Abstract:
A gangable modular electrical box including separate modules that can be combined in various configurations to provide a desired amount of electrical enclosures on a wall. The modules include an end module and an optional inner module that are each molded in one piece of plastic. A rapid alignment and connection arrangement is included on the various modules to facilitate easy assembly of the modules at the job site without the use of sophisticated tools. The modules can be combined to form a two-gang, three-gang, or larger ganged box as desired. In the simplest configuration, two end modules can be combined to create a two-gang electrical box.

Description:
FIELD OF THE INVENTION 
     This invention relates to assemblies for the mounting of electrical devices and specifically to a gangable modular electrical box assembly that includes interlocking modules that can be joined together by an installer at the job site to form an electrical box having a desired number of electrical compartments. 
     BACKGROUND OF THE INVENTION 
     With the plethora of electrical devices found in the modern household, it is frequently necessary to install additional electrical receptacles to provide the required number of outlets. Although outlets can be provided by power strips, these devices are likely to be unsightly and difficult to child-proof as compared to outlets installed in the wall. 
     Many types of electrical boxes are commercially available, including single receptacle boxes, two-gang boxes, three-gang boxes, and so on. However, it would be beneficial to an installer to have available at the job site the ability to assembly a multi-gang box of the correct size to satisfy the requirements of a particular room or area. What is needed is a configurable multi-gang box that can be configured as a two-gang box, a three-gang box, or even larger box as the situation requires. 
     Although several multi-gang boxes have been proposed, many of them cannot be easily assembled and configured by a single electrician or homeowner. Thus, as additional electrical outlets are typically installed by a single person, it is beneficial to provide a configurable multi-gang box that can be easily configured and installed at the job site by a single installer. 
     SUMMARY OF THE INVENTION 
     The invention is a gangable modular electrical box including separate modules that can be combined in various configurations to provide a desired amount of electrical enclosures on a wall. The modules include an end module and an optional inner module that are each molded in one piece of plastic. A rapid alignment and connection arrangement is included on the various modules to facilitate easy assembly of the modules at the job site without the use of sophisticated tools. The modules can be combined to form a two-gang, three-gang, or larger ganged box as desired. In the simplest configuration, two end modules can be combined to create a two-gang electrical box. 
     OBJECTS AND ADVANTAGES 
     A first object of the gangable modular electrical box of the present invention is to provide modular components that can be easily and rapidly assembled at the job site by a single installer to create a multi-gang electrical box. 
     A second object of the gangable modular electrical box of the present invention is to provide an installer the ability to rapidly configure a two-gang, three-gang, or even larger multi-gang electrical box in a modular fashion. 
     A third object is to provide modular members that are molded of plastic in a single piece to minimize production cost. 
     A further object is to provide modular plastic components that include an alignment and connection arrangement is included on the various modules to facilitate easy assembly of the modules at the job site without the use of sophisticated tools. 
     Another object of the present invention is to provide modular components in which an alignment and connection arrangement enables the modules to be snapped together and remain connected initially until permanently fastened together. 
     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 a first and preferred embodiment of a gangable modular electrical box according to the present invention assembled in a configuration to provide a four-gang electrical box. 
         FIG. 2  is an exploded perspective view of the gangable electrical box of  FIG. 1  with the modular components in alignment with each other to be assembled into a four-gang electrical box. 
         FIG. 3  is a front view of the gangable modular electrical box of  FIG. 1 . 
         FIG. 4  is a sectional view of the back wall of the gangable electrical box as taken along line  4 - 4  of  FIG. 3 . 
         FIG. 5  is a front view of two inner modules in alignment with each other to be joined together and depicting the interlocking arrangement of the side panels of the gangable electrical box. 
         FIG. 6  a front view of the two inner modules of  FIG. 5  after they are joined together. 
         FIG. 7  is a rear view of the gangable modular electrical box of  FIG. 1 . 
         FIG. 8  is a left side view of the gangable modular electrical box shown in  FIG. 7 . 
         FIG. 9  is an exploded perspective view of a second embodiment of a gangable modular electrical box with the modular components in alignment with each other to be assembled into a four-gang electrical box. 
         FIG. 10  is a perspective view of the second embodiment of the gangable electrical box according to the present invention assembled in a configuration to provide a four-gang electrical box. 
         FIG. 11  is a left side view of the gangable electrical box of  FIG. 10  including an insertable screw plate that forms a portion of the gangable electrical box. 
         FIG. 12  a front view of the gangable modular electrical box of  FIG. 9 . 
         FIG. 13  is an exploded perspective view of a third embodiment of the gangable electrical box of the present invention with the modular components in alignment with each other to be assembled into a four-gang electrical box. 
         FIG. 14  is a perspective view of the gangable modular electrical box of  FIG. 13 . 
         FIG. 15  is a rear view of an inner module of the gangable modular electrical box according to the present invention. 
         FIG. 16  is two sectional views of an inner module as taken along line  16 - 16  of  FIG. 15  illustrating the modules in alignment to be interlocked together. 
         FIG. 17  is a sectional view taken along line  17 - 17  of  FIG. 7 , depicting the interlocking tabs and slots of the modules of the gangable modular electrical box of the present invention. 
         FIG. 18  is a perspective view of a fourth embodiment of a gangable modular electrical box according to the present invention assembled in a configuration to provide a three-gang electrical box. 
         FIG. 19  is an exploded perspective view of a portion of the gangable electrical box of  FIG. 18  depicting an end body in alignment with an inner body. 
         FIG. 20  is a front view of the end body and inner body of  FIG. 19  in alignment to be secured together. 
         FIG. 21  is a bottom view of the end body and inner body of  FIG. 20  in alignment to be secured together. 
         FIG. 22  is a front view of the assembled gangable electrical box including of  FIG. 18 . 
         FIG. 23  is a sectional view taken along line  23 - 23  of  FIG. 22 . 
     
    
    
     TABLE OF NOMENCLATURE 
     The following is a listing of part numbers used in the drawings along with a brief description: 
     
       
         
               
               
             
               
               
             
           
               
                   
               
               
                 Part Number 
                 Description 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 20 
                 gangable modular electrical box, preferred embodiment 
               
               
                 22 
                 first end body or first module 
               
               
                 24 
                 second end body or second module 
               
               
                 26 
                 inner body or inner module 
               
               
                 28 
                 back wall of end body 
               
               
                 30 
                 top wall of end body 
               
               
                 32 
                 bottom wall of end body 
               
               
                 34 
                 side wall 
               
               
                 36 
                 open side of end body 
               
               
                 38 
                 back wall of inner body 
               
               
                 40 
                 top wall of inner body 
               
               
                 42 
                 bottom wall of inner body 
               
               
                 44 
                 open side of inner body 
               
               
                 46 
                 side edge of end body 
               
               
                 48 
                 side edge of inner body 
               
               
                 50 
                 coupling arrangement 
               
               
                 52 
                 slot 
               
               
                 54 
                 hooked tab 
               
               
                 56 
                 end of hooked tab 
               
               
                 58 
                 hook 
               
               
                 60 
                 alignment arrangement 
               
               
                 62 
                 outer tab 
               
               
                 64 
                 inner tab 
               
               
                 65 
                 corner of body 
               
               
                 66 
                 outer surface of walls 
               
               
                 68 
                 inner surface of walls 
               
               
                 70 
                 gap 
               
               
                 72 
                 fastening arrangement 
               
               
                 74 
                 second tab 
               
               
                 76 
                 aperture in second tab 
               
               
                 78 
                 bore 
               
               
                 80 
                 fastener 
               
               
                 81 
                 front edge 
               
               
                 82 
                 first mounting arrangement 
               
               
                 84 
                 flange 
               
               
                 86 
                 outer surface of side wall 
               
               
                 88 
                 aperture in flange 
               
               
                 90 
                 mounting fastener 
               
               
                 92 
                 second mounting arrangement 
               
               
                 94 
                 wing 
               
               
                 96 
                 boss 
               
               
                 98 
                 bore 
               
               
                 99 
                 captive fastener 
               
               
                 100 
                 gangable modular electrical box, second embodiment 
               
               
                 102 
                 third mounting arrangement 
               
               
                 104 
                 open channel 
               
               
                 106 
                 screw plate 
               
               
                 108 
                 locking arrangement 
               
               
                 110 
                 boss 
               
               
                 112 
                 bore 
               
               
                 114 
                 arm 
               
               
                 116 
                 aperture in arm 
               
               
                 118 
                 captive fastener 
               
               
                 120 
                 outer surface of screw plate 
               
               
                 122 
                 drywall stop 
               
               
                 130 
                 gangable modular electrical box, third embodiment 
               
               
                 132 
                 fourth mounting arrangement 
               
               
                 134 
                 peripheral flange 
               
               
                 138 
                 oversize aperture 
               
               
                 140 
                 mounting fastener 
               
               
                 142 
                 rotatable flag 
               
               
                 150 
                 gangable modular electrical box, fourth embodiment 
               
               
                 152 
                 snap fit fastening arrangement 
               
               
                 154 
                 resilient locking tab 
               
               
                 156 
                 alignment tab 
               
               
                 158 
                 groove in locking tab 
               
               
                 160 
                 raised lip 
               
               
                 162 
                 recessed area 
               
               
                 164 
                 knockout 
               
               
                 166 
                 push-in electrical fitting or connector 
               
               
                 168 
                 integral boss 
               
               
                 170 
                 bore 
               
               
                 172 
                 pair of rails 
               
               
                 W1 
                 width of the slot 
               
               
                 W2 
                 width of the hook 
               
               
                   
               
             
          
         
       
     
     DETAILED DESCRIPTION OF THE INVENTION 
     With reference to  FIG. 1 , there is shown a first and preferred embodiment of a gangable modular electrical box  20  according to the present invention. The gangable modular electrical box  20  includes a first end body  22 , a second end body  24 , and optionally may include one or more inner bodies  26  which, when assembled together as shown in  FIG. 1 , form a multi-gang electrical box. 
     Referring to  FIG. 2 , the first and second end bodies  22  and  24  each include a back wall  28 , a top wall  30 , a bottom wall  32 , and a side wall  34  extending substantially perpendicular from the back wall  28 . One side of each of the end bodies  22  and  24  includes an open side  36 . The inner bodies  26  each include a back wall  38  and a top wall  40  and a bottom wall  42  extending substantially perpendicular from the back wall  38 . Each inner body  26  includes two open sides  44 . 
     The open sides  36  of the first end body  22  and the second end body  24  include side edges  46  on the back wall  28 , the top wall  30 , and the bottom wall  32 . The open sides  44  of each inner body  26  include side edges  48  on the back wall  38 , the top wall  40 , and the bottom wall  42 . The side edges  46  of the first and second end bodies  22  and  24  and the side edges  48  of the inner body  26  are of substantially equal profile and dimensions thereby enabling the side edges  46  and  48  to join flush with each other when the open sides  36  and  44  of the bodies  22 ,  24 , and  26  are joined together. 
     With reference to  FIG. 3 , the gangable modular electrical box assembly  20  includes a coupling arrangement  50  for rapidly aligning and connecting two of the bodies together. The coupling arrangement  50  includes a slot  52  and a hooked tab  54  on each of the back walls  28  of the first and second bodies  22  and  24  and on the back walls  38  of the inner body  26 . Each of the hooked tabs  54  on a first body are aligned for engagement with a corresponding slot  52  on an adjacent body to which it will be connected. With reference to end body  22  and the adjacent inner body  26  in  FIG. 3 , the coupling arrangement  50  for coupling the two bodies together includes a pair of slots  52  and a pair of hooked tabs  54  with a hooked tab  54  and a slot  52  at each side edge of the bodies  22 ,  26 . Each slot  52  corresponds to a hooked tab  54  in the adjacent body. As shown in  FIG. 4 , hooked tabs  54  include ends  56  thereon and a hook  58  extending perpendicular from the end  56  of the hooked tab  54 . The hook  58  extending from the hooked tabs  54  ensures that two bodies will couple to one another. As shown in  FIG. 4 , hook  58  extends into slot  52  to couple the bodies together. Each of the end bodies  22 ,  24  and inner bodies  26  is preferably molded in one-piece of plastic and a tight tolerance is maintained between the width of the slots  52  and width of the hooks  58 . Preferably, the width W 1  of the slots (see  FIG. 3 ) is no more than 0.004-inch greater than the width W 2  of the hooks  58  (see  FIG. 4 ). 
     Referring to  FIG. 3 , the gangable modular electrical box assembly  20  of the present invention further includes an alignment arrangement  60  for aligning the top walls  30 ,  40  and bottom walls  32 ,  42  on the assembly. The alignment arrangement  60  includes an outer tab  62  and an inner tab  64  extending from the side edges  46 ,  48  of each of the bodies  22 ,  24 , and  26 . The outer tabs  62  extend from the outer surface  66  of the top walls  30 ,  40  and bottom walls  32 ,  42  and the inner tabs  64  extend from the inner surface  68  at the side edges  46  and  48  creating a gap  70  there between. Thus, as shown in  FIG. 6 , the top walls  30 ,  40  and bottom walls  32 ,  42  of the bodies  22 ,  24 ,  26  nest within the outer tabs  62  and inner tabs  64  of the adjacent body when two adjacent bodies are coupled together. The alignment arrangement  60  is provided at opposing corners  65  of the inner body. 
     With reference to  FIG. 2 , the gangable modular electrical box assembly  20  includes a fastening arrangement  72  for securing two bodies together. The fastening arrangement  72  includes a second tab  74  extending from the outer surface of the top walls  30 ,  40  and bottom walls  32 ,  42  of the bodies at the side edges  46  and  48 , an aperture  76  in the second tab  74 , and a bore  78  in each of the top walls  30 ,  40  and the bottom walls  32 ,  42  whereby each of the apertures  76  in the second tabs  74  is aligned with each of the bores  78  in the top and bottom walls when the bodies are coupled together with the coupling arrangement  50 . The fastening arrangement  72  further includes fasteners  80  for extending through the second tabs  74  into the bores  78  of the top walls  30 ,  40  and the bottom walls  32 ,  42  for securing the bodies  22 ,  24 , and  26  together. As shown in  FIG. 3 , the second tabs  74  are also provided at opposing corners  65  of the inner bodies  26 . 
     As shown in  FIG. 1 , gangable modular electrical box assembly  20  includes a front edge  81  on each of the top  30  and  40 , bottom  32  and  42 , and side walls  34  of the first end body  22 , the second end body  24 , and the inner body  26 . Two mounting arrangements are provided for mounting the assembly to a surface. A first mounting arrangement  82  includes a flange  84  extending outward from the outer surface  86  of the side wall  34  of the end bodies  22  and  24 . The flange  84  is preferably parallel with and offset from the front edge  81  of the assembly  20 . The flange  84  includes apertures  88  therein for receipt of mounting fasteners  90 . A second mounting arrangement  92  includes wings  94  extending from the top wall  30  and the bottom wall  32  of the first end body  22 , a boss  96  integral with the wings  94 , a bore  98  in the boss, and a captive fastener  99  secured in the bore  98  of the boss  96 . 
     With reference to  FIG. 9  there is shown a second embodiment of a gangable modular electrical box assembly  100  according to the present invention. The gangable modular electrical box assembly  100  includes a third mounting arrangement  102  for mounting the assembled multi-gang box to a stud or similar support. The third mounting arrangement  102  includes an open channel  104  in a side wall  34  of first end body member  22 , a screw plate  106  for insertion in the channel  104 , and a locking arrangement  108  for locking the screw plate  106  into the channel  104 . The locking arrangement  108  includes a boss  110  with a bore  112  therein on the screw plate  106  and an arm  114  extending from the side wall  34  adjacent the channel  104 . The arm  114  includes an aperture  116  therein and a captive fastener  118  in the boss  110 . 
     As shown in  FIG. 10 , after the screw plate  106  is inserted into the channel  104 , a portion of the captive fastener  118  is driven into the aperture  116  in the arm  114  (see  FIG. 9 ) thereby locking screw plate  106  into the channel  104  and making it an integral part of gangable modular electrical box assembly  100 . As shown in  FIG. 11 , the sidewall  34  of the assembly  100  includes two arms  114  and the outer surface  120  of the screw plate  106  includes two drywall stops  122  for locating box assembly  100  with respect to a stud or similar support (not shown). To align the multi-gang box  100  with a stud, the outer surface of side wall  34  is placed flush against the side of the stud (not shown) with alignment stops  122  flush against the front of the stud. As shown in  FIG. 12 , as viewed from the front, screw plate  106  and integral bosses  110  angle captive fasteners  118  toward the front of the box assembly  100  where they will be easily accessible to an installer. After multi-gang box  100  is aligned flush against a stud, captive fasteners  118  are driven fully into bosses  110  and thus fully into the stud. 
     Referring to  FIG. 13  there is shown a third embodiment of a gangable modular electrical box assembly  130  according to the present invention. The gangable modular electrical box assembly  130  includes a fourth mounting arrangement  132  including a peripheral flange  134  extending orthogonally from the front edges  81  of the top wall  30 , bottom wall  32 , and side walls  34  of the end bodies  22  and  24 , oversize apertures  138  in the peripheral flange  134 , mounting fasteners  140  extending through the oversize apertures  138  in the peripheral flange  134 , and rotatable flags  142  connected to the mounting fasteners  140 . With the gangable modular electrical box assembly  130  assembled into a multi-gang electrical box as shown in  FIG. 14 , mounting fasteners  140  are rotated at least 90 degrees counterclockwise to place the flags  142  flush against outer surface  66  of top walls  30  and bottom walls  32  and thereby minimize the outer profile of the box assembly  130 . Box assembly  130  can then be inserted into a hole in the drywall or equivalent wall covering on a wall (not shown). After peripheral flange  134  is flush against the drywall, mounting fasteners  140  are each rotated clockwise until the flags  142  are drawn tight against the back surface of the drywall, thereby securing box assembly  130  to the wall. 
     With reference to  FIG. 18  there is shown a fourth embodiment of a gangable modular electrical box  150  according to the present invention assembled in a configuration to provide a three-gang electrical box. As shown in  FIG. 19 , the gangable modular electrical box assembly  150  includes a snap fit fastening arrangement  152  on the assembly for snap-fitting the first end body  22 , inner body  26 , and second end body  24  (not shown) together. The snap fit fastening arrangement  152  includes a resilient locking tab  154  extending from the side edge  46  of the top wall  30  of the first end body  22  and a resilient locking tab  154  extending from the side edge  48  of the bottom wall  42  of the inner body  26 . In addition, a resilient locking tab  154  is included on the back wall  28  of the first end body  22  and the back wall  38  of the inner body  26  and for snap-fitting and locking the back walls  28  and  38  of adjacent modules together. In addition, alignment tabs  156  are provided on the opposite sides of the walls from the locking tabs  154  to assist in aligning the modules or bodies  22 ,  24 , and  26  as they are joined together to form a multi-gang electrical box  150  (see  FIG. 18 ). 
     Referring to  FIGS. 20 and 21 , the locking tabs  154  of the snap fit fastening arrangement  152  each include a groove  158  therein and the walls  32 ,  42  include a raised lip  160  at the side edges  46 ,  48  of the adjacent body. The bodies, of which end body  22  and inner body  26  are shown in the figures, are secured together at the top walls  30 ,  40  by the resilient locking tab  154  of the first end body  22  engaging the raised lip  160  of the inner body  26  and at the bottom walls  32 ,  42  by resilient locking tab  154  of inner body  26  engaging the raised lip  160  of the first end body  22 . 
     As shown in  FIG. 21 , each embodiment of the gangable modular electrical box assembly described herein include recessed areas  162  in the top walls  30 ,  40  and the bottom walls  32 ,  42  of the end bodies  22  and  24  and inner body  26  and a knockout  164  in the recessed area  162 . The recessed areas  162  in the top and bottom walls enables the use of electrical fittings or connectors such as the BLACK BUTTONB™ push-in connector  166  for connecting non-metallic cable to the multi-gang electrical box. The BLACK BUTTONB™ push-in connector, available from Arlington Industries of Scranton, Pa., is simply pushed into one of the knockouts  164  provided in the recessed area  162 . The recessed area  162  prevents the push-in connectors  166  from projecting outward from the sidewalls of the multi-gang electrical box (see  FIG. 18 ) and thus interfering with placement of the multi-gang electrical box in locations where space is tightly restricted. 
     With reference to the assembled multi-gang electrical box  150  in  FIGS. 22 and 23 , the inner surfaces  68  of the top  30 ,  40  and bottom walls  32 ,  42  each include an integral boss  168  extending from the front edge  81  to the recessed area  162 . The integral bosses  168  include bores  170  therein for receipt of fasteners (not shown) for securing an electrical component, such as a switch or a duplex receptacle, to the modular electrical box assembly  150 . 
     Referring to  FIGS. 7 and 8 , a gangable modular electrical box assembly  20  according to the present invention preferably includes one or more drywall stops  122  on the outer surface  86  of the side walls  34  for locating the multi-gang box  20  with respect to a stud or similar support (not shown). The outer surface  86  of the sidewalls  34  also preferably includes a pair of rails  172  extending there from, the rails  172  being perpendicular to the front edge  81 . Preferably one rail  172  is located above and one below the flange  84 . The rails  172  include a planar outer edge that provides an abutment surface for squaring and supporting the multi-gang electrical box against a stud or similar supporting surface (not shown). 
     Preferably, the first end body  22 , the second end body  24 , and the inner body  26  of a gangable modular electrical box assembly according to the present invention are each molded in one-piece of plastic. Preferably, the plastic is polycarbonate, polyvinyl chloride, acrylonitrile-butadiene styrene, polyethylene, or polypropylene. 
     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.