Electrical box

An electrical box suitable for safely and efficiently housing an electrical connection. The electrical box comprises a bottom and a plurality of adjacent side walls, each side wall being at least partially joined to the bottom and to each adjacent side wall to form an open box. Each side wall has a top edge wherein the top edges define an open box perimeter. A top is hingedly joined to one the top edges of one the side walls and is adapted to be moveable from an open position to a closed position. At least one the side walls comprises at least one notch, the notch comprising deformable plastic members that can be biased in an open position to define a conductor opening to receive at least one of the electrical conductors, the conductor opening being at least partially defined by the top when the top is in the closed position.

FIELD OF THE INVENTION

The invention relates to electrical boxes for housing electrical connections.

BACKGROUND OF THE INVENTION

Electrical boxes for making safe and secure electrical connections are known. For example, metal or plastic boxes, often known as junction boxes, are often used to make connections of household wiring. Known boxes for this purpose often have predetermined openings in the sides that can be removed to permit entry of wiring to be connected. These openings may be formed by removing a portion of the side, so called “knock outs”, or they may be made by deforming a portion of the box side to bend about a hinge line, thereby defining an opening in which wiring or cables can enter the box. Once the conductors to be connected have each entered the interior of the box via one or more of the predetermined openings, the connection can be made, the box cover placed on and secured, and the connection is complete.

One of the drawbacks with current boxes is the relative difficulty in facilitating entry of the conductors into the box. Often the portion of the side wall of the box to be removed must be knocked out with a tool such as a hammer. Often it must be pried out with a tool such as a screw driver. This can be especially difficult with metal boxes, for example.

Another drawback with current boxes is that the top, or lid, is easy to misplace, or forget when doing an electrical connection. For example, an electrician making connections in an attic may forget to bring along the top to a junction box, thereby necessitating an inconvenient and time-consuming trip out of the attic to retrieve the top.

Accordingly, there is a need for an electrical box, e.g., improved junction box, for making electrical connections that minimizes or eliminates the need to remember the top with each junction box.

Additionally, there is a need for an electrical box that is adapted to permit the making of electrical connections faster and easier within the box.

SUMMARY OF THE INVENTION

An electrical box suitable for safely and efficiently housing an electrical connection is disclosed. The electrical box comprises a bottom and a plurality of adjacent side walls, each side wall being at least partially joined to the bottom and to each adjacent side wall to form an open box. Each side wall has a top edge wherein the top edges define an open box perimeter. A top is hingedly joined to one the top edges of one the side walls and is adapted to be moveable from an open position to a closed position. At least one the side walls comprises at least one notch, the notch comprising deformable plastic members that can be biased in an open position to define a conductor opening to receive at least one of the electrical conductors, the conductor opening being at least partially defined by the top when the top is in the closed position.

DETAILED DESCRIPTION OF THE INVENTION

One embodiment of an electrical box of the present invention is shown inFIG. 1. As shown, box1has side walls2joined to a bottom, which together form an open container. AlthoughFIG. 1shows a typical arrangement of four side walls2forming a rectangular box, the invention is not limited only to such a typical configuration. In general, any configuration of three or more side walls2will suffice. The top edges4of side walls2define a peripheral open edge6of the open container. Top8is hingedly joined at hinge10to one of the top edges4, such that the top8can close shut, substantially sealing the container about the peripheral open edge6. A notch or cut-out portion12of the top edge4of at least one side wall2defines a conductor opening adapted to receive at least on conductor, as shown in dotted line inFIG. 1, but it is understood that the conductors shown do not necessarily form a part of the invention. In one embodiment, connectors can form an embodiment of the invention. A connection can be made inside the box, as represented in dotted lines inFIG. 1by two conductors joined by a typical wire nut, and the top closed such that the connection is safely and efficiently housed within box1.

AlthoughFIG. 1shows two notches12, one on each of two opposing side walls2, there could be more, and only one is necessary for the present invention. For example, both conductors to be connected can be placed into the box1via one notch12and still enjoy the advantages of the present invention. Likewise, although the notches12are shown inFIG. 1as being substantially rectangular in shape, the shape is not determinant of the invention For example, the shape of notches12for conductor openings can be practically any geometric shape, and can be shaped to fit specific cross-sectional sizes of specific conductors. Further, it is contemplated that the notches12of the present invention can be fitted with suitable grommets or pliable seals to provide a weatherproof fitting at the conductor openings, as well as providing for some strain relief on the conductors. For example, as shown inFIG. 1, a substantially “U”-shaped seal16can be suitably fitted to the edges of notches12by methods known in the art, such as by press fitting about a longitudinal groove in seal16. Once top8is shut, optional sealing gasket member18can complete the seal about conductor notches12to provide for a weatherproof enclosure, Of course, any known sealing material, such as rubber, neoprene, polymeric elastomer materials, or other polymeric or pliable materials can be used for seal16or gasket member18. Likewise, any suitable shape and size of seal16can be incorporated for proper sealing properties. In fact, a generally circular, or other closed shape of seal can be used, recognizing that such a seal would necessarily need to be fitted onto the electrical conductor prior to making an electrical connection inside the box. The closed shape seal then could be appropriately positioned along the length of the electrical conductor until it coincided with notch12to make a weather proof seal after closing top8.

Top8can be a separate member attached by a hinge connection to one of side walls2. For example, top8can be joined by a “piano” hinge. However, in a preferred embodiment, top8is integral with the side wall2to which it is joined. In a preferred embodiment, the bottom, side walls2, and top8are molded of impact resistant plastic material as a unitary structure, with hinge10being a living hinge. As such, the electrical box1of the present invention can be substantially molded in one piece, in a single mold. The box1can be molded by methods known in the art for producing molded articles. Top8can be retained in the shut position by methods known in the art. For example, top8can be held closed by any number of known snap connections, screw connections, e.g., screw connection19, or simply by friction and force fit.

As can be appreciated by the skilled person, the advantages of the present invention are many. For example, since prior to closing the top8conductor notch12is partially defined by the top edge4of side wall2, the conductor to be connected can enter the box across the top edge4of side wall2. That is, there is no need to feed the conductor(s) through a hole in the side of the box, but the conductors can simply be “laid in” so to speak. This greatly simplifies the job of making electrical connections. In fact, connections can be made prior to putting the connected conductor ends into the box. This permits an electrician, for example, to make connections in the open, then fit them into what can be a relatively confined area of the electrical box1.

Another advantage of the electrical box1of the present invention is the hingedly joined top8. By being joined hingedly, top8is essentially one piece with electrical box1, so that the top8is always with box1and does not get lost or misplaced. This can save much time and effort, for example when an electrician is working in the attic of a house making electrical connections. He or she need not need to remember to carry multiple parts to make a safe, complete connection. The hingedly-joined top8is particularly beneficial when hinge10is a living hinge, as this greatly simplifies production of the box1. As is known in the art, a living hinge is integrally molded with the parts to be hinged together, the hinge simply being a thinned portion of the molded article. When a living hinge is utilized, therefore, box1can simply be molded by known means a one piece, with an integrally-hinged top.

Other variations are contemplated for the present invention. For example, as shown inFIG. 2, conductor openings can be offset from top edge4of side wall2by a predetermined distance d, with a means for conductor access to the notch12for example, as shown on one side wall2of inFIG. 2, a slot20joins the top edge4of side wall2to notch12. As shown on another side wall2of the electrical box1inFIG. 2, a frangible portion22is provided, which can be frangibly separated to form an open pathway to notch12. Frangible portion22, can be, for example, a thinned portion of side wall2, or a perforated portion of side wall2. As such, a simple twisting or tearing motion by a user can break frangible portion22to separate respective portions of side wall2to make an open pathway to notch12(similar to channel20, discussed above).

The advantage of the embodiment shown inFIG. 2is that the relatively constricted channel20, or opened frangible portion22, can help hold electrical conductors in place in the electrical box1prior to closing top8. Therefore, the conductors are relatively constrained and cannot readily come out of the box1while the electrician is doing other things prior to finishing the connection of the electrical conductors.

In either of the illustrated embodiments, notch12can be provided as-is as an actual opening, or it can be provided as an “openable”notch. That is, as shown in a detail of an embodiment of an notch12inFIG. 3, notch12can be formed by, for example, deformable plastic members24that can be biased into an open position. Therefore, notch12is provided for in a closed condition, but is openable by, for example, folding deformable plastic members24inwardly as shown inFIG. 3. Deformable plastic members24can be hingedly joined to edges of notch12and/or can be frangible members that can be removed prior to placing the conductor into notch12. Deformable plastic members24can provide some sealing and strain relief functions.

In another embodiment shown inFIG. 4, electrical box1can comprise two halves,30and31, which can be substantially identical in size and shape. Each half can have the structure of a box having an open side, such that when the two halves are mated together, the electrical box1is an enclosed box enclosed on all sides and having conductor openings defined by the alignment of notches12in each half. AlthoughFIG. 4shows each half,30,31in a typical arrangement of four side walls2joined to a bottom (or top, depending on which half is considered) forming a rectangular box, the invention is not limited only to such a typical configuration. In general, any configuration of three or more side walls2will suffice. As with the box ofFIG. 1, the top edges4of side walls2define a peripheral open edge6of the open container1.

AlthoughFIG. 4shows two notches12per half, one on each of two opposing side walls2, there could be more, and only one notch per half is necessary for the present invention. For example, both conductors to be connected can be placed into the box1via one notch12and still enjoy the advantages of the present invention. The shape of notches12for conductor openings can be practically any geometric shape, and can be shaped to fit specific cross-sectional sizes of specific conductors. Further, it is contemplated that the notches12of the present invention can be fitted with suitable grommets or pliable seals to provide a weatherproof fitting at the conductor openings, as well as providing for some strain relief on the conductors. For example, as shown inFIG. 5, a substantially “U”-shaped seal16can be sized for suitably fitting to the edges of variously-sized notches12by methods known in the art, such as by press fitting about a longitudinally-oriented groove in seal16. Of course, any known sealing material, such as rubber, neoprene, polymeric elastomer materials, or other polymeric or pliable materials can be used for seal16. Likewise, any suitable shape and size of seal16can be incorporated for proper sealing properties. In fact, a generally circular, or other closed shape of seal can be used, recognizing that such a seal would necessarily need to be fitted onto the electrical conductor prior to making an electrical connection inside the box. The closed shape seal then could be appropriately positioned along the length of the electrical conductor until it coincided with notch12to make a weather proof seal after closing the two halves30and31together.

Two halves30and31can be held in a closed position to form electrical box1by any known means, including by screw connections in preformed holes34and threaded or threadable portions36. However, any connection means can be used, including snap together connection members, press-fit frictional engagement members, tape, adhesive, welding or other known method of joining metal or plastic parts together.

Notches12in sidewalls2can be made to be adjustably-sized. For example, notch12of side wall2shown inFIG. 6can be formed and/or made larger by removing frangibly-joined removable portions38as required for a particular wire or cable size. Frangible portions38can be separated at line of weakness39which can be a perforated line, a scored line, or otherwise weakened to frangibly break in a desired shape, such as the generally circular rounded shape shown inFIG. 6. Multiple lines of weakness39can permit various sizes of openings at notches12. Appropriately sized grommets or seals16as shown inFIG. 5can be utilized as necessary for a snug, strain-relieved, or water resistant fit about wires passing through notch12that, together with the mating notch of half30or31forms a conductor opening into electrical box1.

Another embodiment of electrical box1is shown inFIG. 7. As shown inFIG. 7, electrical box1can comprise at least three parts, a lower portion40, an intermediate portion41and a top or lid portion42. Similar to the electrical box shown inFIG. 4, the main difference is that intermediate portion41has neither a top or bottom, but is simply comprised of side walls2. Therefore, while lower portion40has a bottom associated therewith to form an open box structure, intermediate portion is open top and bottom. Once wire connections are made, lower portion and intermediate portion41can be brought together in a manner such that notches12engage in mating fashion to form wire or cable openings, which can be generally circular in shape. To close the box and secure it against the elements, top or lid portion42can be affixed, such as by screws as is known in the art. For example, screws can attach top portion42, intermediate portion41and lower portion40into an enclosed electrical box1by way of through holes34in top portion42, through channels35in intermediate portion41, and threaded or threadable holes36in lower portion40.

In another embodiment, partially shown inFIG. 8, top portion42and intermediate portion41can be joined by hinge10to form a hinged connection. Hinge10can be any of known hinges including living hinges formed by molding the two portions41and42together and using flexible, durable plastic material as is known in the art for living hinges on plastic parts and components.

Other known variations can be made to an electrical box1of the present invention without departing from the scope of the invention. For example, strain relief clamps can be positioned appropriately so as to provide for strain relief on the cables. In one embodiment, screw-down strain relief clamps as known in the art can be molded or otherwise joined to the outside of box1such that once the conductors are connected in the box1, the clamps are screwed tight to secure the conductors from undesirable tension on the connection. Further, various mounting means, such as screw holes, nail guides, brackets and the like, as are known in the art for mounting to joists and the like, can be utilized with box1. In general, therefore, any of known modifications to current electrical or junction boxes can be made to the box of the present invention.