Abstract:
A connection box provides power and/or data distribution for outdoor structures including decks, terraces and patios by including one or more connection points that are sheltered from moisture and harmful weather conditions by a lid having drip edges and a gasket. The connection box mounts flush with a surface so that it does not pose a tripping hazard, and can include a light to aid in locating the connection points.

Description:
FIELD OF THE INVENTION 
     The present invention relates to outdoor power distribution and, more particularly, to electrical connection points that remain sheltered from the elements when connected to an electrical device. 
     BACKGROUND OF THE INVENTION 
     Electrical power has been a part of modern life for more than a century and has become a familiar indoor convenience. Indoors, almost every appliance for daily use requires electrical power. However, outdoor access to electrical power cannot yet be described as convenient. 
     For consumers who wish to combine an outdoor lifestyle with the conveniences of modern life, provision of electrical power presents immediate difficulties. While vertical wall-mounted receptacles are known for outdoor power distribution, such receptacles require use of an extension cord to distribute power to any significant distance from the wall. The inconveniences associated with use of an extension cord, such as a tripping hazard, essentially limit outdoor power distribution to locations near the wall-mounted receptacle. 
     In order to provide electrical power at locations distant from existing walls, various devices have been proposed. For example, post-mounted outdoor receptacles have been provided. However, the post-mounted receptacles can be visually obtrusive. Additionally, the post-mounted receptacles are prone to inadvertent displacement or damage due to their protruding structure. 
     Further, while outdoor provision of electrical power is known, no special provisions are known for outdoor access to telephone, computer, audio-visual, or optical network data. 
     Accordingly, it is desirable to have an outdoor connection point that provides electrical power and/or data, that is suitable for horizontal or vertical use distant from existing structural walls, that is weatherproof, and that is visually and physically unobtrusive. 
     BRIEF SUMMARY OF THE INVENTION 
     The present invention solves a problem of distributing power and/or data to an outdoor environment such as a deck, patio, terrace, or any type of surface subjected to outdoor use. The present invention achieves its objective by providing one or more connection points that are sheltered from the elements. The present invention allows for installation anywhere on/in outdoor living space. 
     According to the present invention, an outdoor connection box provides a connection point that is accessible for connecting an electrical cable, and that is weatherproof. The outdoor connection box is suitable for horizontal use distant from structural walls, and is physically and/or visually unobtrusive. 
     In one embodiment, the outdoor connection box includes a housing defining plug and drip chambers, and at least one cable opening allowing communication between the chambers. A connection point is housed in the plug chamber. A lid is adapted to substantially cover the box, thereby sealing an opening of the plug chamber. When the lid covers the box, a cable connected to the connection point can be passed through the cable opening and egress from the box around an edge of the lid. The lid has drip edges that prevent liquid from entering the box, and has a liquid collection area with drain hole. 
     The connection box according to the present invention is capable of being mounted flush with the mounting surface and does not pose a tripping hazard. 
     Another feature of the present invention is a safety switch that allows the connection point to be energized only when the lid is closed. The safety switch helps to protect the connection point from problems that might occur if the connection point was exposed to moisture while energized when the lid is in an open position. 
     A further feature of the present invention is a light that aids in locating the unit and allows safe attachment of the plug of the connected equipment to the device in low light situations. 
     According to an embodiment of the present invention, the connection box provides a separate compartment for low voltage devices/connections. 
     The outdoor floor box can be installed into application such as decks, patios, terrace, or any type of surface subjected to outside use. The floor box can be mounted in a horizontal position as well as in a vertical position. 
     These and other objects, features and advantages of the present invention will become apparent in light of the detailed description of the best mode embodiment thereof, as illustrated in the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a flush-mounted outdoor connection box with a lid in an open position, according to an embodiment of the present invention; 
         FIG. 2  is a front sectional view of the outdoor connection box of  FIG. 1  with the lid in a closed position; 
         FIG. 3  is a side sectional view of the outdoor connection box of  FIG. 2 ; 
         FIG. 4  is a perspective view of a surface-mounted outdoor connection box with a lid in a fully open position, according to another embodiment of the present invention; 
         FIG. 5  is a perspective view of the flush-mounted box of  FIG. 1  with the lid in a closed position; and 
         FIG. 6  is a perspective view of the surface-mounted box of  FIG. 4  with the lid in a closed position. 
     
    
    
     DETAILED DESCRIPTION OF EMBODIMENTS 
     Referring to  FIG. 1 , an outdoor connection box  10  housing one or more electrical connection points  12 , such as electrical power receptacles, data jacks, or optical fiber connectors, is horizontally mounted to a deck  14 . The connection box  10  includes a housing  20  and a lid  24 . The lid  24  is hingedly connected to the housing  20  and is movable relative to the housing  20  between a closed position substantially covering the housing  20  and a plurality of open positions, including the partially open position shown in  FIG. 1 . An electrical appliance or data device (not shown) can be connected to a selected connection point  12  via a cable  16  having a plug  18 . 
     Referring to  FIG. 2 , the housing  20  includes side walls  26  and end walls  27 , a back wall  28 , and sloped walls  30 , which together define and partially enclose a drip chamber  32 . The drip chamber  32  has an opening  33  opposite the back wall  28 , and includes a trough  34  defined between the sloped walls  30  and the side walls  26 . Drain holes  36  are provided at corners of the trough  34 . 
     The side walls  26  include a mounting flange  44  and a deformable outer gasket  46 . Alternatively, the outer gasket  46  can be attached to the lid  24 . The side walls  26  and the mounting flange  44  are arranged so that the box  10  can be fastened to upper or lower surfaces of deckboards between joists of the deck  14 , as shown in  FIGS. 1 and 4 . The mounting flange  44  can be integrally formed with the side walls  26  or can be attached as a separate piece to the side walls  26 . If formed as a separate piece, the mounting flange  44  can be adjusted relative to the side walls  26  so that, when the box  10  is mounted to the deck  14  and the lid  24  is closed, an upper surface of the lid  24  is substantially flush with an upper surface of the deck  14 , as shown in  FIGS. 5 and 6 . 
     As best seen in  FIGS. 2 and 4 , inner walls  38  extend from the back wall  28  to the opening  33 , defining an upper edge  39  substantially coplanar with the opening  33 , and supporting a bracket  42 . The inner walls  38  include cable openings  43  for passage of electrical cables  16 . The bracket  42  is adapted to receive and support the connection points  12 . As shown in  FIG. 2 , the bracket  42  and the inner walls  38  define a plug chamber  40  extending from the bracket  42  to the upper edge  39  and a wiring chamber  41  extending from the bracket  42  to the back wall  28 . The inner walls  38  separate the plug chamber  40  and the wiring chamber  41  from the drip chamber  32 . Plugs  18  can be inserted into the connection points  12  from the plug chamber  40 , while wiring for the connection points  12  is disposed in the wiring chamber  41  and can be accessed via the back wall  28 . Alternatively, the back wall  28  can be omitted. Also, the bracket  42  can be supported by the back wall  28 , can be hung from the upper edge  39  of the inner walls  38 , or can be supported by other means which would be within the scope of one of ordinary skill in the art. 
     As shown in  FIGS. 1-4 , the lid  24  includes a weather surface  48  and an inner surface  50  bordered by outer edges  51 . The mounting flange  44  is adapted for attachment to an upper surface of the deck  14 , as shown in  FIGS. 4 and 6 , or to a lower surface of the deck  14 , as shown in  FIGS. 1 and 5 . In the embodiment shown in  FIGS. 1 and 5 , material matching the deck  14  is fastened to the lid  24  to form the weather surface  48 , thereby adjusting a height of the lid  24  to substantially match a thickness of the deck  14 , and also making the lid  24  inconspicuous against the deck  14  as shown in  FIG. 5 . Alternatively, referring to  FIG. 6 , the weather surface  48  can be fabricated from other material, and the weather surface  48  can be made substantially flush with the deck  14  by fastening the mounting flange  44  to the upper surface of the deck  14 . Referring back to  FIG. 4 , the inner surface  50  of the lid  24  includes an inner gasket  54 , a perimeter gasket  55 , and a drip edge  56 . As best seen in  FIG. 2 , the drip edge  56  is arranged to extend from the inner surface  50  toward the trough  34  when the lid  24  is closed. 
     Referring to  FIG. 3 , the end walls  27  have inner surfaces  29  which are arranged to define a ledge  31  with a portion of the upper edge  39  of the inner walls  38 . The outer edges  51  of the lid  24  are arranged to abut the end walls  27  when the lid  24  is closed. The perimeter gasket  55  is arranged to sealingly abut the ledge  31  when the lid  24  is closed. 
     Referring back to  FIG. 1 , in one embodiment, the connection points  12  include electrical power receptacles. The connection box  10  includes a safety switch  64  to energize the power receptacles  12  when the lid  24  is closed, and to interrupt power to the power receptacles  12  when the lid  24  is not closed. Preferably, the safety switch  64  is weatherproofed individually. The safety switch  64  can be located anywhere within the box  10 . 
     In an embodiment of the present invention, the connection box  10  also includes a light switch  65  that activates a light  66 , which is energized when the lid  24  is not closed and is de-energized when the lid  24  is closed. The light  66  is, for example, an LED light powered by, for example, solar energy. An associated solar panel  67  can be disposed in the weather surface  48  of the lid  24 , as shown in  FIG. 6 . Other variations on the light  66  are within the scope of ordinary skill in the art. 
     Preferably, the lid  24  is biased to the closed position. For example, the lid  24  may be biased to the closed position by a spring  68 , as shown in  FIG. 1 . Other biasing means or devices, such as torsion springs, live hinges, counterweights, and the like, are known to those of ordinary skill, and are intended to be within the scope of the present invention. 
     Referring to  FIG. 4 , in an embodiment of the present invention, the connection points  12  include a data jack  72 . The data jack  72  can be provided in a separate compartment  74  defined by cross wall  76 . 
     The connection points  12  can be obtained commercially. The housing  20 , the lid  24 , and the bracket  42  can be formed from metal or polymer stock. As discussed above, the lid  24  in some embodiments can include a weather surface  48  formed from material matching the deck  14  or other mounting surface. Optimally, the lid  24  and the housing  20  are arranged to support a design live floor load of the deck  14 . 
     In operation, during normal conditions, the lid  24  is closed, as shown in  FIG. 2 . Accordingly, the outer edges  51  of the lid  24  sealingly abut the outer gasket  46 , the inner surface  50  of the lid  24  abuts the upper edge  39  of the inner walls  38 , the inner gasket  54  sealingly abuts the inner walls  38 , and the drip edge  56  extends between the inner walls  38  and the side walls  26 . Also, as shown in  FIG. 3 , when the lid  24  is closed, the perimeter gasket  55  sealingly abuts the ledge  31 . 
     Referring back to  FIG. 2 , when the plug  18  is inserted into one of the receptacles  12 , the cable  16  is passed through one of the cable openings  43 , and when the lid  24  is in the closed position, one of the outer edges  51  presses the cable  16  against the outer gasket  46  while the drip edge  56  and the cable openings  43  cooperate to impose a drip loop  58  in the cable  16 . The drip loop  58  ensures that any moisture passing along the cable  16  will be diverted from the plug chamber  40  and will drop from the drip loop  58  into the trough  34 . Alternatively, the inner walls  38  can be omitted and the bracket  42  can be arranged so that the plug  18  and the drip edge  56  cooperate to impose the drip loop  58  in the cable  16 . The moisture that drops from the drip loop  58  drains from the connection box  10  through the drain holes  36  formed in the trough  34 . Thus, the lid  24  and the housing  20  allow horizontal installation of upward-facing connection points  12  while preventing entry of moisture into the connection points  12 . 
     When the lid  24  is opened, the plug  18  can be accessed via the plug chamber  40  for insertion or removal of the plug  18  into or from one of the connection points  12 . Referring to  FIG. 1 , in some embodiments, opening the lid  24  causes the safety switch  64  to deenergize the connection points  12 . In some embodiments, opening the lid  24  causes the light switch  65  to energize the light  66 . 
     One advantage of the present invention is that infiltration of moisture into the connection box  10  is prevented, thereby permitting the connection box  10  to be mounted horizontally in the deck  14 , which is exposed to inclement weather. 
     Another advantage of the present invention is that the connection box  10  can be mounted in the deck  14  so that the weather surface  48  of the lid  24  is substantially flush with the deck  14  while the connection points  12  are in use, thereby providing access to electrical power without posing a trip hazard. 
     A further advantage of the present invention is that the connection box  10  can be mounted in the deck  14  so that the connection points  12  face substantially upward, thereby providing easy insertion and removal of the plug  18  into or from one of the connection points  12 . 
     Accordingly, the present invention provides horizontally installed, weatherproof electrical connection points with reduced trip hazards. 
     Although this invention has been shown and described with respect to the detailed embodiments thereof, it will be understood by those skilled in the art that various changes in form and detail thereof may be made without departing from the spirit and the scope of the invention. For example, the connection box  10  can be mounted vertically in a building wall, with the mounting flange  44  providing attachment to vertical stringers, and the back wall  28  providing access for cables from the building wall to the connection points  12 . As another example, the connection box  10  could be mounted in a concrete or flagstone patio, with the back wall  28  providing access for subsoil cables to the connection points  12 .