Abstract:
A multi-part electrical/electronics enclosure that may be used for in-wall installation of intercom, home audio, lighting, HVAC or other automation controls and similar system components. The enclosure includes two major components including a back box, serving to enclose low voltage electronics, and a power pocket portion, fitting into at least one wall of the back box. The power pocket serves as an enclosure for high voltage alternating current electrical wire terminations, equipment connections, power supplies and the like. A trade separator fits between the back box and power pocket to completely enclose and isolate high voltage electrics from low voltage electronics. This solution provides maximize use of available space especially in retrofit applications. It also provides for servicing of electronics (disposed in back box) without accessing or servicing high voltage electrics in the power pocket.

Description:
RELATED APPLICATION(S) 
       [0001]    This application claims the benefit of U.S. Provisional Application No. 61/189,955, filed on Aug. 25, 2008. The entire teachings of the above application are incorporated herein by reference. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    The present invention relates to an in-wall enclosure serving as a housing for both low voltage and high voltage circuitry, while also providing isolated connection(s) to a high voltage Alternating Current (AC) power line. 
         [0003]    Systems for automated distribution of entertainment media, control of lighting, intercom, security, and multi-room audio-visual systems are becoming more and more desirable in both homes and businesses. These systems typically involve some sort of control unit placed on or within a wall. The control unit may typically serve to enclose electronics and needs some sort of connection to a power source. 
       SUMMARY OF THE INVENTION 
       [0004]    In one preferred embodiment, a multi-piece electrical/electronics enclosure may be used for in-wall installation of keypads, controllers and similar devices. The devices may typically form part of an intercom, home audio, automated lighting, HVAC, security or similar system. The multi-piece enclosure includes a back box serving to house low voltage electronics, and a power pocket fitting into at least one wall of the back box. The power pocket fits into and extends away from the back box to provide additional space. The power pocket preferably serves as a housing for high voltage electrical wires, high voltage circuitry connections, power supplies or the like. 
         [0005]    A trade can separator fit between the back box and power pocket to enclose and isolate high voltage electric circuits from low voltage electronics. 
         [0006]    In still other optional embodiments, a power supply sub-housing may fit into the power pocket. 
         [0007]    This solution can be used in applications to retrofit existing buildings, to maximize use of available space between vertical wall studs. 
         [0008]    The arrangement also provides ease in later servicing of electronics, disposed in the back box, without the need for access to high voltage electrics or wiring that can now remain enclosed in the power pocket. The arrangement permits certain trades, such as audio equipment installers, to access the low voltage circuitry without being exposed to high voltage line currents or voltages. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]    The foregoing will be apparent from the following more particular description of example embodiments of the invention, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating embodiments of the present invention. 
           [0010]      FIG. 1  is an isometric view of an in-wall enclosure according to certain aspects of an embodiment. 
           [0011]      FIG. 2  is an exploded view of the components of the enclosure. 
           [0012]      FIG. 3  is a more detailed view of a back box. 
           [0013]      FIG. 4  is a more detailed view of a trade separator. 
           [0014]      FIG. 5  is a more detailed view of a power pocket. 
           [0015]      FIG. 6  is a more detailed view of a power supply sub-housing. 
           [0016]      FIG. 7  illustrates the enclosure assembled in a wall. 
           [0017]      FIG. 8  illustrates a faceplate attached to the enclosure. 
           [0018]      FIG. 9  is a side view of the assembled unit. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0019]    A description of example embodiments of the invention follows. 
         [0020]      FIG. 1  shows an electrical/electronics enclosure assembly  10  that embodies one or more aspects of the present invention. Enclosure assembly  10  includes a back box  12 , a power pocket  14 , and trade separator  16 . An optional frame  17  and optional power supply sub-housing  19  are also shown. The assembly  10  can be used as an in-wall enclosure for system components that require both high voltage electrics and low voltage electronics. Such enclosures  10  can find use as housings for switches, buttons, keypads and other user control devices. These devices may control various types of systems such as distributed multimedia, intercom, automated lighting, security, alarm, heating ventilating air conditioning (HVAC) and other systems. The components of enclosure  10  may be formed of aluminum, metallic-coated polymers, or other suitable materials. 
         [0021]      FIG. 2  is an exploded view showing these same components and how they fit is together. Assembly of the enclosure  10  will be described below. 
         [0022]    In general the power pocket  14  serves to enclose high voltage wiring and any associated high voltage circuitry that are connected to a high voltage power source, for example, a household (mains) 120 or 240 volt Alternating Current (AC) source. Power pocket  14  may optionally enclose a power supply (within sub-housing  19 ) to convert incoming 120 volt AC to low voltage (5 volt) DC as needed to provide low voltage power for electronic circuits. 
         [0023]    Back box  12  serves to enclose such Direct Current (DC) low voltage electronic components (e.g., 5 to 10 volts) that may include lighting controls, keypads, audio amplifiers, intercom circuits, speakers, HVAC/automation controls and the like. The back box  12  may also contain low voltage speaker wire termination points for external speakers or the like. 
         [0024]    The removable trade separator  16  allows for the high voltage electric circuits to be isolated and enclosed by power pocket  14 , while still allowing for easy access to the electronics inside back box  12  even after initial assembly, without removing back box  12  from a wall in which it may be installed. This solution, including a separately manufactured back box  12  and power pocket  14 , provides several other advantages. It is especially advantageous in a retrofit installation where access to interior portions of a wall may be limited, as will be discussed in more detail below. 
         [0025]    Turning attention to  FIG. 3  a back box  12  is shown in more detail. This embodiment of back box  12  has top flanges  21  and side  22  on the front face thereof. These flanges are provided for attachment to wallboard using screws or nails and the like as is conventional for electrical wiring boxes. 
         [0026]    The back box  12  has openings (or punch outs)  25  such as in the top portion thereof to provide egress for low voltage wires. 
         [0027]    Notably, back box  12  also has an opening  24  in a bottom portion thereof. The opening  27  accommodates insertion of power pocket  14  after back box  12  is installed into a wall. The opening  27  may have peripheral elements associated with it to accommodate snap-fit type installation of power pocket  14 . In particular, one or more clips  26  may be placed on a lower portion of the back wall  29  of back box  12 . A front is lip portion  28  may also be shaped to support the power pocket  14  at the front of back box  12 . 
         [0028]    While opening  27  is shown in the bottom portion of back box  12 , it should be understood that opening  27  can be in an upper or either side portion as well. 
         [0029]    Power pocket  14  is shown in more detail in  FIG. 5 . Power pocket  14  may have formed thereon upper front flange  31  and upper rear flange  32 . Flange  31  is shaped to rest on front lip  28  of back box  12 , and rear flange  32  is shaped to engage clips  26  in the back wall  29  of back box  12 . Power pocket  14  is intended to enclose high voltage connections, terminal points, or components. For example, connections can be made therein between a power supply and a main 120/240 volt AC supply. Such a power supply (not shown in  FIG. 3 ) converts an AC voltage on the main to a DC supply voltage. The power supply circuitry may be enclosed in a separate sub-housing, as shown in  FIG. 6 , for ease of installation and later servicing. 
         [0030]    The trade separator  16 , as shown in  FIG. 4 , is typically a metal or metallic-coated plate having flanges  41 ,  42  shaped to engage the upper portion of power pocket  14 . For example, one or more ball portions  43  on flange  42  may engage corresponding socket portions  34  formed in the upper portion of power pocket  14 . This ball and socket friction fit allows for later removal of trade separator  16  should that become necessary for servicing of wiring and/or components installed in power pocket  14 . One or more egress holes  45  for wires or connectors are provided in trade separator  16  so that low voltage signal connections can pass between power pocket  14  and the electronics in back box  12 . 
         [0031]    It should be understood that power pocket  14  may be assembled into to back box  12  using other than the clip and friction fit type fastenings. The same is true for engagement of trade separator  16  with the top portion of power pocket  14 . For example, screw type fasteners can also be used for these purposes. However, it is believed that in most implementations the tool-less friction-fit flanges  31 ,  32  and  42 , clips  26 , balls  42  and sockets  34  are preferred for ease of assembly and dis-assembly. 
         [0032]      FIG. 6  illustrates a sub-housing  19  that may be used to further enclose high voltage circuitry such as an AC to DC power supply. If utilized, power supply sub-housing  19  also friction-fits into power pocket  14  via nubs  61 ,  63  and corresponding clips  37  or holes  33 . 
         [0033]    Back box  12 , power pocket  14 , sub-housing  19  and trade separator  16  are typically installed in wall board  50  in a particular order. Referring to  FIGS. 2 and 7 , a first tradesperson brings a source of 120/240 AC line voltage such as a Romex™ cable  52  near the desired location. Romex™ is a trademark of the Southwire Company of Carrolton, Ga., USA. This step would typically be performed by a licensed high voltage electrician. The electrician can then make a suitable opening (but only the size of back box  12 ) in existing wall board  50 , and then place back box  12  into the opening and secure it to the wall using wallboard screws  55 . The licensed electrician can then run Romex™ (non-metallic cable or other suitable electrical feeding medium)  52  into the power pocket  14  and make connections inside power pocket  14 , e.g. to a power supply  19 , and then feeding out any low voltage wires and/or connectors from the power supply through holes in or connectors adjacent trade separator  16 . He then snaps power pocket  14  into the back box  12 , and then also snaps trade separator  16  into place. 
         [0034]    At this point, an audio equipment system integrator (who may not necessarily be a licensed electrician) can then arrive at the location and install the low voltage components, e.g., install keypad electronics in back box  12 , make the connection from power supply  19  to the same, and place face plate  17  and any keypads or facia (not shown in  FIG. 2  or  7 ) to complete the installation. 
         [0035]    Of course other trades can be involved. For example, a carpenter may first install back box  12  into wall board  50 , leaving it to a licensed electrician to then later insert power pocket  14  into back box  12  and connect the high voltage wiring and/or power supply  19 , and install trade separator  16 . 
         [0036]      FIG. 8  is the fully assembled unit, including an illustrated keypad/facia  80 . 
         [0037]      FIG. 9  illustrates the assembled unit from a cut away side view. Wall board  50 , into which back box  12  was installed, is on the right hand side of the figure. Wall board  70  associated with, for example, a wall in an adjacent room, is shown on the left hand side. In this view it can be understood that if entire electrical enclosure  10  had been of is unitary construction, it would only have been possible to provide an area of about W 1 ×H 1 ×D 1  ( FIG. 3 ) into which system components could be placed. This limitation would be imposed by the distance E between wall board  50  and wall board  70  and the need to fit the unit into the wallboard opening  24 . 
         [0038]    However, by first installing back box  12  having an opening  24  into which only power pocket  14  can be fit, and then placing power pocket  14  therein, an additional area of approximately W 2 ×L 2 ×D 2  ( FIG. 5 ) is provided. In other words, especially in a retrofit situation, the depth D 1  of back box  12  could otherwise be no wider than the distance E between the two pieces of wall board  50  and  70 , without our invention. 
         [0039]    In addition, electronics installed in the back box  12  can be serviced without interrupting and/or requiring access to high voltage wiring or components in power pocket  14 . For example, in case of a lightening strike, component failure, or system component upgrades, a system integrator can merely remove facia  80  and then face plate  17 , and obtain access to electronic low voltage system components. There is no need for exposure to high voltage wiring or power supply sub-housing  19  in power pocket  14 . Thus a high voltage licensed electrician need not be called in to further service enclosure  10  in such situations. 
         [0040]    The invention can be used to satisfy Underwriter Laboratories (UL) and/or local building codes that require high and low voltage electric and electronics to be in physically separate enclosures. 
         [0041]    While this invention has been particularly shown and described with references to example embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the scope of the invention encompassed by the appended claims.