penetrating engagement with a stud.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     Electrical wiring and component boxes are customarily mounted between adjacent wall studs of building structures. The boxes are typically made with side panels spaced apart a distance slightly less than the spacing between studs. However, in some applications distortion or misalignment of studs creates an excessive spacing between studs. In that case, mounting of a box with screw fasteners extending through mounting holes into penetrating engagement with the studs can produce forces causing undesirable distortion of the box.  
         [0002]     The object of this invention, therefore, is to provide an improved electrical box which will resist undesirable deformation when mounted between distorted or misaligned studs.  
       SUMMARY OF THE INVENTION  
       [0003]     The invention is a box for electrical components and wiring and adapted for mounting between adjacent studs of a structural wall, the box including parallel, spaced apart right and left side panels; parallel, spaced apart top and bottom panels having ends joined to ends of the right and left panels and arranged orthogonally therewith so as to form a cubic chamber; a back panel joining rear edges of the panels; and wherein each of the right and left side panels define a plurality of vertically spaced apart mounting holes for receiving fasteners actuatable into penetrating engagement with the adjacent studs, and each of the right and left side panels define around the holes stress relief regions adapted to deflect outwardly in response to actuation of the fasteners. The stress relief regions prevent other deformation of the box when being mounted between distorted studs.  
         [0004]     According to one feature of the invention, the region defines slots partially encompassing the hole. The slots establish the desired deflectability for the stress relief regions.  
         [0005]     According to another feature, the slots comprise a pair of substantially parallel slots straddling the hole. The parallel slots efficiently provide the desired stress relief.  
         [0006]     In one embodiment the slots include a second pair of slots aligned with the hole and straddled by and parallel to the parallel slots. The second pair of slots enhances the effectiveness of the stress relief regions.  
         [0007]     In another embodiment, the slots include a third slot joining ends of the pair of parallel slots. The third slot substantially improves the deflection characteristics of the stress relief regions.  
         [0008]     According to another feature, the hole is defined in an outwardly indented central portion of the region. The indented portion simplifies mounting of the box.  
         [0009]     According to yet another feature of the invention, each hole is horizontally elongated. The elongated holes accommodate proper alignment of the box between studs.  
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0010]     These and other objects and features of the invention will become more apparent upon a perusal of the following description taken in conjunction with the accompanying drawings wherein:  
         [0011]      FIG. 1  is a perspective view of a structured wiring box according to the preferred embodiment of the invention;  
         [0012]      FIG. 2  is a cross-sectional view taken along lines  2 - 2  of  FIG. 1 ;  
         [0013]      FIG. 3  is a perspective view of the structured wiring box of  FIG. 1  with the cover door, module door, and computer server door opened;  
         [0014]      FIG. 4  is an exploded perspective view of the structured wiring box of  FIG. 1 ;  
         [0015]      FIG. 5  is a left side view of the structured wiring box of  FIG. 1 ;  
         [0016]      FIG. 6  is a front view of the structured wiring box of  FIG. 1  with the cover door opened;  
         [0017]      FIG. 7  is a detailed view of the trim ring of the structured wiring box of  FIG. 1 ; and  
         [0018]      FIG. 8  is a partial view of another side panel embodiment of the invention. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0019]     A structured wiring box  100  according to the preferred embodiment of the invention is depicted in  FIGS. 1 through 7 . The structured wiring box  100  consists of a base box housing  101  that fits between standard sixteen-inch-on-center wall studs. As shown in  FIG. 3 , the base box  101  is formed by right and left side panels  102 ,  103 , a top panel  104 , a bottom panel  105 , and a back panel  106 . Together, the panels  102 - 106  form a housing chamber  112  having a front opening  110 . Both the right and left side panels  102 ,  103  and the top and bottom panels  104 ,  105  are parallel and arranged orthogonally with the also parallel back panel  106  and opening  110  such that the housing  100  and housing chamber  112  are cubic. Formed in the top and bottom panels  104 ,  105  are access ports  108  for entry and exit of wiring extending into and out of the chamber  112 . Preferably, the right and left panels  102 ,  103  are spaced slightly less than sixteen inches apart to facilitate mounting of the box  101  between wall studs (not shown).  
         [0020]     In a default minimum configuration, a flat front cover (not shown) is used to close the structured wiring box  100  and hide the rough edges of sheet rock surrounding the mounting hole in the house&#39;s wall. All wires, components, and modules are contained within a volume  112  ( FIG. 3 ) defined by the base box  101  and a flat front cover (not shown).  
         [0021]     As illustrated in  FIGS. 1 and 2 , each side panel  102 ,  103  of the box  101  has a plurality of vertically spaced apart regions  182  which are flexible to allow adjustment of the box  101  within warped studs. Centrally located within each region  182  is a horizontally elongated mounting slot  184  for receiving a suitable fastener (not shown) such as a screw. Each slot  184  is positioned in an outwardly indented bracket portion  183  of the region  182 . Formed within each region  182  are a pair of vertically oriented stress relief slots  185 ,  186  located on opposite sides of each mounting slot  184  and another vertical pair including one slot  187  located above the mounting slot  184  and straddled by and parallel to the stress relief slots  185 ,  186  and another slot  188  located below the mounting slot  184  and straddled by and parallel to stress relief slots  185 ,  186 . Thus, the relief slots  185 - 188  partially encompass the stress relief regions  182 . During the insertion of screw fasteners (not shown) through the mounting slots  184  and into penetrating engagement with warped adjacent studs (not shown) of a wall, the stress relief regions  182  can deflect outwardly and thereby prevent other deformation of the box  101 . Thus, the structured wiring box  101  maintains its form in spite of being tightly anchored to imperfect studs.  
         [0022]     For non-minimal configurations, or when retrofitting significant upgrades, a decorative trim ring  202  ( FIG. 7 ) is secured to the outer edge of the box  101 . The trim ring  202  includes a flange portion  203  extending parallel to the wall space so as to hide rough edges of the sheet rock hole providing a pleasing appearance for the unit on the wall. Other functions of the trim ring  202  are provided by built-in hinge pins  208 A spaced along a left vertical section  209  of the trim ring  202  and hinge pins  208 B spaced along a right vertical section  211  of the trim ring  202 . The hinge pins  208 A,  208 B are mounted on tabs  212  secured to a sheet metal strip  213  projecting inwardly from an inner periphery of the trim ring  202 . Holes  215  extending through the tabs  212  and strip  213  receive screws (not shown) that secure the ring  202  to inner surfaces of the side panels  102 ,  103  of the box  101 . The outer periphery of the trim ring  202  ( FIG. 2 ) is formed by an inwardly curved rim  217  having an edge  218  for engaging the wall face (not shown) surrounding the box  101 . Hinge pins  208 A allow the easy addition of an outwardly projecting swinging cover door  206  as described below while hinges  208 B allow the easy addition of swinging electrical component and module retaining doors  203 ,  205  ( FIG. 3 ). Thus, addition of the trim ring  202  allows for upgrading without replacement of base box  101 .  
         [0023]     The hinge pins  208 A allow a default cover (not shown) to be easily replaced with the outwardly projecting cover door  206 . During such replacement, the hinge pins  208 A receive hinge sleeves  228  mounted on door  206 . Together, the pins  208 A and sleeves  228  form hinges  231  which allow swinging movement of the door between a closed position covering a composite chamber including the housing chamber  112  and extension chamber  222  (described below) and an open position allowing access thereto. Similar, hinge sleeves  218  are provided on the module doors  203 ,  205 . As shown in  FIG. 2 , an inner surface  221  of the cover door  206  is outwardly spaced from the trim ring  202  by a distance B so as to establish a portion of an extension chamber  222  having a depth C. The space between the inner door surface  221  and the trim ring  202  is concealed by an inwardly projecting rim  224  along the perimeter of the door  206 . In addition, the depth A of the trim ring  102  provided by the rim  217  establishes another portion of the extension chamber  222  which accommodates more and/or larger components. The extension chamber  222  provides space for modules and components that are otherwise too large to fit only within housing chamber  112 . For example, the extension chamber accommodates the swinging module doors  203 ,  205  as well as an outer portion of a removable rack  225  for retaining electrical components. Consequently, a new house built with minimal structured wiring cost can later support very complex configurations and many additional or larger components as upgrades or retrofit options are desired.  
         [0024]     The hinges  231  are made with the bottom hinge pin  208 A,  208 B of a set longer than the others to allow for easier installation of the door  206  and modules  203 ,  205 . The different length hinge pins allow the bottom hinge pin to be aligned with a hinge sleeve  228  and partially slid on without alignment of the other hinges. Once a bottom hinge sleeve  228  has been partially slid on a bottom pin  208 , the remaining pins and sleeves are aligned and the door or module is moved into a fully retained position.  
         [0025]      FIG. 8  illustrates another side panel embodiment providing stress relief when the box  101  is mounted between warped or distorted studs. As in the side panels  102 ,  103  of the embodiment shown in  FIGS. 1-7 , a side panel  102  includes a plurality of vertically spaced apart, horizontally elongated mounting slots  184  each surrounded by a stress relief region  182 . The mounting slots  184  again are formed in outwardly indented bracket portions  183  of the regions  182 . Establishing each stress relief region  182  in the  FIG. 8  embodiment are a pair of substantially parallel slots  190 ,  191  straddling the mounting slot  184  and a third slot  181  joining ends of the slots  190 ,  191 , so as to partially encompass the mounting slot  184 . As described above, the region  182  will deflect outwardly when screw fasteners (not shown) are actuated through the mounting slots  184  into penetrating engagement with deformed studs.  
         [0026]     It should be understood that the afore-described is merely the preferred one of many possible embodiments of the invention, and that the scope of the invention should therefore only be limited according to the following claims.