Abstract:
A power inlet box suitable for outdoor or external use is configured in such a manner that an electrical socket may be electrically coupled to an interior load before the electrical socket is secured within the power inlet box. The power inlet box may be formed from weather or otherwise corrosion resistant material such as plastic and is designed such that the electrical socket faces downward toward an exposed lower end of the power inlet box. The electrical socket is supported by a mounting member that may be removably mounted to the power inlet box to secure the electrical socket within the power inlet box.

Description:
BACKGROUND OF THE INVENTION 
   The present invention is generally directed to a power inlet box, which is typically mounted to the exterior of a building and which provides an inlet for the supply of electrical power from an auxiliary power source such as a generator, and more particularly to a power inlet box having a removable socket mounting member that allows a user to connect the socket to the power leads of a load prior to the socket being secured within the power inlet box. 
   In an auxiliary power supply system, a remote power generator is interconnected with a power inlet box which is typically mounted to the exterior of a building or dwelling. The power inlet box is, in turn, typically interconnected with a transfer switching arrangement, which is connected to the main electrical panel or load center of the building. A cord is interconnected with the power outlet of the generator and with a power inlet receptacle or socket associated with the power inlet box for providing power from the generator through the power inlet box to the transfer panel, and ultimately to the main electrical panel in order to supply power to certain circuits of the building in the event of a power outage or the like. 
   Prior art power inlet boxes generally include a base member adapted to be mounted to a wall of the building, and a cover member or assembly that is movably interconnected with the base member. The base member defines an internal cavity, and the cover member is configured to enclose the internal cavity. The power inlet includes a a power receptacle or socket to which is attached various electrical wiring from the building. The socket includes an access cover, which is pivotable between a closed position in which the access cover prevents access to the power receptacle socket structure, and an open position providing access to the power receptacle socket structure. 
   With such conventional power inlet boxes, the power inlet socket is fixedly secured to the power inlet box, and thus is fixed in position on the wall of the building to which the power inlet box is mounted. This can be problematic when making the electrical connections between the power inlet socket and the electrical circuits, i.e., the transfer panel, of the building. More particularly, the fixed position of the socket, combined with the relatively tight interior volume of the power inlet box, provides very little space for a user to connect the wires to the terminals of the power inlet socket. 
   Therefore, there is a need in the art for a power inlet box suitable for outdoor use that allows a user to first mount a portion of the power inlet box to an exterior support structure, make the necessary electrical connections between the power inlet socket and the electrical circuits to which power is to be provided with the power inlet socket detached from the power inlet box, and then secure the power inlet socket to the power inlet box. 
   SUMMARY OF THE INVENTION 
   The present invention is directed to a power inlet box suitable for outdoor or external use and configured in such a manner that electrical wiring may be electrically coupled to the electrical socket before the electrical socket is secured to the power inlet box. The power inlet box may be formed from weather resistant material such as plastic, and may be designed such that the electrical socket faces downward. In this regard, the power inlet box may have an exposed bottom opening so that it complies with relevant electrical codes. 
   In one embodiment, the power inlet box includes a base or frame that may be mounted to the wall of a building. The frame receives an electrical socket mounting member that is configured to be protected against rain, snow, dust, dirt, and the like by a removable outer cover. The mounting member may be mounted to the frame in a number of ways. For instance, a groove may be formed along an interior wall of the frame and the mounting member may be inserted into the groove. In a preferred embodiment, the mounting member may be mounted to the frame after an electrical socket supported by the mounting member is electrically coupled to power leads of an interior load, such as those used to connect the electrical socket to a transfer panel. In this manner, a user is not confined by the size of the power inlet box when making the necessary electrical connections to the socket. The mounting member is secured to the frame such that the face of the electrical socket faces downwardly relative to the power inlet box. The bottom of the power inlet box is open, which allows a user to access the electrical socket without removing a cover or other member of the power inlet box. The mounting member is mounted to the frame so that the electrical socket is upwardly recessed from the bottom of the power inlet box. 
   Therefore, it is one object of the present invention to provide a power inlet box that provides access to an electrical socket without requiring removal of an otherwise fixed cover plate or similar member. 
   It is another object of the present invention to provide a power inlet box segmented into separate components such that a frame of the power inlet box can be secured to a support structure and then the necessary electrical connections between the electrical socket and the interior electrical components may be made without the user being restricted by the location and/or interior volume of the power inlet box. After the electrical connections are made, the user can then mount the electrical socket within the power inlet box and then secure a cover to the frame, to shield the electrical socket from weather, such as rain, sleet, snow and the like. 
   Other objects, features, and advantages of the invention will become apparent to those skilled in the art from the following detailed description and accompanying drawings. It should be understood, however, that the detailed description and specific examples, while indicating preferred embodiments of the present invention, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the present invention without departing from the spirit thereof, and the invention includes all such modifications. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Preferred exemplary embodiments of the invention are illustrated in the accompanying drawings in which like reference numerals represent like parts throughout. 
     In the drawings: 
       FIG. 1  is a partial section view of a building showing interconnection of a remote power generator with the main electrical panel of the building using the power inlet box of the present invention; 
       FIG. 2  is an isometric view of the power inlet box of the present invention shown mounted to an exterior wall of a dwelling; 
       FIG. 3  is a side elevation view of the power inlet box shown in  FIG. 2 ; 
       FIG. 4  is a rear elevation view of the power inlet box shown in  FIG. 2 ; 
       FIG. 5  is a bottom plan view of the power inlet box shown in  FIG. 2 ; 
       FIG. 6  is a bottom plan view of the power inlet box similar to that shown in  FIG. 5  with the cap of the electrical socket hidden; 
       FIG. 7  is an isometric view of the frame for the power inlet box shown in  FIG. 2   
       FIG. 8  is an isometric view of the power inlet box shown in  FIG. 2  with the mounting member supporting the electrical socket mounted to the frame shown in  FIG. 7 ; 
       FIG. 9  is a perspective view of the electrical socket mounting member in the power inlet box of  FIG. 8 ; and 
       FIG. 10  is an exploded isometric view of the power inlet box shown in  FIG. 2 . 
   

   DETAILED DESCRIPTION 
     FIG. 1  illustrates a system for interconnecting a remote power generator  10  with the main electrical distribution panel or load center  12  of a building. A manual transfer panel  14  is mounted to the building interior wall adjacent main panel  12 , and is connected to main panel  12  via wiring disposed within a conduit  16  extending therebetween, in a manner as is known. Alternately, the transfer panel  14  may be an automatic transfer panel, as is known in the art. 
   A power inlet box  18 , in accordance with the present invention, is mounted to the exterior of a building wall, shown at  22 . A conduit  24  extends from the interior of building wall  22 , and is interconnected with power inlet box  18  via any satisfactory, conventional wire routing structure, such as a conduit  26  extending through wall  22  for interconnection with conduit  24 . A junction box  28  is mounted to the interior wall of the building, and a flexible cord  34  is attached to junction box  28 . Flexible cord  34  has a plug which is engageable with a power inlet receptacle provided on transfer panel  14 , to complete the electrical connection between power inlet box  18  and manual transfer panel  14  for supplying power to main panel  12  in the event of a power outage or the like. Alternatively, cord  34  may be replaced with wiring contained within a conduit or sheath, to provide a wired connection between power inlet box  18  and transfer panel  14  rather than a plug-type connection. In addition, it is understood that power inlet box  18  may be mounted in any desired location on the building, e.g. on the interior wall, and is not limited to securement to the exterior wall of the building as shown. 
   A flexible cord  36  includes a plug  38  at one end which is engageable with the power outlet of generator  10 . At its opposite end, cord  36  includes a connector  40  engageable with power inlet box  18  for supplying power to power inlet box  18  from generator  10 . When cord  36  is installed in this manner, auxiliary power supplied by generator  10  is transferred to manual transfer panel  14  through inlet box  18  and the wiring in conduit  26 , conduit  24 , junction box  28  and cord  34  to transfer panel  14 . The wiring in conduit  16  transfers power to selected circuits of main panel  12  according to the position of certain switches on transfer panel  14 , so as to provide power to such circuits in the event of a power outage, in a manner as is known. 
   Referring now to  FIG. 2 , the power inlet box  18  in accordance with the invention includes a base or frame  42  that is defined by a rear wall  44 , a first sidewall  46 , and a second sidewall  48 . In one embodiment, the rear wall  44  and sidewalls  46 ,  48  are integrally formed as a single unit such that no seams are formed between the rear wall  44  and each sidewall  46 ,  48 . When assembled, the power inlet box  18  further includes a cover  50  defined by a front wall  52  and a top  54 . In a preferred embodiment, the cover  50  is formed as a single unit such that there is no seam between the front wall  52  and the top  54 . In the illustrated embodiment, the front wall  52  and the top  54  also include an integral side flange  56  at each side, and each side flange  56  is configured to overlie the upper end portion and outer end portion of one of frame sidewalls  46 ,  48 . Representatively, frame  42  and cover  50  may be formed of a thermoplastic material in an injection molding process, although it is understood that any other satisfactory material and forming method may be employed. 
   When assembled, the cover  50  fits onto the frame  42  such that the top  54  of cover  50  rests atop the rear wall  44  and the sidewalls  46 ,  48  of frame  42 . The front wall  52  of the cover  50  engages the outer edges of the sidewalls  46 ,  48  generally perpendicular to the plane of the top  54 . Collectively, the frame  42  and the cover  50  define an interior volume  58  in which an electrical socket  60  may be removably mounted. As will be described more fully below, the electrical socket  60  is secured to and carried by a mounting member, in the form of a mounting plate  62 , which is mounted to an interior surface of the frame  42 . Holes  64  formed in the front wall  52  of the cover  50  align with passages  98 ,  FIG. 9 , formed in the mounting plate  62  which, in turn, align with openings  65 ,  FIG. 4 , formed in the rear wall  44  of the frame  42 . Fasteners  100 ,  FIG. 10 , such as screws or bolts, may be inserted through the front holes  64  and the passages  98  to secure the mounting plate  62  and the cover  50  to the frame  42 . As shown in  FIG. 2 , the electrical socket  60  is recessed from an exposed bottom end  66  of the power inlet box  18 . 
   With additional reference to  FIG. 3 , the exposed bottom end  66  is code-compliant because the power inlet box  18  is designed to be mounted with the rear wall  44  generally flush against the surface of an exterior wall (not shown) of the building. With this orientation, the bottom end  66  faces downward. Thus, any precipitation falls along the exterior surfaces of the side walls of the frame and the front wall of the cover and not into the interior of the power inlet box  18  or into contact with socket  60 . 
   In addition to openings  65 , the rear wall  44  of the frame  42  further includes hanging holes  72 ,  74 , as best seen in  FIG. 4 , through which suitable fasteners, such as screws or bolts, may be used to secure the frame  42  to the exterior wall of the dwelling. At each opening  65 , a nut  75  is embedded in rear wall  44 . Each nut  75  defines threads that are adapted to engage the threads of one of fasteners  100 . With this construction, the fasteners  100  function to removably assemble frame  42 , cover frame  42  and mounting plate  62  together. The power inlet box  18  is constructed so that the frame  42  is mounted to the exterior wall, and power connections are inserted through a knockout  68  and connected to the electrical socket  60  supported by the mounting plate  62  while the mounting plate is detached from the frame  42 . 
   The inner surfaces of rear wall  44  and sidewalls  46 ,  48  of frame  42  include a pair of spaced ribs that define a groove or channel  86 , as shown in  FIG. 7 . The groove or channel  86  has a shape that corresponds to the shape defined by the front and side edges of mounting plate  62 , as well as a height that is slightly greater than the thickness of mounting plate  62 . 
   The electrical socket  60  (hidden by sidewall  46  in  FIG. 3 ) may be electrically coupled to wiring (not shown) inserted through knockout  68  formed in the rear wall  44  of the frame  42  or through one of a pair of knockouts  70  formed in the sidewalls  46 ,  48 . In a preferred embodiment, the knockouts may also be removed by applying a blunt force to the knockouts from within the power inlet box  18 . In this regard, the interior volume of the power inlet box  18  cannot be accessed by applying a blunt force to the knockouts from outside the power inlet box  18 . Construction of such a knockout is more fully described in U.S. Ser. No. 12/199,490, the disclosure of which is incorporated herein. 
   The electrical socket  60 , when mounted within the power inlet box  18 , is slightly recessed from the exposed bottom end  66 . This recessed configuration of the electrical socket  60  isolates electrical socket  60  from environmental elements, such as rain, sleet, snow, and the like. Notwithstanding the environmental protection provided by the power inlet box  18 , the electrical socket  60  also includes a cap  76  that is coupled to a cylindrical body  78  that forms a housing for conductive blades  80 , as best shown in  FIGS. 5-6 . The cap  76  is coupled to the body  78  using a hinge structure  82  that allows the cap  78  to be opened, thereby exposing the blades  80  without detaching the cap  78  from the electrical socket  60 . The hinge structure  82  includes a spring (not shown) that biases the cap  78  to a closed position, as is known in the art. Preferably, the cap  78  has a flange or tab  84  that can be easily grasped and pulled to move the cap  78  from a normally closed position to an open position. 
   As further illustrated in  FIG. 8  (which shows the cylindrical housing of socket  60  in phantom), the electrical socket  60  includes connectors  88  as known in the art for connecting power leads (not shown) from a load, such as a transfer panel  14 , to the conductive blades  80  so that when the connector  40  is engaged with electrical socket  60 , power is available from the generator  10  to the load  14 . 
   Referring to  FIG. 9 , the mounting plate  62  has a generally planar surface  90  with an opening  92  formed therein. The opening  92  is sized to receive the electrical socket  60 . In one embodiment, the electrical socket  60  includes fasteners (not shown) that extend through holes  94  to connect the electrical socket  60  to the mounting plate  62 . Raised portions  96  extend above the planar surface  90  and each defines a respective elongated passage  98 . The mounting plate  62  is constructed such that the elongated passages  98  align with openings  65  of the rear wall  44 . When the cover  50  is placed onto the frame  42 , the holes  64  formed in the front wall  52  of the cover  50  will also align with elongated passages  98 . Thus, a fastener  100 , such as a bolt, may be inserted into the holes  64  through elongated passages  98  and threadingly engaged with nuts  75  in openings  65  of the rear wall  44  to secure the mounting plate  62  and cover  50  to the frame  42 . Because the cover  50  and frame  42  collectively enclose all but the bottom end  66  and further because the electrical socket  60  faces downward, the face of the electrical socket  60  can be accessed without removing cover  50  from the frame  42 . Representatively, mounting plate  62  may be formed of a thermoplastic material in an injection molding process, like frame  42  and cover  50 , although it is understood that any other satisfactory material and forming method may be employed. 
   In use, the power inlet box  18  is constructed such that a user can first fix the frame  42  to the exterior wall of a dwelling using fasteners through mounting holes  72 ,  74  in rear wall  44 . The user can then hold mounting plate  62  in his or her hand separately from frame  42 , and then make the necessary electrical connections to the electrical socket  60 , which is mounted to and carried by mounting plate  62 . The user then mounts the electrical socket  60  via mounting plate  62  to the frame  42 , such that mounting plate  62  is engaged within groove  86  and supported by the ribs that define groove  86 . The cover  50  may then be secured to the frame  42 , such that cover  50  and frame  42  are securely fastened together, with mounting plate  62  therebetween, using fasteners  100 . The groove  86  is formed at a height from the bottom of the rear wall  44  and sidewall  46 ,  48  such that, when the mounting plate  62  is positioned within the groove  86 , the electrical socket  60  will be recessed within the interior volume  58  of the power inlet box  18 , as shown in  FIG. 8 . 
   It is contemplated that the components of the power inlet box  18  may be packaged as a kit. In this regard and referring to  FIG. 10 , the frame  42 , cover  50 , electrical socket  60 , mounting plate  62 , and fasteners  100  may be packaged together with appropriate assembly instructions. As noted above, the construction of the power inlet box  18  allows the frame  42  to be mounted to the exterior wall of a dwelling or building without the electrical socket  60  coupled to the frame  42 , so that the user can make the electrical connections to socket  60  without socket  60  being fixed in position on the building. 
   While the mounting member has been shown and described as a mounting plate  62  that is slidably received by the frame  42 , it is understood that the mounting member may have any desired configuration that is separate from the frame or base, and may be engageable with the frame or base using any desired mounting technique. For instance, hangers may be formed on the interior surfaces of the frame and the mounting member may be retained by the hangers. In another example, the mounting plate may include teeth that interface with corresponding slots formed along the interior surface of the frame. It is recognized that other types of mountings different from those described herein may be used and are deemed within the scope of the present invention. It is also understood that, which the mounting member and the cover are shown and described as being separate components, the mounting member and the cover may be formed as a separate subassembly. In a construction such as this, the base member is first secured to the support structure such as a wall, and the user makes the electrical connections to the socket while holding the mounting member and cover member subassembly. The mounting member and cover member subassembly is then secured to the base member to form the final power inlet box assembly. 
   Additionally, while the power inlet box  18  has been described as being mounted on the outside wall of a building for electrically connecting a transfer panel to an electric generator, it is understood that the present invention may also be used to provide ease of connection for any electrical receiver, socket or outlet that is adapted to be connected to any stationary structure such as a wall, whether in an indoor or outdoor environment. 
   Various alternatives and modifications are contemplated as being within the scope of the following claims, which particularly point out and distinctly claim the subject matter regarded as the invention.