Abstract:
A two-piece electrical box assembly for recessing a duplex receptacle or similar electrical device within a wall. An inner box portion is constructed of metal and includes sidewalls and a back wall defining a cavity therein. The cavity is capable of receiving the electrical device therein. An outer box portion includes an outward extending flange and provides a protective enclosure surrounding the inner box portion and the electrical device within the inner box portion. The electrical box assembly is capable of recessing into a hole in a wall until the outward extending flange is flush with the wall. A cover on the outer box portion can be closed to provide a rainproof enclosure therein for the plug ends of electrical cords while they are connected to the electrical device.

Description:
This application is a Continuation-In-Part of U.S. patent application Ser. No. 11/264,857 filed Nov. 2, 2005 and still pending, which is a Continuation-In-Part of U.S. patent application Ser. No. 11/246,985, filed Oct. 7, 2005 and still pending, which is a Continuation-In-Part of U.S. patent application Ser. No. 11/185,256, filed Jul. 20, 2005 and still pending, which is a Continuation-In-Part of U.S. patent application Ser. No. 11/102,392, filed Apr. 8, 2005 now abandoned, which is a Continuation-In-Part of U.S. patent application Ser. No. 11/070,344, filed Mar. 2, 2005 and now U.S. Pat. No. 6,965,078, which is a Continuation-In-Part of U.S. patent application Ser. No. 11/009,116 filed Dec. 10, 2004 now U.S. Pat. No. 7,005,578, which is a Continuation-In-Part of U.S. patent application Ser. No. 10/863,942 filed Jun. 9, 2004 and now U.S. Pat. No. 6,956,171. 

   FIELD OF THE INVENTION 
   This invention relates to assemblies for the mounting of electrical devices and specifically to a recessed outlet box that includes a metal electrical box portion and a plastic front portion for providing a front cavity for housing and protecting an electrical device therein. 
   BACKGROUND OF THE INVENTION 
   Recessed electrical boxes for retrofitting on finished walls or for use in new construction were disclosed in U.S. Pat. Nos. 6,965,078 and 6,956,171 and in co-pending U.S. application Ser. Nos. 11/009,116, 11/264,857, 11/246,985, 11/185,256, and 11/102,392, all of which are commonly owned by the assignee of the present invention and the entire contents of which are incorporated herein by reference. 
   The recessed electrical boxes disclosed in the aforementioned patents and applications comprised an electrical box having an inner enclosure for housing an electrical device and an outer enclosure for recessing the inner enclosure well within a wall. The recessed electrical box including the inner enclosure and outer enclosure were either integrally formed in one piece or provided in two pieces each formed of the same material of construction. 
   Although a recessed electrical box of the type described in the aforementioned disclosures provided an adequate means for recessing an electrical device substantially within the wall of a structure, they did not address the needs of certain localities in which the electrical code has additional restrictions. The electrical code in certain localities, for example, requires that an electrical box be constructed of metal to ensure more positive grounding for the electrical connections therein in case of a short within the box. 
   Accordingly, the present invention provides a two-piece recessed electrical box that includes a metal inner box for surrounding and housing the electrical connections. An outer box portion includes a cover member for protecting the inner box, the outlet installed within the inner box, and the electrical cords while they are in use and plugged into the outlet within the inner box. The outer box portion may be constructed of metal or plastic. 
   SUMMARY OF THE INVENTION 
   The invention is a two-piece electrical box assembly for recessing a duplex receptacle or similar electrical device within a wall. An inner box portion is constructed of metal and includes sidewalls and a back wall defining a cavity therein. The cavity is capable of receiving the electrical device therein. An outer box portion includes an outward extending flange and provides a protective enclosure surrounding the inner box portion and the electrical device within the inner box portion. The electrical box assembly is capable of recessing into a hole in a wall until the outward extending flange is flush with the wall. A cover on the outer box portion can be closed to provide a rainproof enclosure therein for the plug ends of electrical cords while they are connected to the electrical device. 
   OBJECTS AND ADVANTAGES 
   A first object of the recessed electrical box assembly of the present invention is to provide an electrical box that positions an electrical device well within an exterior wall, thereby shielding the electrical device from impacts. 
   A second object is to provide an electrical box assembly including a cover that shields the electrical device and any electrical cords plugged therein from rain and other environmental elements. 
   A further object of the present invention is to provide a two-piece electrical box assembly that includes an inner box portion constructed of metal for providing positive grounding for electrical connections and electrical devices therein. 
   These and other objects and advantages of the present invention will be better understood by reading the following description along with reference to the drawings. 

   
     DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is an exploded perspective view of a preferred embodiment of the recessed electrical box assembly according to the present invention along with a duplex outlet and its complementary faceplate. 
       FIG. 2  is a front view of the inner box portion of the electrical box assembly of  FIG. 1 . 
       FIG. 3  is sectional view of the inner box taken along line  3 — 3  of  FIG. 2 . 
       FIG. 4  is sectional view of the inner box taken along line  4 — 4  of  FIG. 2 . 
       FIG. 5  is a front view of the outer box portion of the electrical box assembly of  FIG. 1 . 
       FIG. 6  is sectional view of the outer box taken along line  6 — 6  of  FIG. 5 . 
       FIG. 7  is sectional view of the outer box taken along line  6 — 6  of  FIG. 5 . 
       FIG. 8  is a rear perspective view of the cover member portion of the electrical box assembly of  FIG. 1 . 
       FIG. 9  is a front perspective view of the cover member. 
       FIG. 10  is a front elevation view of the cover member. 
       FIG. 11  is a bottom view of the cover member. 
       FIG. 12  is a section view of the cover member taken along line  12 — 12  of  FIG. 10 . 
       FIG. 13  is a detail view of the pin portion extending from the sidewall of the outer box portion of the electrical box assembly. 
       FIG. 14  is a side view of a recessed electrical box assembly according to the present invention with the cover in the closed position. 
       FIG. 15  is a side view of a recessed electrical box assembly according to the present invention with the cover in the open position. 
       FIG. 16  is a perspective view of the recessed electrical box assembly of the present invention. 
       FIG. 17  is a front conceptual view of the outer box fitted onto the inner box. 
       FIG. 18  is a bottom view of the recessed electrical box assembly of the present invention including the circular cord openings. 
       FIG. 19  is a side view depicting the recessed electrical box assembly of the present invention installed in a wall of a building. 
   

   TABLE OF NOMENCLATURE 
   The following is a listing of part numbers used in the drawings along with a brief description: 
   
     
       
             
             
           
             
             
           
         
             
                 
             
             
               Part Number 
               Description 
             
             
                 
             
           
           
             
                 
             
           
        
         
             
               20 
               electrical box assembly 
             
             
               22 
               inner box 
             
             
               24 
               outer box 
             
             
               26 
               electrical device 
             
             
               28 
               sidewalls of inner box 
             
             
               30 
               front edge 
             
             
               32 
               sidewalls of outer box 
             
             
               34 
               rear abutment surface 
             
             
               35 
               fastening arrangement 
             
             
               36 
               cover 
             
             
               38 
               front opening of inner box 
             
             
               40 
               panel 
             
             
               42 
               fastener receiving aperture 
             
             
               44 
               electrical contact point 
             
             
               46 
               back wall of inner box 
             
             
               48 
               removable wall portions 
             
             
               50 
               line at planar front edge 
             
             
               52 
               grounding screw 
             
             
               54 
               rear edge of outer box 
             
             
               56 
               partial back wall of outer box 
             
             
               58 
               rear opening of outer box 
             
             
               60 
               rear surface 
             
             
               64 
               pin 
             
             
               66 
               top end of sidewalls of outer box 
             
             
               68 
               aperture in partial back wall 
             
             
               70 
               tab 
             
             
               72 
               flange 
             
             
               74 
               rear surface of flange 
             
             
               76 
               mounting arrangement 
             
             
               78 
               mounting aperture in flange 
             
             
               80 
               mounting fastener 
             
             
               82 
               electrical contact point on outer box 
             
             
               86 
               front panel of cover 
             
             
               88 
               sidewalls of cover 
             
             
               90 
               ear 
             
             
               92 
               aperture in ear 
             
             
               93 
               latch arrangement 
             
             
               94 
               latch 
             
             
               96 
               opening in latch 
             
             
               98 
               surface on latch 
             
             
               100 
               rear edge of cover sidewall 
             
             
               102 
               U-shaped slots in cover 
             
             
               104 
               longitudinal axis of pin 
             
             
               106 
               base portion of pin 
             
             
               108 
               tip portion of pin 
             
             
               110 
               fastener 
             
             
               111 
               electrical box 
             
             
               112 
               front edge of outer box 
             
             
               114 
               U-shaped slots in outer box 
             
             
               116 
               circular opening 
             
             
               118 
               hole 
             
             
               120 
               surface of building 
             
             
               124 
               electrical device fastener 
             
             
               126 
               face plate 
             
             
                 
             
           
        
       
     
   
   DETAILED DESCRIPTION OF THE INVENTION 
   With reference to  FIG. 16 , the present invention comprises an electrical box assembly  20  including an inner box  22  and an outer box  24 . The electrical box assembly  20  is used for recessing an electrical device  26  (partially shown) within a wall. 
   Referring to  FIG. 1 , the inner box  22  includes sidewalls  28  that terminate in a front edge  30 . The outer box  24  includes sidewalls  32  and a rear abutment surface  34 . A fastening arrangement  35  is provided for securing the outer box  24  to the inner box  22 . The outer box  24  is secured to the inner box  22  in such a manner that the rear abutment surface  34  of the outer box  24  abuts the front edge  30  of the inner box  22 . A cover  36 , shown exploded away from the outer box  24  in  FIG. 1 , will be pivotally attached to the outer box  24 . 
   With reference to  FIGS. 2–4 , the inner box  22  includes a front opening  38  and panels  40  that extend orthogonally from the front edge  30  of the inner box  22  into the front opening  38 . The inner box  22  is preferably constructed of metal to enable the inner box  22  to provide positive grounding for electrical connections and electrical devices (not shown) that will be mounted therein and also to enable the electrical box assembly to meet the electrical code in those localities that require all electrical boxes containing electrical devices and wiring therein to be constructed of metal. The panels  40  further include fastener receiving apertures  42  and electrical contact points  44 . The inner box  22  includes a back wall  46  and one or more removable wall portions  48  on the sidewalls  28  and back wall  46 . The removable wall portions  48  may be removed when necessary to provide a hole for passage of wiring into the inner box  22 . As depicted by line  50  in  FIGS. 3 and 4 , the front edge  30  of the sidewalls  28  of the inner box  22  are planar. Furthermore there is provided on the interior of the box, shown on the back wall  46 , a grounding screw  52  for providing a connection point for later securing a ground wire to facilitate grounding of the metal inner box  22 . The electrical code in some localities specifies that the electrical box housing wiring connections must be constructed of metal. The electrical box assembly of the present invention includes a metal inner box  22  and a grounding screw  52  to enable the assembly to satisfy the electrical code in those areas having the stricter code. 
   Referring to  FIGS. 5–7 , the sidewalls  32  of the outer box  24  include a rear edge  54  and a partial back wall  56  extending inwardly from the rear edge  54  (see  FIGS. 6 and 7 ) forming a rear opening  58  therein. The partial back wall  56  includes a rear abutment surface  34 . As shown in  FIG. 5 , the outer box  24  also includes pins  64  extending from the top end  66  of the sidewalls  32 . The partial back wall  56  also includes apertures  68  for use in securing the outer box  24  to the inner box  22 . A tab  70 , which will be work in conjunction with a cover arrangement, is provided at the bottom of the outer box  24  with the tab  70  extending outwardly from the sidewalls  32 . A flange  72  is provided on the outer box  24  extending outwardly from the sidewalls  32 . The flange  72  is planar and includes a rear surface  74  for abutment against the surface of the building when the electrical box assembly is later mounted on a building. The flange  72  further includes a mounting arrangement  76  that will facilitate securing the electrical box assembly to a building with the mounting arrangement  76  including mounting apertures  78  in the flange  72  and mounting fasteners  80  for fastening through the mounting apertures  78  into the building. Electrical contact points  82  are provided on the partial back wall  56  to facilitate later connection of an electrical device (not shown) thereto. 
   With reference to  FIGS. 8–12 , the electrical box assembly further includes a cover member  36  that includes a front panel  86 , sidewalls  88 , ears  90  extending from the sidewalls  88 , and apertures  92  in the ears  90 . The electrical box assembly further includes a latch arrangement  93  for holding the cover  36  closed on the outer box  24 . The latch arrangement  93  includes a downward extending latch  94  on the cover  36 . The downward extending latch  94  is provided with an opening  96  and an exposed surface  98  that will function to lock the cover closed as will be described hereinafter. The sidewalls  88  of the cover  36  include a rear edge  100  and U-shaped slots  102  extend inwards at the rear edge  100 . 
   Referring to  FIG. 13 , the pins  64  on the outer box  24  include a longitudinal axis  104 , a base portion  106 , and a tip portion  108 . The base portion  106  of the pins  64  includes a conical surface having an angle θ with respect to the longitudinal axis  104  and the tip portion  108  of the pins  64  includes a rounded surface. 
   With reference to  FIG. 14 , the breakaway cover  36 , which is typically molded of resilient plastic in one piece, is pressed over the pins  64  on opposing sides of the outer box  24 . Being constructed of a resilient plastic, the ears  90  may be biased outwards and the cover  36  pressed upon the outer box  24  until the pins  64  snap into the apertures  92  in the ears  90 . 
   When the cover  36  is in a raised or open position, such as shown in  FIG. 15 , as a result of the shape and design of the pins  64 , an excessive force applied to the cover  36  will knock the cover  36  off of the pins and therefore protect the cover from breakage or other damage. The resilient properties of the cover  36  and the shape of the pins  64  cause the cover  36  to spread outwards in dimension at the ears  90  and thereby slip off of the pins  64  without damage to the cover. 
   With reference to  FIG. 14 , the cover  36  when closed upon the outer box  24  of the electrical box assembly  20  is held closed upon the outer box  24  by the tab  70  on the outer box  24  extending through the opening  96  on the cover  36 . Details of the breakaway cover of the present invention are provided in U.S. patent application Ser. No. 11/246,985, entitled Recessed Outlet Box with Breakaway Cover, filed Oct. 7, 2005, the contents of which are incorporated by reference herein it its entirety. 
   With reference to  FIG. 1 , the fastening arrangement  35  for securing the outer box  24  to the inner box  22  includes the apertures  68  in the partial back wall  56  of the outer box  24 , the fastener receiving apertures  42  in the inner box  22 , and fasteners  110 . To secure the outer box  24  to the inner box  22 , the apertures  68  in the outer box  24  are placed in axial alignment with the fastener receiving apertures  42  in the inner box  22  and the fasteners  110  secured thereto. The fastener receiving apertures  42  in the inner box  22  can be threaded to receive the fasteners  110  or can be smooth bore for use with self-tapping fasteners. The fasteners  110  are secured through the apertures  68  in the partial back wall  56  of the outer box  24  into the fastener receiving apertures  42  in the inner box  22 . After the outer box  24  and inner box  22  are secured together, the inner box  22  provides a metal electrical box  111  having a cavity therein for holding an electrical device and its associated wiring and the outer box  24  provides an outer enclosure for enclosing the plug ends of an electrical cord (not shown). Although it can be constructed of metal or plastic, the outer box  24  most preferably is molded of plastic in one piece. Preferably, the front edge  30  of the inner box  22  is planar and the rear abutment surface  34  of the outer box  24  is planar. Therefore, securing the outer box  24  to the inner box  22  with the fastening arrangement  35  will create a rainproof seal between the outer box  24  and the inner box  22 . 
   Referring to  FIG. 17 , after the outer box  24  (shown in solid lines) and the inner box  22  (shown in broken lines) are secured together by the fastening arrangement  35 , the rear opening  58  in the outer box  24  is equal to or smaller than the front opening  38  in the inner box  22  and no portion of the panels  40  or the sidewalls  28  of the inner box  22  extend within the rear opening in the outer box  24 . 
   As shown in  FIG. 1 , the outer box  24  includes a front edge  112  and U-shaped slots  114  in the front edge  112  of the sidewalls  32 . 
   With reference to  FIG. 18 , after the cover  36  is closed upon the outer box  24  the U-shaped slots  114  in the front edge  112  of the sidewalls  32  of the outer box  24  and the U-shaped slots  102  in the sidewalls  88  of the cover  36  create substantially circular openings  116  therein for passage of electrical cords (not shown). 
   As shown in  FIG. 19 , the electrical box assembly  20  of the present invention is adapted for insertion into a hole  118  in the surface  120  of a building. To operate the invention, a hole  118 , large enough to accommodate the inner box  22  and outer box  24 , is formed in the surface  120 . One or more of the removable wall portions  48  can then be removed and wiring (not shown) fed into the electrical box portion  111  of the assembly  20 . The electrical box assembly  20  is then inserted into the hole  118  until the rear surface  74  of the flange  72  contacts the surface  120 . The mounting arrangement  76  is then used to secure the electrical box assembly to the building, with the mounting fasteners  80  secured through the mounting apertures  78  in the flange  72  and into the surface  120 . 
   With reference to  FIG. 1 , the installer can then complete wiring connections (not shown) to an electrical device, such as the duplex outlet  26  shown. The duplex outlet  26  can then be secured to the electrical contact points  44  (see  FIG. 2 ) in the inner box  22  with electrical device fasteners  124  and a faceplate  126  installed thereon to complete the installation of the electrical box assembly  20 . 
   Having thus described the invention with reference to a preferred embodiment, it is to be understood that the invention is not so limited by the description herein but is defined as follows by the appended claims.