Recessed electrical outlet cover and box

An electrical box assembly that includes a box body having a screw mount aperture and a base insert slidably coupled into the box body. The base insert may include a back wall, and the back wall may have an electrical device aperture therethrough, a box mounting screw aperture therethrough, a center mounting screw aperture therethrough, and a rear face. The rear face may include a center mounting plane at the center mounting screw aperture substantially parallel to the back wall and at least one spacer extending above the center mounting plane from the rear face at the box mounting screw aperture. Other particular implementations of an electrical box assembly may include at least two removable flanges coupled along a front side of the box body.

BACKGROUND

1. Technical Field

Aspects of this document relate generally to covers and boxes for electrical devices.

2. Background Art

Electrical devices are often installed in buildings by pulling wire into an opening in an electrical box into which an electrical device has been coupled. Conventionally, many electrical boxes are installed while a wall is being constructed, often through attachment to a wall stud. Later, as drywall or siding materials are used to cover the wall studs, the electrical box often becomes recessed with respect to the surface of the finished wall. When electrical boxes are installed in an exterior wall of a building, the depth the electrical box is recessed often varies considerably depending upon the type of wall finish used (siding, stucco, brick, etc.). Also, when an electrical box is installed in an exterior wall, the electrical device within the box may require protection from water and other contaminants while an electrical connector is coupled with the electrical device.

SUMMARY

Aspects of this invention relate to an electrical box assembly with a box body having removable flanges and a base insert with spacers to aid in securing electrical devices installed within the assembly. Implementations of an electrical box assembly may include one, any combination, or all of the following aspects:

In one aspect, an electrical box assembly may include a box body having a screw mount aperture and a base insert slidably coupled into the box body. The base insert may include a back wall, and the back wall may have an electrical device aperture therethrough, a box mounting screw aperture therethrough, a center mounting screw aperture therethrough, and a rear face. The rear face may include a center mounting plane defined by the back wall of the center mounting screw aperture and at least one spacer at the box mounting screw aperture extending above the center mounting plane from the rear face.

In a second aspect, an electrical box assembly may include a box body having a front edge and at least one removable flange and in particular implementations at least two removable flanges each having a length. The flanges may each be grooved for at least a majority of its length along a side of the flange. The flanges and the box body may be coupled together at the front edge of the box body and the groove of each flange may be substantially parallel to the front edge of the box body.

Implementations may include one, any combination, or all of the following:

The base insert may include a spacer that may extend around the box mounting screw apertures. In other implementations, the spacer may be adjacent to the box mounting screw aperture.

The box body may have an interior surface with a mounting feature configured to couple with a clip of an extension frame. The mounting feature may further include at least one reentrant slot configured to engage with the clip of the extension frame. In particular implementations, the electrical box assembly may further include a surface cover configured to couple with the extension frame. In other implementations, the surface cover may be configured to couple with the box body. The extension frame also may be coupled to the box body between a base insert and the box body. In other particular implementations, the surface cover piece may be coupled to the box body between a base insert and the box body.

A base insert may be slidably coupled with the box body and may include an electrical device aperture large enough to receive at least one electrical device face. The base insert may also include a lid coupled with the base insert through a hinge. In particular implementations, the base insert may also have a front edge with a width. The width may have at least one groove therein and the lid may include at least one shield projection extending outward from a rear surface of the lid. The at least one shield projection may couple into the at least one groove of the front edge of the base insert when the lid is closed over the base insert through the hinge.

The base insert may also include, in particular implementations, at least one removable tab, where removal of the at least one removable tab converts the electrical device aperture from an electrical device aperture opening configured for a first electrical device configuration to an electrical device aperture opening configured for a second electrical device configuration different from the first electrical device configuration. The base insert may further include an adapter plate, the adapter plate having an electrical device aperture large enough to receive at least one electrical device face and at least one removable tab, where removal of the at least one removable tab converts the electrical device aperture from an electrical device aperture opening configured for a first electrical device configuration to an electrical device aperture opening configured for a second electrical device configuration different from the first electrical device configuration.

The at least two flanges each grooved for at least a majority of its length along a side of the flange and coupled to the front edge of the box body may also include a thickness and the groove of each flange may be on a first side of the flange. The groove may include a depth equal to between 40% and 50% of the thickness of the flange. In other particular implementations, the at least two flanges may include a thickness and the groove of each flange may be on a second side of the flange. The groove may include a depth equal to between 20% and 40% of the thickness of the flange. In yet other implementations, the at least two flanges may include a thickness and each have at least one of a groove on a first side and a groove on a second side having a depth equal to between 20% and 50% of the thickness of the flange.

The box body may also include at least two angled nail attachment features coupled to the box body.

In a third aspect, an electrical box assembly may include a method of installation which includes the steps of sliding a base insert into the box body of an electrical box assembly over an electrical device coupled with the box body. The base insert may include a rear face, and the rear face may have a center mounting plane at the center mounting screw aperture substantially parallel to the back wall of the box body and at least one spacer extending above the center mounting plane from the rear face at the box mounting screw aperture. The method of installation may also include the step of coupling the at least one spacer with the electrical device by coupling the base insert to the box body with a box mounting screw. The method may also include the step of flexing the rear face of the base insert by coupling the electrical device to the base insert by inserting a center mounting screw through the center mounting screw aperture of the rear face.

Particular implementations of an electrical box assembly may include an installation method that further includes the step of coupling an extension frame with the box body. The method may also include the step of coupling a surface cover with the box body in particular implementations.

These general and specific aspects may be implemented using an electrical box assembly, a method, or any combination of electrical box assemblies and methods.

DESCRIPTION

This disclosure, its aspects and implementations, are not limited to the specific components or assembly procedures disclosed herein. Many additional components and assembly procedures known in the art consistent with the intended electrical box assembly and/or assembly procedures for an electrical box assembly will become apparent for use with implementations of an electrical box assembly from this disclosure. Accordingly, for example, although particular box bodies, adapter plates, extension frames, or spacers are disclosed, such box bodies, adapter plates, extension frames, or spacers and implementing components may comprise any shape, size, style, type, model, version, measurement, concentration, material, quantity, and/or the like as is known in the art for such box bodies, adapter plates, extension frames, or spacers and implementing components, consistent with the intended operation of an electrical box assembly.

Referring toFIG. 1, a particular implementation of an electrical box assembly2is illustrated. As illustrated, the electrical box assembly2may include a box body4. The box body4may include a screw mount aperture6for use in coupling an electrical device with the box body4. Particular implementations of a box body4may include an interior surface8which includes a mounting feature10having a reentrant slot12or alternatively a slot through the box body wall. The mounting feature10which includes the reentrant slot12may be dimensioned to couple with a clip26of an extension frame24. To aid in installing the electrical box assembly2against a wall stud, at least two nail attachment features18may be coupled with the box body4.

Particular implementations of a box body4may be coupled directly to a wall surface and may therefore include a front edge20and at least two flanges14that are coupled at the front edge20. The flanges14may each be grooved with a groove16along a side22for at least a majority of the length of the side22to permit them to be removed if the box body4is to be mounted to a stud. In particular implementations of a box body4, the flanges14grooved for at least a majority of the length of their sides22may include grooves16that continuously extend down the sides22of the flanges14or grooves16that may have ungrooved or perforated areas in locations along the sides22of the flanges14. The grooves16may be located on either a first or a second side of the flanges14or on both the first and second sides and inwardly extend into the thickness of the flanges14.

Removal of the flanges14an important feature of the grooves16, and research has been done to determine which ranges of thicknesses of grooves work best. When the grooves16are located on a first side of the flanges14, the depth of the grooves16may be equal to between 40% and 50% of the flanges'14thickness. When the grooves16are located on a second side of the flanges14the depth of the grooves16may be equal to between 20% and 40% of the thickness of the flanges14. When the grooves16are located on both the first and second side of the flanges14, the depth of the grooves16may be equal to between 20% and 50% of the flanges'14thickness. The grooves16may also include groove peaks. In particular implementations of flanges14that include grooves on both the first and second sides of the flanges14, the groove peaks on each of the sides of the flanges14may be unaligned with each other to ensure the flanges14are more cleanly separated from the front edge22of the box body4. Relevant disclosure regarding the structure and use of the grooves16may be found in U.S. Pat. No. 6,960,721 to Shotey et al. entitled “Convertible Electrical Device Cover Having Removable Tabs With Offset Grooves,” the disclosure of which is hereby incorporated by reference (see in particular FIG. 5 of the referenced patent).

Referring toFIG. 2, particular implementations of an electrical box assembly2may include an extension frame24. The extension frame24may have clips26dimensioned to engage with the mounting features10on the box body4to hold the extension frame24in place. The extension frame24may also include a flange28that extends substantially perpendicular to and beyond the front edge22of the box body4. A sleeve30aligned with and that extends the front edge22of the box body4outward may project from the extension frame24.

Referring toFIG. 3, an electrical box assembly2may include a surface cover32in particular implementations. The surface cover32may include mounting features34that allow it to be either coupled with the box body4, the extension frame24, or with both the box body4and extension frame24. The surface cover32may also include a cover sleeve36that slidably couples into the sleeve30in the extension frame24or the interior surface8of the box body4.

In particular implementations of an electrical box assembly2, a base insert38, like that illustrated inFIG. 4, may also be slidably coupled into the box body4. The base insert38may include a back wall40which may have an electrical device aperture42, box mounting screw apertures44, and a center mounting screw aperture46therethrough. The electrical device aperture42may be large enough to receive at least one electrical device face. The back wall40may also include a rear face48. The rear face48may also include a center mounting plane substantially parallel to the back wall40and substantially co-planar with the rear face48at the level of the center mounting screw aperture46. This center mounting plane may be located inwardly or outwardly relative to the overall back wall40in particular implementations of a base insert38. Regardless of the location of the center mounting plane relative to the back wall40, a spacer50may extend above the center mounting plane from the rear face48at the box mounting screw aperture44. The spacer50may be coupled with the rear face48as a separate piece, or may be formed integrally with the back wall40of the base insert38. In particular implementations, the spacer50may extend around the box mounting screw aperture44, may be adjacent to it, or only partially extend around the box mounting screw aperture44.

The back wall40of the base insert38may also include at least one removable tab52. Removal of the at least one removable tab52allows the electrical device aperture42to be converted from a first electrical device configuration to a second electrical device configuration. In the implementation illustrated inFIG. 4, the electrical device aperture42is large enough to accommodate the face of a duplex receptacle. Removal of the removable tab52would convert the electrical device aperture42to receive the face of a round outlet. Other particular implementations of a base insert38may include an adapter plate that has at least one removable tab large enough to receive the face of an electrical device. The adapter plate and/or removal of the removable tab in the adapter plate may allow the electrical device aperture42in the base insert38to be converted from a first to a second electrical device configuration. Relevant disclosure regarding the structure and use of removable tabs and adapter plates and the attachment of adapter plates to the base are found in U.S. Pat. No. 6,960,721 to Shotey et al. entitled “Convertible Electrical Device Cover Having Removable Tabs With Offset Grooves,” the disclosure of which was previously incorporated by reference.

Referring toFIGS. 1 and 5, particular implementations of an electrical box assembly2may include a lid54coupled to the base insert38through a hinge. The hinge may be composed of base hinge members56coupled to the base insert38and lid hinge members58coupled to the lid54. The lid54may also include a shield projection60that extends outwardly from a rear face62of the lid54. The shield projection60may be sized to couple into a groove68in a width66of a front face64of the base insert38. The shield projection60may extend entirely around the lid54and may be partially or completely interrupted by cord port openings70aligned to accommodate passage of an electrical cord through a cord port72. The cord port72in particular implementations may be in a surface of the lid54or the base insert38, or may be in a surface of both the lid54and the base insert38. In addition, in other implementations, the aperture in the cord port72may be open, closed by a barrier intended to limit the ingress of water or other contaminants into the cover through the cord port72, or closed by a removable tab in the base insert38, the lid54, or in both the base insert54and the lid54. Removal of the removable tab by the user may open the aperture in the cord port72and allows the user to close the lid54when an electrical device connector is inserted into the electrical box assembly2. Particular implementations may also include a plurality of cord ports72.

The components defining any implementation of an electrical box assembly2may be formed of any of many different types of materials or combinations thereof that can readily be formed into shaped objects, provided that the components selected are consistent with the intended operation of an electrical box assembly2implementation. For example, the components may be formed of: rubbers (synthetic and/or natural) and/or other like materials; glasses (such as fiberglass), carbon-fiber, aramid-fiber, any combination thereof, and/or other like materials; polymers such as thermoplastics (such as ABS, Fluoropolymers, Polyacetal, Polyamide; Polycarbonate, Polyethylene, Polysulfone, and/or the like), thermosets (such as Epoxy, Phenolic Resin, Polyimide, Polyurethane, Silicone, and/or the like), any combination thereof, and/or other like materials; composites and/or other like materials; metals, such as zinc, magnesium, titanium, copper, led, iron, steel, carbon steel, alloy steel, tool steel, stainless steel, brass, tin, antimony, aluminum, any combination thereof, and/or other like materials; alloys, such as aluminum alloy, titanium alloy, magnesium alloy, copper alloy, any combination thereof, and/or other like materials; any other suitable material; and/or any combination thereof.

Referring toFIGS. 1 and 4, for the exemplary purposes of this disclosure, the box body4, extension frame24, surface cover32, base insert38, and lid54illustrated inFIG. 1may be formed of a plastic material. The spacers50may be formed of a plastic, rubber, or metal material.

Moreover, some of the components defining any electrical box implementation may be manufactured simultaneously and integrally joined with one another, while the other components may be purchased pre-manufactured or manufactured separately and then assembled with the integral components. The various implementations may be manufactured using conventional procedures as added to and improved upon through the procedures described here.

Accordingly, manufacture of these components separately or simultaneously may involve vacuum forming, injection molding, blow molding, casting, forging, cold rolling, milling, drilling, reaming, turning, grinding, stamping, pressing, cutting, bending, welding, soldering, hardening, riveting, punching, plating, and/or the like. Components manufactured separately may then be coupled or removably coupled with the other integral components in any manner, such as with adhesive, a weld joint, a solder joint, a fastener (e.g. a bolt and a nut, a screw, a rivet, a pin, and/or the like), washers, retainers, wrapping, wiring, any combination thereof, and/or the like for example, depending on, among other considerations, the particular material forming the components.

Referring toFIGS. 6 and 7, a particular implementation of a base insert38is shown slidably coupled into a box body4. To form the assembly illustrated inFIG. 6, in particular implementations, an electrical device74(here a duplex receptacle) may be inserted into the box body4with the yokes76of the electrical device74resting against the screw mount apertures6in the box body4and the box mounting screws78loosely holding the electrical device74in place. The base insert38may then be slidably coupled into the box body4until the spacers50rest against the yokes76of the electrical device74and the box mounting screws78extend through the keyhole slot apertures used for the box mounting screw apertures44of the base insert38. Box mounting screws78may then be tightened into the screw mount apertures6of the box body4.

After the box mounting screw78are tightened down, a center mounting screw80may then inserted into the center mounting screw aperture46of the base insert38. The back wall40of the base insert38may then be flexed by tightening the center mounting screw80and pulling the spacers50against the yokes76of the electrical device74. Since the flexing of the back wall40pulls the spacers50against the yokes76of the electrical device74, the amount the electrical device74can bend under the insertion force of an electrical connector may be reduced. This may help reduce the likelihood of damage to the base insert38and increase the solid feel of the electrical device74when installed in the electrical box assembly2.

Referring toFIG. 1, an electrical box assembly2may be assembled by first placing a box body4into a wall during construction. The box body4may be installed within the wall directly to a stud through the nail attachment features18or may be installed directly to the wall material (siding, drywall, etc.) through the flanges14. When the box body4is installed directly to a stud with the nail attachment features18, the flanges14will normally be removed through the grooves16. In some implementations, an extension frame24may be coupled with the box body24through the clips26. The extension frame24is likely to be used when the box body4is installed in an exterior wall where brick, stucco, or siding makes the wall thickness greater than an interior wall. The sleeve30of the extension frame24may allow the exterior wall material (brick, stucco, or siding) to be placed over the flange28against the sleeve30after the box body4has been installed inside the wall. In some implementations, after the extension frame24has been coupled with the box body4, a surface cover32may be coupled to the sleeve30of the extension frame to provide aesthetic appeal and aid in sealing the electrical box assembly2against contaminants. In other implementations, the surface cover32may installed directly within the box body4and no extension frame24may be required as when the electrical device assembly2is installed within an interior wall where wall thickness is minimal.

Depending upon whether the surface cover32or extension frame24are being used, a base insert38may be slidably coupled into the box body4through the cover sleeve36and the sleeve30of the extension frame24or through either the cover sleeve36or the sleeve30of the extension frame24. In other particular implementations, the base insert38may slidably couple directly into the box body4when neither the surface cover32nor the extension frame24have been installed. Finally, a lid54may be coupled to the base insert38through a hinge composed of base hinge members56and lid hinge members58. As the lid54is rotated down over the base insert, the shield projection60on the rear surface62of the lid54may couple into the groove68in the width66of the front edge64of the base insert38. When the shield projection60is coupled into the groove68, the shield projection60may help ensure that water or other contaminants cannot easily find access into the interior of the electrical box assembly2, even while the electrical box assembly2is in use with an electrical cord extending through a cord port in a surface of the assembly.

It will be understood that implementations are not limited to the specific components disclosed herein, as virtually any components consistent with the intended operation of a method and/or system implementation for an electrical box assembly may be utilized. Accordingly, for example, although particular box bodies, adapter plates, or spacers may be disclosed, such components may comprise any shape, size, style, type, model, version, class, grade, measurement, concentration, material, weight, quantity, and/or the like consistent with the intended operation of a method and/or system implementation for an electrical box assembly may be used.

In places where the description above refers to particular implementations of an electrical box assembly, it should be readily apparent that a number of modifications may be made without departing from the spirit thereof and that these implementations may be applied to other electrical box assemblies. The accompanying claims are intended to cover such modifications as would fall within the true spirit and scope of the disclosure set forth in this document. The presently disclosed implementations are, therefore, to be considered in all respects as illustrative and not restrictive, the scope of the disclosure being indicated by the appended claims rather than the foregoing description. All changes that come within the meaning of and range of equivalency of the claims are intended to be embraced therein.