Integrated electrical receptacle system for outdoor application

The present invention is directed to a receptacle assembly for receiving and attaching to a support an electrical device connectable to an electrical conductor. The receptacle assembly has an enclosure, a first mount, and a second mount. The enclosure has a sidewall with an outer surface having a shape generally corresponding to a shape of an outer surface of a body formed by the intersection of a first cylinder eccentric to a second cylinder. The enclosure has a first opening for receiving the electrical device and a second opening for receiving the electrical conductor. The first mount is connected to the enclosure for attaching the receptacle assembly to the support. The second mount is connected to the enclosure for securing the electrical conductor to the enclosure.

BACKGROUND OF THE INVENTION

This invention relates to an integrated electrical receptacle system for outdoor application. More particularly, this invention relates to a system comprising an electrical receptacle mountable in chambered cast-concrete blocks and masonry stones for providing electrical outlets on the exterior surfaces of buildings, retaining walls and outdoor structures.

It is often desired to provide electricity to areas outside of commercial and industrial buildings along with residential properties. Although many such buildings have electrical outlets installed on an outside wall, the outlet, when found on concrete and masonry block construction, is typically powered in a “surface mount” method; i.e. a cable is inserted through metal or plastic conduit that runs along the outside wall of the building and through a portion of the foundation of the structure.

The “surface mount” method of installation has several drawbacks; the outlet is not protected by the structure of the building; locating and installing outlets in a “surface mount” manner is difficult and time consuming; and the outlet is exposed to a variety of moisture from various sources. In time, outlets installed in this manner can break open exposing electrical current carrying parts, which present a dangerous shock hazard.

The present invention allows for multiple electrical connections to be placed in various locations in stone, masonry block and concrete foundations without incurring any of the aforementioned drawbacks. The invention allows for electrical and other types of low voltage outlets such as signals for cable television, telephone/internet access, lighting and stereo speaker wires to located within the masonry block structure itself instead of on its surface. This protects the outlet from moisture and traffic damage, makes it easier to install when the building is originally being constructed and prevents dangerous shock hazards due to loose or broken outlet fixtures.

The present invention allows multiple electrical connections to be placed in various stone, masonry and block structures without incurring any of the aforementioned drawbacks.

BRIEF SUMMARY OF THE INVENTION

Briefly stated, one embodiment of the present invention is directed to a block supporting at least one electrical connection and enclosing in a conduit at least one electrical conductor in electrical communication with the at least one electrical connection, the block having a cavity, a front surface and a rear surface. The front surface bears an opening to the cavity. The at least one electrical connection is disposed in the cavity to be accessible via the opening in the front surface of the block. The at least one electrical conductor extends between the at least one electrical connection and the rear surface of the block, wherein the at least one electrical connection and the at least one electrical conductor enclosed in the conduit are electrically insulated from the block and are insulated from moisture in the block.

The present invention is alternatively directed to a combination of a block and a device for enclosing in a conduit at least one electrical conductor and for supporting at least one electrical connection. The combination includes the block having a cavity for receiving the device, a front surface and a rear surface. The device includes a box having a chamber therein, a front side and a rear side. The front side bears a first opening to the chamber and the rear side bears a second opening to the chamber. The box is positioned in the cavity with the front side generally aligned with the front surface of the block. The at least one electrical connection is generally disposed in the chamber of the box to be accessible from the front surface of the block. A tube is positioned on the rear side of the box and has a chute therethrough. The chute is aligned with the second opening to the chamber. The tube is at least partially disposed in the cavity and generally extends from approximately the rear side of the box to approximately the rear surface of the block. The at least one electrical conductor extends through the tube and is in electrical communication with the at least one electrical connection.

The present invention is alternatively directed to a device for enclosing in a conduit at least one electrical conductor and for supporting at least one electrical connection. The device includes a box having a chamber therein, a front side and a rear side. The front side bears a first opening to the chamber and the rear side bears a second opening to the chamber. The box has a flange disposed around the front side of the box and oriented generally parallel relative to the rear side of the box. The flange has a first major surface for receiving a face plate. The at least one electrical connection is generally disposed in the chamber of the box and is positioned proximate to the front side of the box. A tube is positioned on the rear side of the box and has a chute therethrough. The chute is aligned with the second opening to the chamber. At least one electrical conductor extends through the tube and is in electrical communication with the at least one electrical connection.

The present invention is alternatively directed to receptacle assembly for containing an electrical device and a length of an electrical conductor extending from a supply conduit to the electrical device. The receptacle assembly is mountable in a block having a first side and a second side opposed to and spaced a first distance from the first side. The first side has a first exterior surface and a first interior surface. The second side has a second exterior surface and a second interior surface. A cavity extends from the first interior surface to the second interior surface. The cavity has a first cavity opening in the first side and a second cavity opening in the second side. The receptacle assembly comprises an enclosure, a flange, a hub, a tubular member and a conduit coupling. The enclosure has a unitary wall forming a chamber for containing the electrical device. The unitary wall has a first chamber opening for providing access to the electrical device. The first chamber opening corresponds to the first cavity opening. The flange is integral with the unitary wall and attaches the receptacle assembly to the block. The hub is integral with the unitary wall and provides a second chamber opening for receiving a portion of the length of the electrical conductor. The tubular member has a first longitudinal axis, a first end and a second end. The tubular member extends from the hub to the second cavity opening. The first end is joined to the hub. The conduit coupling has a first coupler and a second coupler. The first coupler is joined to the second end of the tubular member. The second coupler is for being joined to the supply conduit. The receptacle assembly forms a passageway within the cavity. The passageway has a second longitudinal axis and extends from the first exterior surface of the block to the second exterior surface of the block. The passageway is impermeable to fluid in the block.

The present invention is alternatively directed to a block for containing a receptacle assembly. The receptacle assembly has a passageway for containing an electrical device and a length of an electrical conductor. The passageway has a second longitudinal axis. A first portion of the passageway has an outer surface having a first shape generally corresponding to a shape of an outer surface of a body formed by the intersection of a first cylinder with a second cylinder. The first cylinder has a third longitudinal axis. The second cylinder has a fourth longitudinal axis. The third longitudinal axis is coaxial with the second longitudinal axis of the passageway. The fourth longitudinal axis is generally parallel to and spaced-apart from the third longitudinal axis. A second portion of the passageway has a generally circular cross sectional shape. The block comprises a first side, a second side and a cavity. The first side has a first exterior surface and a first interior surface. The second side is opposed to and spaced from the first side. The second side has a second exterior surface and a second interior surface. The cavity extends from the first interior surface to the second interior surface. The cavity has a first cavity opening in the first side and a second cavity opening in the second side. The first cavity opening has a third sidewall extending from the first exterior surface of the first side to the first interior surface of the first side. The third sidewall circumscribes the first cavity opening and has a third shape generally corresponding to the first shape of the outer surface of the first portion of the passageway. The second cavity opening has a fourth sidewall extending from the second exterior surface of the second side to the second interior surface of the second side. The fourth sidewall circumscribes the second cavity opening and has a fourth shape generally corresponding to the generally circular cross-sectional shape of the second portion of the passageway. The second cavity opening has a fifth longitudinal axis coaxial with the third longitudinal axis of the first cylinder.

The present invention is alternatively directed to a method for preparing a block for receiving a receptacle assembly having a passageway. The passageway has a second longitudinal axis. A first portion of the passageway has an outer surface having a first shape generally corresponding to a shape of an outer surface of a body formed by the intersection of a first cylinder with a second cylinder. The first cylinder has a third longitudinal axis. The second cylinder has a fourth longitudinal axis. The third longitudinal axis is coaxial with the second longitudinal axis of the passageway. The fourth longitudinal axis is generally parallel to and spaced a second distance from the third longitudinal axis. A second portion of the passageway has a generally circular cross sectional shape. The block has a first side and a second side opposed to and spaced a first distance from the first side. The first side has a first exterior surface and a first interior surface. The second side has a second exterior surface and a second interior surface. A cavity extends from the first interior surface to the second interior surface. The method comprising the following steps: drilling a first circular opening through the first side of the block, the first circular opening forming a first cavity opening, the first circular opening having a sixth longitudinal axis corresponding to the to the second longitudinal axis of the passageway; drilling a second circular opening through the first side of the block, the second circular opening having a seventh longitudinal axis corresponding to the fourth longitudinal axis; and drilling a third circular opening through the second side of the block, the third circular opening forming a second cavity opening, the third circular opening having an eighth longitudinal axis coaxial with the sixth longitudinal axis.

The present invention is alternatively directed to a method for preparing a block for receiving a receptacle assembly having a passageway. The passageway has a second longitudinal axis. A first portion of the passageway has an outer surface having a first shape generally corresponding to a shape of an outer surface of a body formed by the intersection of a first cylinder with a second cylinder. The first cylinder has a third longitudinal axis. The second cylinder has a fourth longitudinal axis. The third longitudinal axis is coaxial with the second longitudinal axis of the passageway. The fourth longitudinal axis is generally parallel to and spaced a second distance from the third longitudinal axis. A second portion of the passageway has a generally circular cross sectional shape. The block has a first side and a second side opposed to and spaced a first distance from the first side. The first side has a first exterior surface and a first interior surface. The second side has a second exterior surface and a second interior surface. A cavity extends from the first interior surface to the second interior surface. The method comprising the following steps: drilling with a first-step corer of a three-step coring drill a pilot bore through the first side of the block, the pilot bore having a sixth longitudinal axis corresponding to the second longitudinal axis of the passageway; extending the first-step corer through the pilot bore to the interior surface of the second side of the block; drilling with the first-step corer a second cavity opening through the second side of the block; extending the first-step corer through the second cavity opening; drilling with a second-step corer of the three-step coring drill, the second corer having a diameter larger than the first corer, a first circular opening through the first side of the block; extending the second-step corer through the first circular opening; drilling with a third-step counter-borer of the three-step coring drill a first counter bore in the first side of the block; withdrawing the three-step coring drill from the block; removing the first-step corer from the three-step coring drill; drilling with the second-step corer a second circular opening through the first side of the block, the second circular opening having a seventh longitudinal axis corresponding to the fourth longitudinal axis; extending the second-step corer through the second circular opening; drilling with the third-step counter-borer a second counter bore in the first side of the block; and withdrawing the three-step core drill from the block.

The present invention is alternatively directed to a receptacle system for containing an electrical device and a length of an electrical conductor extending from a supply conduit to the electrical device. The receptacle system comprises a block and a receptacle assembly. The block comprises a first side, a second side and a cavity. The first side has a first exterior surface and a first interior surface. The second side is opposed to and spaced a first distance from the first side. The second side has a second exterior surface and a second interior surface. The cavity extends from the first interior surface to the second interior surface. The cavity has a first cavity opening in the first side and a second cavity opening in the second side. The receptacle assembly comprising an enclosure, a flange, a hub a tubular member and a conduit coupling. The enclosure has a unitary wall forming a chamber for containing the electrical device. The unitary wall has a first chamber opening for providing access to the electrical device. The first chamber opening corresponds to the first cavity opening. The flange is integral with the unitary wall and is attached to the block. The hub is integral with the unitary wall and provides a second chamber opening for receiving a portion of the length of the electrical conductor. The tubular member has a first longitudinal axis, a first end and a second end. The tubular member extends from the hub to the second chamber opening. The first end is joined to the hub. The conduit coupling has a first coupler and a second coupler. The first coupler is joined to the second end of the tubular member. The second coupler is for being joined to the supply conduit. The receptacle assembly forms a passageway within the cavity. The passageway has a second longitudinal axis and extends from the first exterior surface of the block to the second exterior surface of the block. The passageway is impermeable to fluid within the block.

The present invention is alternatively directed to a receptacle assembly for receiving and attaching to a support an electrical device connectable to an electrical conductor, the receptacle assembly comprising an enclosure, a first mount and a second mount. The enclosure has a sidewall with an outer surface having a shape generally corresponding to a shape of an outer surface of a body formed by the intersection of a first cylinder eccentric to a second cylinder. The enclosure has a first opening for receiving the electrical device and a second opening for receiving the electrical conductor. The first mount is connected to the enclosure for attaching the receptacle assembly to the support. The second mount is connected to the enclosure for securing the electrical conductor to the enclosure.

The present invention is alternatively directed to a receptacle assembly for containing an electrical device and a length of a non-metallic sheathed electric cable to the electrical device. The receptacle assembly is mountable in a block having a first side and a second side, the first side having a first exterior surface and a first interior surface, the second side having a second exterior surface and a second interior surface. A cavity extends from the first interior surface to the second interior surface. The cavity has a first cavity opening in the first side and a second cavity opening in the second side. The receptacle assembly comprises an enclosure, a first mount and a second mount. The enclosure has a unitary wall forming a chamber for containing the electrical device. The unitary wall has a first chamber opening for providing access to the electrical device. The first chamber opening corresponds to the first cavity opening. The first mount is connected to the unitary wall for securing the enclosure to the block. The first mount comprises a flange circumscribing the outer surface of the unitary wall proximal to the first chamber opening and a retainer pivotably connected to the unitary wall. The retainer is pivotable about a retainer axis between a retracted position and an extended position and is movable along the retainer axis between a disengaged position and an engaged position. The first mount secures the enclosure to the block when the first side of the block is positioned between the flange and the retainer and the retainer is in the extended and engaged positions. The second mount is integral with the unitary wall and is configured to provide a second chamber opening for receiving a portion of the length of the electrical cable, and to connect the electrical cable to the unitary wall.

DETAILED DESCRIPTION OF THE INVENTION

Certain terminology is used in the following description for convenience only and is not limiting. The words “right,” “left,” “lower” and “upper” designate directions in the drawings to which reference is made. The words “inwardly” and “outwardly” refer to directions toward and away from, respectively, the geometric center of a combination block and device, and designated parts thereof. The word “a,” as used in the claims and in corresponding portions of the specification, means “at least one.” The term “connected” means that there exists between any two or more elements a structural path, which may include additional elements not explicitly recited. The word “block,” as used in the claims and in the corresponding portions of the specification, means “any one of a brick, a concrete block, a masonry block, a masonry unit, a block, and a stone.” The term “building,” as used in the claims and in the corresponding portions of the specification, means “any one of a house, a commercial establishment, an apartment unit, a commercial building, and a factory.” The terminology includes the words noted above, derivatives thereof and words of similar import.

Referring to the drawings in detail, wherein like numerals represent like elements throughout,FIGS. 1 and 2illustrate a block, generally designated as600′, supporting at least one electrical connection according to the present invention.FIGS. 3-5illustrate a modular outlet assembly, generally designated as700, according to the present invention.FIGS. 6-10and14illustrate portions of a first preferred embodiment of a device, generally designated as800, for supporting at least one electrical connection according to the present invention.FIGS. 11-13illustrate portions of a second preferred embodiment of a device, generally designated as800′, for supporting at least one electrical connection according to the present invention.

While one embodiment of electrical conductors and connections is discussed in detail in conjunction withFIG. 2, those of ordinary skill in the art will appreciate from this disclosure that similar electrical conductors and connections can be used with any of the devices shown in the drawings. Accordingly, reference to the electrical conductors and connections shown inFIG. 2will be made throughout the specification while discussing embodiments of the present invention illustrated in other figures with the understanding that similar electronic structures, or their equivalents, can be used with each of the disclosed embodiments of the present invention.

Referring toFIG. 2generally speaking, a block600′ supports at least one electrical connection604,606, or608and encloses at least one electrical conductor622a,622b,622c,624a, or624bin electrical communication with the at least one electrical connection604,606, or608. The block600′ has a cavity603, a front surface602and a rear surface612. The front surface602bears an opening603′ to the cavity603. The at least one electrical connection604,606, or608is disposed in the cavity603to be accessible via the opening603′ in the front surface602of the block600′. The at least one electrical conductor622a,622b,622c,624a, or624bextends between the at least one electrical connection604,606, or608and the rear surface612of the block600′, wherein the at least one electrical connection604,606, or608and the at least one electrical conductor622a,622b,622c,624a, or624bare electrically insulated from the block600′ and are insulated from moisture in the block600′.

Referring toFIGS. 2,6-10and14, the combination of the block600′,600and the device800preferably encloses at least one electrical conductor622a,622b,622c,624a, or624band supports at least one electrical connection604,606, or608. The block600′,600has a cavity603that preferably receives the device800and has a front surface602and a rear surface612. The device800preferably includes a box802having a chamber804therein. The box802preferably has a front side806and a rear side808. The front side806bears a first opening810to the chamber804and the rear side808bearing a second opening812to the chamber804.

The box802is positioned in the cavity603with the front side806generally aligned with the front surface602of the block600. The term “generally aligned” encompasses the front side806being recessed into the block600(as shown inFIG. 14) and encompasses the front side806of the box802protruding marginally from the block600. Accordingly, those of ordinary skill in the art will appreciate from this disclosure that the front surface806of the box802can be slightly recessed into the block600to allow a face plate832(shown in phantom inFIGS. 12 and 13) to be generally flush (or slightly recessed) with the front portion602of the block600without departing from the scope of the claimed invention. Additionally, those of ordinary skill in the art will appreciate, that the front surface806of the box802can extend slightly from the front portion602of the block600while still being generally aligned with the front surface602of the block600.

The at least one electrical connection604,606, or608is generally disposed in the chamber804of the box802to be accessible from the front surface602of the block600. Those of ordinary skill in the art will appreciate from this disclosure that the at least one electrical connection can protrude partially outwardly from the chamber804while still being generally disposed in the chamber804. A tube (or conduit)814is positioned on the rear side808of the box802and has a chute816extending therethrough. The chute816is preferably aligned with the second opening812to the chamber804. The tube814is preferably at least partially disposed in the cavity603and generally extends from the rear side808of the box802to the rear surface612of the block600. The at least one electrical conductor622a,622b,622c,624a, or624bextends through the tube814and is in an electrical communication with the at least one electrical connection604,606, or608.

Additionally, the combination block600and device800,800′ can be used to form part of an exterior wall of a building having at least one electrical connection604,606, or608accessible from outside the building. Referring toFIG. 1, such a building would include an exterior wall605having a wall exterior surface607disposed outside of the building. The exterior wall605preferably includes the block600having the cavity603for receiving the device800,800′, a front surface602and a rear surface612.

Referring toFIG. 2, a front portion602of the block600′ preferably, but not necessarily, includes at least one electrical outlet604, at least one telephone connector606or at least one cable connector608. A rear portion612of the block600′ preferably includes first and second junction boxes614,634which will be discussed in more detail herein. The block600′ preferably has a cavity603comprising two channels616,618extending from the front602to the rear612of the block600′. The cavity603preferably, but not necessarily, contains at least one electrical channel, such as a power channel616and a low voltage channel618.

Referring to the block600′ shown inFIGS. 1 and 2, the channels616,618are preferably separated by a partition620. The power channel616may include a plurality of conductors622including a hot conductor622a, a neutral conductor622b, and a ground conductor622cfor transmitting electrical power from the rear612of the block600′ to the front602of the block600′. The low voltage channel618preferably includes low voltage cables624connecting the rear612of the block600′ to the surface602of the block600′. The low voltage cables624can include co-axial cables624a, telephone cables624b, or other multi-conductor cables (not shown).

Referring toFIG. 2, the second junction box634includes a first opening626at a forward end of the junction box634which is in communication with the power channel616. The plurality of conductors622extend through the first opening626and terminate within the junction box634. The second junction box634preferably includes a removable cover628at a rear end of the second junction box634opposite the first opening626. The cover628preferably includes a conduit connection630to connect the interior of the second junction box634to a well known electrical conduit fitting632(in phantom). Also preferably, the cover628includes a gasket629or other type of seal to provide a watertight seal between the cover628and the second junction box634.

The electrical insulation and moisture insulation between the block600′ and the at least one electrical connection604,606, or608and the at least one electrical conductor622a,622b,622c,624a, or624bis preferably provided by a PVC sheath or similar dielectric material. However, those of ordinary skill in the art will appreciate from this disclosure that various other suitable materials, such as rubber, can be used to provide electrical and moisture insulation from the block600′, or the surrounding blocks, without departing from the scope of the present invention.

The first junction box614preferably includes a first opening636at a forward end of the junction box614which is in communication with the low voltage channel618. The plurality of low voltage conductors624extend through the first opening636and terminate at appropriate connectors606,608within the first junction box614. The first junction box614also preferably includes a removable cover638at a rear end of the first junction box614opposite the first opening636. The cover638preferably includes a conduit connection640to connect the interior of the first junction box614to a well known electrical conduit fitting642(shown in phantom lines in FIG.2). Also preferably, the cover638includes a gasket639or other type of seal to provide a watertight seal between the cover638and the first junction box614.

Those skilled in the art will recognize that, instead of first and second junction boxes614,634, a single junction box (not shown) can be used with the block600′ for terminating the plurality of conductors622and for supporting at least one electrical connector606,608shown in FIG.2. It is preferable that the power channel616and the low voltage channel618are separated by a solid partition620and that two separate conduit connectors, one on either side of the partition620, are used. Additionally, instead of two separate covers628,638, a single cover (not shown) can be used.

The block600′ can be, but is not necessarily, constructed from a polymeric material or some other suitable dielectric material. If the block600is constructed of a polymeric material, the block600′ is preferably shaped and colored similarly to other construction or decorative blocks surrounding the block600′ to blend in with those blocks. Also, the front602of the block600′ preferably, but not necessarily, includes a power cover644and a low voltage cover646(shown inFIG. 1) which are each hingedly connected to the block600′. Each cover644,646is pivotable between a first, closed position covering the at least one electrical connection604,606, or608and a second, open position exposing each of the respective outlets or connections. In the closed position, the covers644,646preferably seal the respective outlets604or connections606,608, forming a generally watertight seal over the outlets or connections. Also, the covers644,646can preferably be locked closed either individually or as a group, preferably by a well known lock hasp and a padlock arrangement (not shown). However, those skilled in the art will recognize that the covers644,646can be locked in the closed position by other methods as well.

The block600′ is preferably, but not necessarily, constructed so that the block600′ can be located at any level of the wall as shown in FIG.2and so that the block600′ can support the weight of any subsequent blocks stacked upon the block600. Additionally, the block600′ can include at least one speaker connection834(shown inFIG. 13) disposed within the cavity603or within the device800,800′. While a speaker connection is shown in device800′, those of ordinary skill in the art will appreciate from this disclosure that the speaker connection834can optionally be added to the block600′ shown inFIGS. 1 and 2or to the first preferred embodiment of the device800.

To connect the block600′ to a power or low voltage source (not shown), the user preferably runs conduits632,642to the rear side612of the block600′. To access a junction box614,634, the cover628,638is preferably removed from the block600′. If power cables are being run, the ends of the power cables are run through the conduit632and through the conduit connection630in the cover628and are then connected to the conductors622in the second junction box634. The cover628is then reinstalled on the junction box634and the conduit fitting632is connected to the conduit connection630. If low voltage cables are being run, the ends of the low voltage cables are run through the conduit642and through the conduit connection640in the cover638and the end connectors (not shown) are connected to the connectors606,608injunction box634. The cover638is then reinstalled on the junction box634and the conduit fitting642is connected to the conduit connection640.

Although the junction boxes614,634are preferably located at the rear612of the block600′, those skilled in the art will recognize that the junction boxes614,634can be located on other sides of the block600′ as well.

Those of ordinary skill in the art will appreciate from this disclosure that other methods of conveying power to the at least one electrical connection604,606, or608can be used without departing from the scope of the present invention. For example, electrical connections can be disposed on both sides of the block600′.

Referring toFIGS. 6-10and14, a first preferred embodiment of a device800for use with a block600is shown. Referring toFIG. 8, the box802is preferably formed as a separate piece from the tube814. Referring toFIG. 7, the box802preferably has a generally rectangular box-like shape. However, those of ordinary skill in the art will appreciate from this disclosure that the box802can have any shape without departing from the scope of claimed invention. For example, the box802can be hemispherical, elliptical, rectangular, irregularly shaped or the like without departing from the scope of the present invention. For example, referring toFIGS. 11-13, a box802having a generally cylindrical shape is shown.

During the assembly of the first preferred embodiment of the device800, a watertight seal using a molded in PVC joint832is preferably formed between the tube814and the box802. It is preferred, but not necessary, that the device800be formed of PVC material. However, those of ordinary skill in the art will appreciate from this disclosure that various materials can be used to form the device800without departing from the scope of the present invention. Additionally, those of ordinary skill in the art will appreciate from this disclosure that the tube814and the box802can be formed as a single element without departing from the scope of the claimed invention.

Referring toFIGS. 7 and 11, the device800,800′ preferably, but not necessarily, includes a flange818disposed around the front side806of the box802which is oriented generally parallel relative to the front surface of the block600. Those of ordinary skill in the art will appreciate from this disclosure that many types of block600do not have an even planar front surface and, accordingly, it is only possible to be generally parallel with the average front surface602of a block600. Thus, the term “generally parallel” as used in the claims and in the corresponding portions of the specification should not be interpreted to exclude the use of the device800,800′, with blocks having a curved, decorative, or irregular front surfaces (as shown in FIG.14). Instead, generally parallel should be interpreted to mean generally parallel to the overall front surface of the block or wall of which the block600is a part.

The flange preferably bears fastener holes830to allow an outlet plate832(shown in phantom lines inFIGS. 12 and 13) to be secured over the first opening810of the box802. Those of ordinary skill in the art will appreciate that various methods can be used to secure the outlet plate832to the device800,800′ or that the outlet plate832can be omitted altogether without departing from the scope of the present invention.

Referring toFIGS. 6 and 7, the flange818preferably has a first major surface820for receiving a face plate and preferably has a second major surface822for at least partially abutting the block600, as shown in FIG.14. WhileFIG. 14shows the device800seated off-center in the block600, those of ordinary skill in the art will appreciate that the position of the device800within the block600can be varied without departing from the scope of the present invention. Referring to the second embodiment of the device800′ shown inFIG. 11, the front side806of the box802is preferably designed to accommodate a round electrical cover plate832. Those of ordinary skill in the art will appreciate from this disclosure, that the front806of the device800,800′ and the cover plate832can have any desired shape without departing from the scope of the present invention.

Referring toFIG. 14, the flange818is preferably, but not necessarily, aligned with the front surface602of and recessed into the block600. Referring toFIG. 7, an adhesive824is preferably, but not necessarily, disposed on the second major surface822of the flange818to securely engage the box802with the block600. The adhesive is preferably, but not necessarily, disposed on the second major surface in a plurality of strips of adhesive.

The second major surface822preferably includes grooves826which allow fluid to drain without contacting the adhesive824. Referring toFIG. 8, the tube816preferably extends generally perpendicularly from the rear side808of the box802. The term generally perpendicularly as used in the claims means within about thirty degrees of perpendicular from the rear side808of the box802which is comparable to the tolerance error which can occur on a construction site with such an item. More preferably still, the term generally perpendicular, as used in the claims, means within about fifteen (15) degrees of perpendicular from the rear surface612of the block600. Referring toFIGS. 6 and 9, a wire clamp828is preferably, but not necessarily, disposed within the chamber804for securing at least one electrical conductor622a,622b,622c,624a, or624b.

It is preferable that the at least one electrical connection604,606, or608include at least one electrical outlet604, at least one phone jack606, or at least one cable connector608. It is more preferable, that the at least one electrical connection include at least one electrical outlet604and at least one phone jack606. It is more preferable still, that the at least one electrical connection include at least one electrical outlet604, at least one phone jack606and at least one cable connector608.

The present invention also includes a method of forming a block600for receiving a device800,800′ which extends from approximately a rear, or first, side612of the block600to approximately a front, or second, side602of the block600. The device800,800′ is adapted to convey at least one electrical conductor622a,622b,622c,624a, or624bto at least one electrical connector604,606, or608positioned proximate to the second side602of the block600. The device800,800′ includes a box802having a front side806and a rear side802. A tube814is positioned on the rear side808of the box802and generally extends outwardly from the rear side808of the box802. The method of forming the block600for receiving the device preferably includes positioning a mold to receive material to be formed into a block600having a cavity603for receiving the device800,800′. The cavity603is formed so that when the device is placed in the cavity603the front side806of the box802is generally aligned with the second side602of the block600and so that the tube814extends from the rear side808of the box802to approximately the first side612of the block600. The method of the present invention also includes placing material in the mold and removing the block from the mold. Processes for molding blocks are set forth in detail in U.S. Pat. Nos. 5,277,853, 5,887,401, and 6,113,379 which are each hereby incorporated by reference herein in their entirety.

As shown inFIGS. 3-5, as an alternative to using blocks, the electrical cables can be run to outlets720and/or connectors722,724mounted in a railing section700, particularly in a side post702, a top rail704or a spindle706. The modular outlet assembly can be in the form of other items typically found in a residential or commercial outdoor environment, including, but not limited to, a water fountain (not shown), a statue (not shown), or a piece of furniture (not shown).

The railing section700is preferably constructed from a dielectric material, and more preferably, from a plastic or other suitable polymeric material. Preferably, a junction box708is located on the railing section700, such as, by way of example and not meant to be limiting, along a bottom rail as shown in FIG.3. The junction box708is similar to, and preferably identical to, the junction boxes614,634described above in connection with the block600, and includes connections (not shown) for an electrical conduit to bring electrical power and low voltage electrical signals to the junction box708. The junction box708includes a junction box708afor electrical power connections as well as a junction box708bfor co-axial cable and telephone cable connections722,724. The junction boxes708a,708bare partitioned from each other by a wall709.

The railing section700includes an enclosed power cable channel710with power cables720run therethrough which terminate at the outlet720on one end of the cables720and in the junction box708aon the other end of the cables. Electrical power cables (not shown) can be run through the electrical conduit and spliced to the power cables720in the junction box708a. The railing section700also includes an enclosed low voltage channel712with low voltage cables722run therethrough which terminate at the connections722,724on the side post702, the top rail704or the spindle706at one end of the cables722, and at the connectors722,724in the junction box708bat the other end of the cables722. Similar to the block600, the railing section700can include at least one speaker connection (not shown), with a speaker cable (not shown) being run through the low voltage channel712.

Covers726(shown inFIGS. 4 and 5only, for clarity) are hingedly connected to the railing section700and are operable between a closed position, which covers the outlets720and the connectors722,724, and an open position, which exposes the outlets720and the connectors722,724. AlthoughFIGS. 4 and 5show individual covers726for each outlet720and connector722,724, those skilled in the art will recognize that a single cover (not shown can be used to cover all of the outlets720and connectors722,724. Additionally, those skilled in the art will recognize that the covers726can be secured in a closed position by a lock (not shown) to avoid unauthorized use of the outlets720and/or the connectors722,724.

Preferably, each element described above which includes power cables includes a “hot” conductor, a “neutral” conductor, and a “ground” conductor. However, those skilled in the art will recognize that each element can include additional conductors as well. Preferably, the electrical outlets604,720described above are 125 volt, 15 amp, Ground Fault Circuit Interrupter (GFCI) outlets, although those skilled in the art will recognize that the outlets can be other voltages and current ratings, and need not necessarily be GFCI outlets.

Although the low voltage is discussed as being telephone or co-axial cable, those skilled in the art will recognize that other types of cables, including but not limited to, audio speaker cable and fiber optic cable, can also be run through the open or low voltage channels618and712. In addition to or alternatively to the co-axial connectors608,722and the telephone cable connectors606,724, speaker jacks, fiber optic connectors and other connectors (not shown) can be used.

Referring toFIGS. 15-17, there is shown a third preferred embodiment of the integrated electrical receptacle system, generally designated200, and hereinafter referred to as the “receptacle system”200, in accordance with the present invention. The receptacle system200comprises a block210and a receptacle assembly300. The receptacle assembly300forms in the block210a passageway302having a second longitudinal axis304. The passageway302extends from a first exterior surface218of the block210to the second exterior surface224of the block210and is for containing an electrical device410and a length of an electrical conductor420,420′ extending from a supply conduit430or a cable430′ suitable for underground installation to the electrical device410. The passageway302is impermeable to fluid within the block210.

Those having ordinary skill in the art of receptacle systems will understand from the present disclosure that the block210can be a wide variety of block sizes and shapes having a wide variety of decorative facings. The artisan will also understand that the electrical device410may be a variety of well known devices and may or may not include outlets or connection such as a power outlet, a low voltage outlet, a telephone outlet, an audio/video outlet or the like or such additional devices as lighting fixtures, speakers, and displays. Further, the artisan will understand that the electrical conductor420,420′ may be a variety of well known conductors such as high or low voltage cable, co-axial cables, telephone cables and other multi-conductor cables. Still further, the artisan will understand that the passageway302by virtue of its impermeability, insulates the electrical device410and conductor420,420′ from moisture and generally serves as a weather proofing barrier.

Referring toFIG. 16, the block210comprises a first side212, a second side214and a cavity216. The first side212has a first exterior surface218and a first interior surface220. The second side214is opposed to and spaced a first distance222from the first side212. The second side214has a second exterior surface224and a second interior surface226. The cavity216extends from the first interior surface220to the second interior surface226. The cavity216has a first cavity opening228in the first side212and a second cavity opening230in the second side214. The first cavity opening228has a third sidewall232extending from the first exterior surface218of the first side212to the first interior surface220of the first side212. The third sidewall232circumscribes the first cavity opening228and has a third shape generally corresponding to the first shape of the outer surface330of the first sidewall328of the unitary wall322, discussed below. Preferably, the third sidewall232has a counter bore234. The second cavity opening230has a fourth sidewall236extending from the second exterior surface224of the second side214to the second interior surface226of the second side214. The fourth sidewall236circumscribes the second cavity opening230and has a fourth shape generally corresponding to the generally circular cross sectional shape of the second portion308of the passageway302. The second cavity opening230has a fifth longitudinal axis238coaxial with the third longitudinal axis332of the first cylinder.

Referring toFIG. 17, the receptacle assembly comprises an enclosure312, a flange314, a hub316, a tubular member318, and a conduit coupling320. The enclosure312has a unitary wall322forming a chamber324for containing the electrical device410. The unitary wall322has a first chamber opening326for providing access to the electrical device410. The first chamber opening326corresponds to the first cavity opening228. Preferably, the unitary wall322has a first sidewall328that forms a first portion306of the passageway302. The first sidewall328has an outer surface330having a first shape generally corresponding to a shape of an outer surface of a body formed by the intersection of a first cylinder331(partially shown in phantom) with a second cylinder333(partially shown in phantom shown). The first cylinder331has a third longitudinal axis332. The second cylinder333has a fourth longitudinal axis334. The third longitudinal axis332is coaxial with the second longitudinal axis304of the passageway302. The fourth longitudinal axis334is generally parallel to and spaced a second distance336from the third longitudinal axis332. Preferably the first sidewall328is tapered.

The flange314is integral with the unitary wall322and is attached to the block210. Preferably, the flange314circumscribes the outer surface330of the first sidewall328of the unitary wall322proximal to the first chamber opening326and has a second sidewall338spaced from and generally parallel to the outer surface330of the first sidewall328of the unitary wall322. The second sidewall338has a second shape generally corresponding to the first shape of the outer surface330of the first sidewall328. The flange314has a mounting surface340abutting the counter bore234and adhering to the counter bore234. The mounting surface340has at least one adhesive slot342and at least one drainage slot344.

The hub316is integral with the unitary wall322. The hub316provides a second chamber opening346for receiving a portion of the length of the electrical conductor420.

The tubular member318has a first longitudinal axis348, a first end350and a second end352. The first longitudinal axis348is coaxial with the third longitudinal axis332of the first cylinder331. The tubular member318extends from the hub316to the second cavity opening230. The tubular member318forms a second portion308of the passageway302. The first end350of the tubular member318is joined to the hub316. Preferably, the tubular member318is joined to the hub316by an adhesive bond that is impermeable to fluid. Those having ordinary skill in the art will understand that the tubular member318may joined to the hub316by other well known techniques such a threaded connection, a swage fitting and the like without departing from the scope of the invention.

The conduit coupling320has a first coupler354and a second coupler356. The first coupler354is joined to the second end352of the tubular member318preferably by an adhesive bond that is impermeable to fluid. The second coupler356is preferably for being joined to the supply conduit430. Those having ordinary skill in the art will understand from the present disclosure that the conduit coupling320could be adapted for joining to structures other than the supply conduit430without departing from the scope and intent of the present invention. For example, an alternate coupler320′ having a first seal358for sealably joining to a cable430′ suitable for underground installation could be joined to the second end352of the tubular member318. The artisan will also understand that the conduit coupling320could have a seal for preventing the entry of fluid into the passageway302.

Preferably, the receptacle assembly300has an adapter plate360that has a second seal362. The adapter plate360is removably, sealably attached to the flange314and is configured for providing access to the electrical device410and for releasably supporting a cover plate (not shown). Still further, the receptacle assembly300includes a mounting spacer364removably attachable to the tubular member318and insertable in the second cavity opening230for supporting the tubular member318.

Another aspect of the present invention is a method for preparing a block210for receiving a receptacle assembly300having a passageway302. The passageway302has a second longitudinal axis304. A first portion306of the passageway302has an outer surface330having a first shape generally corresponding to a shape of an outer surface of a body formed by the intersection of a first cylinder331(partially shown in phantom) with a second cylinder333(partially shown in phantom shown). The first cylinder331has a third longitudinal axis332. The second cylinder333has a fourth longitudinal axis334. The third longitudinal axis332is coaxial with the second longitudinal axis304of the passageway302. The fourth longitudinal axis334is generally parallel to and spaced a second distance336from the third longitudinal axis332. A second portion308of the passageway302has a generally circular cross sectional shape. The block210has a first side212and a second side214opposed to and spaced a first distance222from the first side212. The first side212has a first exterior surface218and a first interior surface220. The second side214has a second exterior surface224and a second interior surface226. A cavity216extends from the first interior surface220to the second interior surface226.

The method comprises at least the following three steps. One step is drilling through the first side212of the block210a first circular opening having a sixth longitudinal axis that is coaxial with the second longitudinal axis304of the passageway302. Another step is drilling through the first side212of the block210a second circular opening having a seventh longitudinal axis corresponding to the fourth longitudinal axis334of the second cylinder333. The first and second circular openings overlap to form the first cavity opening228. Another step is drilling through the second side214of the block, a third circular opening having an eighth longitudinal axis coaxial with the sixth longitudinal axis of the first circular opening. The third circular opening forms the second cavity opening320. Preferably, the first and second circular openings have the same diameter and the third circular opening has a diameter that is less than the diameter of the first and second circular openings. Those having ordinary skill in the art of preparing a block, such as the block210, for receiving a receptacle assembly, such as the receptacle assembly300, will understand from the disclosure that follows that although the order in which the first, second and third circular openings are drilled may be arbitrary, a preferred drilling order is to drill the first circular opening, then the third circular opening and then the second circular opening.

The artisan will also understand from the present disclosure that preferably, the first, second and third circular openings are drilled with a three-step coring drill, such as the coring drill500shown in FIG.18. The coring drill500has a longitudinal coring drill axis502and comprises a corer hub510, a first corer512, a second corer514and a counter-borer516. The corer hub510is generally cylindrically shaped and has a first bore518for receiving a drive shaft (not shown) of a driver (not shown) well known in the block fabrication art for rotating the corer hub510about the coring drill axis502. The corer hub510has an externally threaded shaft520for mounting the first corer512. The first corer512is cylindrical in shape and has a first coring end522and an internally threaded mounting end524for being removably attached to the threaded shaft520of the corer hub510. The second corer514has a cylindrical-shape second corer body526that is coaxial with the first corer512and has a diameter that is greater than the diameter of the first corer512. The second corer body526has a second coring end528and a second corer flange530spaced from the second coring end528. The second corer flange530is integral with the second corer body526, is annular in shape and has an outer diameter that is greater than the diameter of the second corer body526. The second corer514is fixedly attached by the second corer flange530to the corer hub510for rotation therewith. The counter borer516is annular in shape and is integral with the outer portion of the second corer flange530. The first coring end522, the second coring end528and the counter borer516preferably have an abrasive surface formed by abrasives such as diamond or cubic boron nitride.

Preferably, the first, second, and third circular openings are drilled in the block210by a method that comprises at least the steps discussed below.

A first step is drilling a pilot bore through the first side212of the block210. Preferably the pilot bore is drilled with the first-step corer512of a three-step coring drill, such as the coring drill500shown in FIG.18. The pilot bore has a sixth longitudinal axis corresponding to the second longitudinal axis304of the passageway302. Another step is extending the first-step corer512through the pilot bore to the second interior surface226of the second side214of the block210and drilling with the first-step corer512the second cavity opening230through the second side214of the block210. Another step is extending the first-step corer512through the second cavity opening230and drilling with the second-step corer514of the three-step coring drill500, a first circular opening through the first side of the block. Still another step is extending the second-step corer514through the first circular opening and drilling with the third-step counter-borer516of the three-step coring drill500a first counter bore in the first side212of the block210. The next step is withdrawing the three-step coring drill500from the block210and removing the first-step corer512from the three-step coring drill500. The next step is drilling with the second-step corer514a second circular opening through the first side212of the block210, the second circular opening having a seventh longitudinal axis corresponding to the fourth longitudinal axis. The next step is extending the second-step corer514through the second circular opening and drilling with the third-step counter-borer516a second counter bore in the first side212of the block210. The last step is withdrawing the three-step core drill500from the block210.

In use, after the block210has been prepared for receiving the receptacle assembly300, the receptacle assembly300is partially inserted in the first cavity opening228of the block210. An adhesive is applied to the mounting surface340of the flange314and the receptacle assembly is further inserted into the first cavity opening228until the mounting surface abuts the counter bore234and the receptacle assembly is secured to the block210by the adhesive. The mounting spacer364is slideably positioned on the tubular member318so that the mounting spacer364provides support for the tubular member318within the second cavity opening230. In this condition, the block210is suitable for placement in various stone or masonry structures and for coupling with a supply conduit430for receiving a length of an electrical conductor420extending therefrom and providing an impermeable passageway302for the electrical conductor420through the stone or masonry structure to an electrical device410insertable in the enclosure312of the receptacle assembly300.

Referring toFIGS. 19-22, there is shown a fourth preferred embodiment of the integrated electrical receptacle system, generally designated900, and hereinafter referred to as the “receptacle assembly”900in accordance with the present invention. The receptacle assembly900is for receiving and attaching to a support, such as the first side212of the block210shown inFIG. 16, an electrical device connectable to an electrical conductor, such as the electrical device410and cable430′ shown in FIG.15. The receptacle assembly900comprises an enclosure902, a first mount904connected to the enclosure902for attaching the receptacle assembly to the support and a second mount906connected to the enclosure902for securing the electrical conductor to the enclosure902.

The enclosure902has a sidewall912with an outer surface914having a shape generally corresponding to a shape of an outer surface of a body formed by the intersection of a first cylinder eccentric to a second cylinder. The enclosure902has a first opening916for receiving the electrical device and a second opening918for receiving the electrical conductor.

The first mount904comprises a flange920and a retainer922. The flange920circumscribes the outer surface914of the sidewall912of the enclosure902proximal to the first opening916. The retainer922is pivotably connected to the enclosure902and is pivotable about a retainer axis924between a retracted position (FIG. 21) and an extended position (FIG. 22) and movable along the retainer axis924between a disengaged position distal to the flange920and an engaged position proximal to the flange920. Preferably, the retainer922is entirely within a recess926in the outer surface914of the sidewall912of the enclosure902when the retainer922is in the retracted and disengaged positions (FIG.19). The first mount904secures the receptacle assembly900to the support when the support is positioned between the flange920and the retainer922and the retainer922is in the extended and engaged positions, as shown in phantom in FIG.19.

Preferably, the flange920has a mounting surface928for abutting the support. The mounting surface928has at least one adhesive slot930and at least one drainage slot932. The flange920has a outer perimeter934and an outwardly facing surface936configured for releasably supporting a cover plate (not shown) configured to cover and seal the first opening916. The outer perimeter934of the flange920preferably has a generally rectilinear-shape. However, the shape of the outer perimeter934can have a wide variety of well known geometric shapes or specialty shapes such as the figure-eight-like shape shown inFIGS. 19-24.

The retainer922has a retainer hub938. A lobe940extends from the retainer hub938. The lobe940has an outer surface942preferably with a shape substantially the same as a portion of the outer surface914of the sidewall912of the enclosure902. An actuator944connects the retainer922to the enclosure902. The actuator944has an actuator axis coincident946with the retainer axis924. The actuator944is threadedly connected to retainer hub938and is rotatably within a boss948integral with the enclosure902. A first rotation of the actuator944pivots the retainer between the retracted position and the extended position. Interference with the wall of the recess926in the enclosure902serves as a stop preventing further pivoting of the retainer922upon further rotation of the actuator944. A second rotation of the actuator944moves the retainer922along the actuator axis946from the disengaged position toward the engaged position.

The second mount906preferably is a conduit hub950formed as an extension of a portion of the enclosure902and is configured to provide the second opening918in the enclosure902. The conduit hub950is further configured to receive and secure to the enclosure902a conduit and to receive a an electrical conductor passing through the conduit, such as the supply conduit430or cable430′ and the electrical conductors420,420′ extending therefrom, as shown in FIG.15.

Referring toFIGS. 23-24, alternatively, the second mount906′ comprises a clamp952proximal to the second opening918of the enclosure902for securing the electrical conductor to the enclosure902. Preferably, but not necessarily, the electrical conductor is a non-metallic sheathed electric cable, such as a cable commonly referred to as Romex® (a registered trademark of General Cable Industries, Inc.) and the clamp952comprises a grip954connected by a hinge956to the enclosure902for engaging the cable. Upon insertion of the electrical conductor through the second opening918, the grip engages the cable and resists withdrawal of the cable.

The second mount906,906′ is not limited to the retainer hub950configuration shown inFIG. 19of the grip954and hinge956configuration shown inFIGS. 23 and 24. Referring toFIG. 15, for example, to accommodate a variety of electrical conductors420,420′ and cables430′ and supply conduits430, the present invention provides for an alternate second mount that is integral with the unitary wall322forming the chamber324for containing the electrical device410and configured to provide a second opening346for receiving a portion of the length of the electrical cable (or conductors)420, and to connect the electrical conductors420to the unitary wall322. The alternate second mount comprises a hub316, a tubular member318, and a conduit coupling320. The hub316is integral with the unitary wall322and provides the second chamber opening346. The tubular member318has a first end350and a second end352and extends from the hub316to the second cavity opening346. The first end350is joined to the hub316. The conduit coupling320has a first coupler354and a second coupler356. The first coupler354is joined to the second end352of the tubular member318. The second coupler356is for being joined to the supply conduit430.

The receptacle assembly900can be secured to any support structure having a correspondingly configured cavity providing access to an electrical conductor. The electrical conductor is inserted into the second opening918in the enclosure and secured to the enclosure by the second mount906,906′. The manner is which the conductor is secured to the enclosure918depends on the configuration of the conductor and second mount906,906′. For example, if the second mount906has a hub like configuration and the electrical conductor is in a conduit, the conduit is typically adhesively connected to the hub. If the second mount906′ has a clamp-like configuration and the electrical conductor is a non-metallic sheathed electric cable, the conductor is typically secured to the enclosure by the grasping action of the clamp.

After the electrical conductor has been inserted in the enclosure902, the receptacle assembly900is partially inserted in a cavity in the support, such as the cavity216in the block210as shown inFIG. 16, with the retainer922in the retracted and disengaged position. Adhesive is applied to the adhesive slots930of the flange920and the receptacle assembly900is further inserted into the cavity until the mounting surface928of the flange920abuts the support.

The receptacle assembly900is secured to the support by the first mount902. TO secure the receptacle assembly to the support, the retainer actuator944is rotated to pivot the retainer922first to the disengaged and extended position in which the retainer lobe940extends outwardly beyond the outer surface914of the sidewall912of the enclosure920. When the retainer922pivots sufficiently to strike the sidewall912, further rotation of the actuator944moves the retainer922toward the support. Continued rotation of the actuator944causes the retainer922to abut the support and secure the receptacle assembly900to the support. Preferably, the receptacle assembly900has another first mount spaced from the first mount902that is similarly actuated to secure the receptacle assembly900to the support at another location.

Those skilled in the art will appreciate that changes could be made to the embodiments described above without departing from the broad inventive concept thereof. It is understood, therefore, that this invention is not limited to the particular embodiments disclosed, but it is intended to cover modifications within the spirit and scope of the present invention as defined by the appended claims.