Electrical assembly having an outlet with both power and communications connectors

An electrical assembly comprising an electrical box and a single gang electrical outlet having both a power connector and at least one communications connector and being supported in the box. The electrical outlet is receivable in the box, which has a barrier to isolate the power and communications connectors, but is not receivable in a standard box, which would not have the required barrier, due to the spacing and locations of the mounting fasteners and protrusions extending downwardly near the ends of the outlet. In addition to the electrical outlet with the power and communications connectors, the electrical box can receive a standard single gang outlet therein upon removal of the barrier.

FIELD OF THE INVENTION

The invention relates to an electrical assembly comprising an electrical box and a single gang electrical outlet having both a power connector and at least one communications connector, the outlet being supported in the box. A removable barrier is supported in the box to electrically isolate the power connector and the communications connector. When the barrier is removed, the electrical box can support a standard single gang outlet having two power connectors. The power/communications outlet is constructed so that it cannot be erroneously received in a standard electrical box which has no barrier therein, due to the spacing and locations of the mounting fasteners and protrusions extending downwardly near the ends of the outlet.

BACKGROUND OF THE INVENTION

Standard single gang electrical outlets typically have two power connectors for receiving electrical plugs from various electrical devices, such as lighting fixtures, computers, printers, telephones, toasters and other typical electrical devices found in homes and offices. With increased use of computers, televisions, and telephones, it is advantageous to have an outlet with at least one power connector and at least one communications connector, such as a coaxial television cable connector, and a voice and/or data cable connector, for their diversity.

However, known electrical outlets with both power and communications connectors have various disadvantages. Various electrical codes, for example, require a barrier between the power and communications connectors to electrically isolate for safety the relatively high voltage power connectors and the relatively low voltage communications convectors. This typically results in use of a barrier fixedly coupled to the electrical outlet or to the electrical box which complicates the manufacture process and increases manufacture costs. Fixedly connecting a barrier to an electrical box also limits the use of the box and increases inventories. In addition, due to the need for a barrier, electrical outlets supporting power connectors and communications connectors typically are formed as multi-gang outlets with two power connectors and two communications connectors, which increases manufacturing costs and provides unnecessary multiplicity of the connectors.

Complicating manufacture of outlets with power and communications connectors is the need to prevent these outlets from inadvertently being connected to conventional electrical boxes without the required barriers.

SUMMARY OF THE INVENTION

Accordingly, an object of the present invention is to provide a single gang electrical outlet with a power connector and at least one communications connector that is relatively easy and cheap to manufacture and use in different environments and with different types of electrical boxes.

A further object of the present invention is to provide an electrical outlet with a power connector and at least one communications connector that can releasably receive a barrier therein, which barrier is also releasably coupled to an electrical box.

A further object of the present invention is to provide an electrical outlet with a power connector and at least one communications connector that will not be inadvertently connected to a standard electrical box having no barrier.

A further object of the present invention is to provide an electrical box that can receive both a standard electrical outlet having two power connectors, and an electrical outlet having a power connector and at least one communications connector.

The foregoing objects are basically attained by providing a single gang electrical outlet, the combination comprising: a main body having a first flange at a first end for receiving a first mounting fastener and a second flange at a second end for receiving a second mounting fastener; a first set of apertures in said main body adjacent the first end; a power connector coupled to said main body and in communication with said first set of apertures; at least one additional aperture in said main body adjacent the second end; and a first communications connector coupled to said main body and in communication with said at least one additional aperture.

The foregoing objects are also basically attained by providing an electrical assembly, the combination comprising: an electrical box having first and second ends and having a first supporting flange at said first end and a second supporting flange at said second end; a single gang electrical outlet comprising a main body having a first mounting flange at a first end for receiving a first mounting fastener, and a second mounting flange at a second end for receiving a second mounting fastener, a first set of apertures in said main body adjacent the first end, a power connector coupled to said main body and in communication with said first set of apertures, at least one additional aperture in said main body adjacent the second end, and a first communications connector coupled to said main body and in communication with said at least one additional aperture; said power connector and said first communications connector defining a slot therebetween; and a barrier coupled to said box and located in said slot for separating the power and first communications connector, said first mounting fastener being received in said first supporting flange and said second mounting fastener being received in said second supporting flange to couple said outlet to said box.

The foregoing objects are also basically attained by providing an electrical box, the combination comprising: a housing having a longitudinal axis; a first supporting flange located on said housing having a first aperture therein intersected by said longitudinal axis and a second aperture therein and transversely spaced from said longitudinal axis; and a second supporting flange located on said housing having a third aperture therein intersected by said longitudinal axis and a fourth aperture therein and transversely spaced from said longitudinal axis, said first and third apertures adapted to receive electrical outlet mounting fasteners coupled to a first outlet, and said second and fourth apertures adapted to receive electrical outlet mounting fasteners coupled to a second outlet which is different from the first outlet.

Other objects, advantages, and salient features of the invention will become apparent from the following detailed description, which, taken in conjunction with the annexed drawings, discloses preferred embodiments of the invention as defined in the annexed claims.

DETAILED DESCRIPTION OF THE INVENTION

As seen inFIGS. 1-11, the electrical assembly10in accordance with the invention comprises an electrical junction box12and a single gang electrical outlet14supported in the box12, the outlet14having both a power connector16and two communications connectors18and20thereon. The box12has first and second supporting flanges22and24thereon to receive, respectively, first and second threaded mounting fasteners58and60on the outlet14. The box12has a vertical barrier26therein to separate the power connector16and the two communications connectors18and20as required by electrical codes.

Outlet14and box12have respective mounting fasteners58and60and threaded mounting apertures48and54that allow the outlet14to be securely mounted to the box12. However, the outlet14mounting fasteners58and60are so positioned that they cannot mount the outlet14to a standard electrical box, such as box208seen inFIG. 14, which would not have the required barrier therein. In addition, the outlet14has a pair of protrusions106and108that also prevent the outlet14from being mounted to a standard electrical box208. On the other hand, box12has additional apertures50and56in supporting flanges22and24to mount a conventional dual-connector electrical power outlet28, as seen inFIG. 11, to the box12, as desired.

As seen best inFIGS. 1,2and7-10, box12comprises a housing30having first and second side walls32and34, first and second end walls36and38, a bottom wall40, and a rectangular opening42defined by the side and end walls. The housing walls are preferably substantially planar, and the housing has a longitudinal central axis44extending between the first and second ends defined by first and second end walls36and38.

The housing30has the first supporting flange22located adjacent the first end wall36having a first threaded aperture50therein intersected by longitudinal axis44and a second threaded aperture48therein transversely spaced and offset from axis44in a first direction. The housing30also has the second supporting flange24located adjacent the second end wall38having a third threaded aperture56therein intersected by the axis44and a fourth threaded aperture54therein and transversely spaced from and offset from axis44in a second direction opposite the first offset direction of second aperture50. The centerlines of apertures50and56are separated by a distance “d”, which is less than the distance “e” between the centerlines of apertures48and54, as seen inFIGS. 2 and 11. Distance “d” is a standardized distance of about 3¼ inches on outlets having a length of about 3 inches and a width of about 1 7/16 inches. Distance “e” advantageously can be about 3⅝ inches.

The second and fourth apertures48and54are adapted to receive first and second mounting fasteners58and60from outlet14as seen inFIGS. 1-3and7, and the first and third apertures50and56are adapted to receive mounting fasteners62and64from standard conventional outlet28, as seen inFIG. 11, outlets14and28being different by having different electrical connectors supported thereon and by having mounting fasteners in different locations. Outlet28mounting fasteners62and64are also receivable, respectively, in apertures63and65in standard box208seen inFIG. 14which apertures have their centerlines also spaced a distance “d”. Box208also has additional flanges with apertures therein but they are for mounting the box to a wall not for mounting an outlet to the box.

As best seen inFIGS. 1,2, and8-10, first end wall36has a first upwardly-opening recess66therein at its top, and second end wall38has a second upwardly-opening recess68therein at its top, the first and second recesses being substantially U-shaped slots located on opposite sides of and transversely spaced and offset from axis44.

As seen inFIGS. 1,2and8, barrier26is a thin plate and is releasably coupled to housing30by being slidably received in first and second sets of vertically spaced slots70and72formed, respectively, in side walls32and34by series of opposed abutments74and76in side wall32and abutments78and80in side wall34. Two upwardly opening stabilizing slots82and84are formed in the top of barrier26to receive, respectively, downwardly directed edges in opposite sides of the outlet14main body86. Advantageously, barrier26is substantially planar, rectangular and made of non-conductive polymeric material.

As seen in FIGS.1and3-10, single gang electrical outlet14is comprised of a main polymeric body86having a first mounting flange88integrally formed with body86at a first end for receiving the first mounting fastener58, and a second mounting flange90integrally formed with body86at a second end for receiving the second mounting fastener60. The main body86has a first set of apertures92adjacent the first end in communication with the electrical power connector16rigidly coupled to the main body and delivering 15 or 20 amps. The main body has two additional rectangular apertures94and96adjacent the second end in communication with and receiving the two communications connectors18and20therein via a conventional snap-fit. The communications connectors transmit, for example, voice, data, or video information and can be connectors for coaxial cables, Category 5 cables, telephone lines, and audio equipment cables.

Once the power connector16and the two communications connectors18and20are received on the main body as seen in FIGS.1and3-10, they are spaced apart to define a vertical slot98therebetween below the main body. This slot98receives the barrier26therein once the outlet is connected to the box12to separate the power and communications connectors as required by electrical codes, as best seen inFIGS. 1,5and8.

The main body86has a longitudinal central axis100, seen inFIG. 3, extending between first and second ends of the body, the first mounting flange88having a first opening102for receiving the first mounting fastener58, this first opening being located on a first side and spaced and transversely offset from the axis100. The main body86second mounting flange90has a second opening104therein for receiving the second mounting fastener60, this second opening being located on a second side, which is opposite the first side, and spaced and transversely offset from the axis100. Main body86has a center point101midway between the ends and sides of the body, and a line103extending through center point101and the centerlines of openings102and104forms an angle “a” with longitudinal central axis100of about 8° to about 12° degrees, and preferably about 10°. Additional smaller openings105and107can be formed in outlet14along axis100for receipt of additional fasteners for further support and/or a face plate. Box12has additional threaded apertures51and55along axis44to receive such additional fasteners.

The first mounting flange88, as best seen inFIGS. 1,5,6and8-10, has a downwardly extending triangular first protrusion106that will be received in slot66in box12when the box12and outlet14are coupled together. Similarly, second mounting flange90has a downwardly extending triangular second protrusion108that will be received in slot68in box12when the box and outlet are coupled together. Advantageously, the outer straight edge of each protrusion106and108slidably engages the outer edges of slots66and68, respectively, to keep the outlet14and box12in the desired alignment, which has opening102in flange88aligned with aperture48in flange22so that fastener58is readily received in both, and opening104in flange90aligned with aperture54in flange22so that fastener60is readily received in both.

Assembly and Operation

To assemble the electrical box12and outlet14in a configuration to deliver both power and communication, the outlet14is first asssembled with power connector16and communications connectors18and20coupled to main body86as seen in FIGS.1and3-10. Barrier26is also inserted into housing30in box12.

Next, outlet14is aligned with box12such that fasteners58and60at opposite ends of the outlet14can be threadedly received in threaded apertures48and54at opposite ends of the box12, as indicated inFIGS. 1 and 7. At the same time, the protrusions106and108at opposite ends of the outlet14are aligned with and received in recesses66and68at opposite ends of the box12as seen inFIGS. 9 and 10. The fasteners58and60can then be tightened in apertures48and54as seen inFIGS. 7 and 8.

When the outlet14is received on box12, the barrier26is fully received in the slot98between power connector16and communications connectors18and20, and preferably the top of the barrier26engages the bottom of the main body86in the outlet14. This placement of the barrier safely separates the power and communications connectors.

If an installer were to try to couple the outlet14to a conventional electrical box208as seen inFIG. 14, the outlet would not align with or fit with the box. The transversely offset fasteners58and60do not align with the standard locations of the threaded apertures63and65on a standard electrical box, which are separated by a distance “d” and are substantially along the longitudinal central axis of the box208. As illustrated inFIG. 11, the longitudinal axis110of a standard outlet28would align with such an axis in a standard box208and fasteners62and64would threadedly mate with threaded apertures63and65in box208.

In addition, the protrusions106and108on the outlet14would engage the top edges of the ends of the standard box208, thereby preventing the outlet14from being received in the standard box208.

On the other hand, if desired, the standard outlet28shown inFIG. 11can be coupled to box12by engaging standard mounting fasteners62and64on box12in standard apertures50and56as shown inFIG. 1, which are located in positions and spaced a distance “d” to readily receive fasteners62and64.

Preferably before the outlet14is actually coupled to the box12, suitable electrical power conduits and communications cables are introduced into the inside of the box through suitably removed knockout discs and the conduits and cables are coupled to the power and communications connectors in a conventional manner.

As seen inFIGS. 12 and 13, a second embodiment of the present invention utilizes the same single gang electrical outlet14of FIGS.1and3-10but with a round PVC floor box112and a removable tubular barrier126to form electrical assembly111.

The PVC floor box112comprises a tubular body114with hollow electrical conduit hubs116,118,120and122at the bottom, a tubular carpet flange124slidably received in the tubular body114, and a leveling ring128engaging the bottom of the carpet flange124and slideably engaging the inner surface130of the tubular body, the ring128having a plurality of flexible legs that resiliently engage the inner surface of the tubular body.

A circular platform132is located near the bottom of the tubular body114and supports the tubular barrier126thereon. The barrier126is advantageously formed by a left side wall134, a right side wall136, a rear wall138, and a front wall140, these walls being slightly upwardly and inwardly tapered and forming a substantially rectangular transverse cross section for the barrier126. As in the previous embodiment, barrier126is advantageously formed of polymeric material and electrically isolates the relatively low voltage communications connectors18and20on outlet14from the relatively high voltage power connector16once the outlet14and box112are fully connected. Advantageously, platform132has an opening therein communicating with the inside of barrier126so the electrical wires from the hubs can be attached to the communications connectors.

The carpet flange124has opposed, inwardly-facing first and second supporting flanges142and144rigidly coupled thereto having suitable threaded apertures145and146therein, like apertures48and54in outlet14, to similarly receive mounting fasteners58and60, as in outlet14, to couple the outlet14to box112. Likewise, these first and second supporting flanges142and144have suitable threaded apertures147and148therein, like apertures50and56in outlet14, to receive mounting fasteners62and64in a standard outlet28seen inFIG. 11having two power connectors therein as desired. As seen inFIG. 13, apertures147and148have their centerlines separated by a distance “d” that is less than the distance “e” between the centerlines of apertures145and146receiving fasteners58and60in outlet14. Therefore, standard outlet28inFIG. 11can be coupled to box112if desired, but outlet14cannot be inadvertently coupled to a standard box208seen inFIG. 14.

As seen inFIG. 13, flange142has a recess149formed therein offset transversely from aperture145, and flange144has a recess151formed therein offset transversely from aperture146, these recesses receiving the protrusions106and108on outlet14therein when the outlet is coupled to box112as seen inFIG. 12.

To assemble the electrical assembly shown inFIGS. 12 and 13formed from outlet14and box112, first electrical wires are run through the hubs116,118,120and122and then up through suitable openings in the platform132to be connected to the power connector16and through the opening below the barrier126and through the barrier to be connected to the communications connectors18and20. Platform132can be adjusted vertically relative to the top of body114as desired.

Next, the outlet14is coupled via mounting fasteners58and60to the supporting flanges142and144on carpet ring124with protrusions106and108fitting into recesses149and151. Then carpet ring124, leveling ring128and outlet14are moved downwardly into tubular body114to the desired height until the top of the barrier126engages the bottom of main body86of outlet14. In this position, right side wall136of barrier126is fully received in slot98between the power connector16and the two communications connectors18and20to isolate them from one another and the entire barrier126surrounds the two communications connectors.

Advantageously, barrier126is removably coupled to platform132, by being snap-fitted into a suitable opening in the platform for example, so it can be removed and a standard electrical outlet28, seen inFIG. 11, can be installed instead of outlet14, as desired, with mounting fasteners62and64being threadedly received in apertures147and148.

As seen inFIG. 15, a third embodiment of the present invention uses the same single gang electrical outlet14of FIGS.1and3-10but with an under cabinet or counter box150and a planar removable barrier152to form electrical assembly154.

Box150has a bottom wall156, a left side wall158, a right side wall160, a low front wall162, and a rear wall164hingedly supporting a curved top wall166thereon, the top wall having an opening168to allow access from the outside of the box150to the outlet14.

Box150has a series of abutments170,172,174,176,178and180defining four slots182,184,186and188for removably supporting the barrier152in the box150. As seen inFIG. 15, the barrier152is supported by the slots formed in the rear wall164, bottom wall156, front wall162, and has two upwardly-opening slots190and192therein for receiving side edges of the outlet14main body86.

Box150has opposed, inwardly-facing first and second supporting flanges194and196rigidly coupled, respectively, to left and right side walls158and160, having threaded apertures198and200, respectively, therein for threadedly receiving threaded fasteners60and58as seen inFIG. 15to couple outlet14to box150. In this case, flanges194and196are planar and the protrusions106and108on outlet14do not engage or interfere with the flanges since apertures198and200are located close enough to the edges of the flanges.

As in box14and box112inFIGS. 1-12above, the first and second supporting flanges194and196have threaded apertures202and204therein along the longitudinal central axis206of the box150, as seen inFIG. 15, and at a standard distance apart to receive therein mounting fasteners62and64in a standard outlet28seen inFIG. 11having two power connectors therein, as desired.

Once box150is located in its desired place under a cabinet or counter, suitable electrical wires can be introduced into the inside of the box via removable of knock-out discs. The barrier152is put in place and the electrical wires are suitably connected to the power connector16and communications connectors18and20. Then, the outlet14can be coupled to the box150via fasteners58and60and apertures198and200in the flanges on the box, with the barrier152being received in the slot98between the power and communications connectors to isolate them. Finally, the top wall166can be closed with the outlet14being accessible via opening168for placement of an electrical plug into the power connector16and a coaxial TV cable and computer or telephone cable into the communications connectors18and20.