Abstract:
An electrical box described herein allows for separate wire connection areas for low voltage and line voltage wiring within a single box. The electrical box includes a voltage divider positioned within the box that divides the box into two distinct portions, thereby providing a low voltage wiring connection area that is separate from the line voltage wiring connection area. The electrical box also includes multiple knockouts, each covering an opening that provides a passageway from the interior of the box to the exterior of the box. At least one knockout and associated opening are positioned to provide access to the low voltage wiring connection area and another knockout and associate opening is positioned along to the box to provide access to the line voltage wiring connection area. The box provides an electrical junction for a luminaire, such as a downlight, or other electrical device.

Description:
TECHNICAL FIELD 
     The present application relates generally to an electrical box, enclosure, or receptacle. More specifically, the application relates to an electrical box, enclosure, or receptacle configured to separate low voltage control wiring and line voltage wiring. 
     BACKGROUND OF THE INVENTION 
     Electrical boxes are used to allow installers to install lighting fixtures in buildings pre-wired for low voltage and line voltage wiring. The electrical box is coupled to a lighting fixture having low voltage dimming capabilities. Typically, low voltage and line voltage wiring extends from the lighting fixture into the interior of the electrical box by way of a flexible electrical conduit. In many cases, terminal connections of the low voltage and line voltage wiring (present within the electrical box) are electrically coupled to a dimmer switch and a load source, respectively, to complete installation of the lighting fixture. 
     The presence of low voltage and line voltage wiring within a single enclosure can result in a hazardous condition in the event that the terminal connections of the low voltage and line voltage wiring are in close proximity to one another or physically contact each other. In order to comply with standard electrical codes and maintain a separation between the terminal connections of the low voltage and line voltage wiring, installers may use multiple electrical boxes to separately house low voltage and line voltage wiring. However, the use of multiple electrical boxes is undesirable, as it is costly and results in too much space being needed. 
     SUMMARY OF THE INVENTION 
     Electrical boxes and systems described herein allow separation of circuits between low voltage wiring and line voltage wiring. In one aspect, an electrical box of the present invention can include four side walls defining an enclosure and arranged in a rectangular shape to form an interior space within the enclosure, and a voltage divider positioned within the interior space of the enclosure. The voltage divider can be positioned within a single quadrant of the interior space to define a separate space within the interior space. The shape of the space can be rectangular, triangular, have a curved portion, or be asymmetrically-shaped. At least one of the side walls of the enclosure can include at least one knockout. The knockout can provide a passageway from an exterior of the electrical box to the interior space and/or the space defined by the voltage divider and the enclosure. The voltage divider can also include at least one opening that allows a passageway between the interior space and the space defined by the voltage divider and the enclosure. 
     In another aspect, a system is defined that includes an electrical box of the present invention having low voltage and line voltage wiring therein. The low voltage and line voltage wiring can be positioned at least partially within the interior space of the enclosure. At least a portion of the low voltage wiring can extend from the interior space, through the opening in the voltage divider, and into the space defined by the voltage divider and the enclosure. In some aspects, the system includes multiple electrical boxes. The line voltage wiring extends from the interior space of one electrical box into the interior space of another electrical box via knockouts present along an exterior of each electrical box. 
     In yet another aspect of the present invention, a voltage divider can include an attachment wall having a first opening sized substantially similar to a knockout of an electrical box, and at least one wire receiving wall having a second opening for receiving low voltage wiring. The voltage divider can include two wire receiving walls coupled to each other. The wire receiving wall can be curved, flat, or asymmetrically-shaped. 
     These and other aspects, objects, and features of the invention will become apparent to those having ordinary skill in the art upon consideration of the following detailed description of exemplary embodiments exemplifying the best mode for carrying out the invention as presently perceived. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of an electrical box, showing an interior thereof, according to an exemplary embodiment. 
         FIG. 2  is a perspective view of the electrical box of  FIG. 1  coupled to a lighting fixture, according to an exemplary embodiment. 
         FIG. 3  is a perspective view of another electrical box, showing an interior thereof, according to an alternative exemplary embodiment. 
         FIG. 4  is a perspective view of yet another electrical box, showing an interior thereof, according to another alternative exemplary embodiment. 
         FIG. 5  is a perspective view of a voltage divider for an electrical box, according to an exemplary embodiment. 
     
    
    
     DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS 
     The invention may be better understood by reading the following description of non-limiting, exemplary embodiments with reference to the attached drawings wherein like parts of each of the figures are identified by the same reference characters. 
     The exemplary electrical enclosure, receptacle, housing, or box can be made of metal (for example, steel), plastic (for example, PVC), or other material, and can provide a structure for housing an electrical connection. The exemplary embodiments describe a box, but the box is not intended to be limited only to a box for housing low voltage and line voltage wiring. Although the exemplary embodiments describe a box, the box can be any configuration of box, including those boxes having a removable back or cover (also known as an “open back” box) or those boxes having a fixed back. For example, in one exemplary embodiment, the back panel of the open back box is attached using screws or other suitable fasteners. In an alternative exemplary embodiment, the back panel of the box is attached by inserting protrusions of the back panel into corresponding apertures in the box. 
     Referring to  FIG. 1 , a perspective view of an electrical box  100  is shown. The box  100  includes four side walls  105   a ,  105   b ,  105   c ,  105   d , collectively referred to as side walls  105 , arranged in a rectangular shape. The box  100  also includes a fixed back wall  110  that is coupled to and disposed orthogonally to the side walls  105 . The side walls  105  and the back wall  110  define a cavity  115  of the box  100 . In one exemplary embodiment, a front side of the box  100  remains open to allow access to the cavity  115 . Also, in certain exemplary embodiments, a cover (not shown) is removably coupled to the front side of the box  100  to close off the box and prevent access to any components (not shown) housed therein. The side walls  105  include one or more knockouts  120 . The knockouts  120  are partially stamped openings that can be removed to allow quick entry of a wire, cable, or pipe into the interior of the electrical box  100 . It is understood that knockouts  120  can be configured along side walls  105  to provide access to the interior of box  100 , but knockouts  120  are not intended to be limited to any particular configuration. 
     The box  100  also includes a voltage divider  130  positioned in a lower quadrant of the cavity  115 . The voltage divider  130  includes a top wall  130   a  and a side wall  130   b . In one exemplary embodiment the top wall  130   a  is orthogonal to or substantially orthogonal to the side wall  130   b  at an intersection  135  of the top wall  130   a  and the side wall  130   b . In one exemplary embodiment, the top wall  130   a  is coupled to the side wall  105   a  at a position such that at least one knockout  120   a  remains between the top wall  130   a  and the side wall  105   d  of the box  100 , and at least one knockout  120   b  remains between the top wall  130   a  and the side wall  105   b  of the box  100 . In certain exemplary embodiments, the side wall  105   a  includes only one knockout  120   b  that remains between the top wall  130   a  and the side wall  105   b  of the box  100 . In certain exemplary embodiments, the side wall  130   b  is coupled to the side wall  105   b  at a position about midway along the length of the side wall  105   b . In certain exemplary embodiments, the voltage divider  130  is integral to the side walls  105   a ,  105   b . In alternative embodiments, the voltage divider  130  includes flanges (not shown) extending orthogonally from the top wall  130   a  and the side wall  130   b , respectively. The flanges or the side walls  130   a ,  130   b  themselves are secured to the box  100  by any means known to one having ordinary skill in the art, including, but not limited to, screws, adhesives, and welding. 
     The top wall  130   a  of the voltage divider  130  includes an opening  145   a , and the side wall  130   b  includes an opening  145   b . The openings  145   a ,  145   b  provide a passageway between the interior of the voltage divider  130  and the interior  115  of the box  100 , and are configured to receive wiring (not shown) therethrough. In certain exemplary embodiments, the openings  145   a ,  145   b  are circular and can accommodate up to two wires. In alternative embodiments, the shape of the openings  145   a ,  145   b  are triangular, rectangular, pentagonal, hexagonal, and the like. In other embodiments, the openings  145   a ,  145   b  are asymmetrically-shaped. The openings  145   a ,  145   b  may be configured in any shape so long as the openings  145   a ,  145   b  are sized appropriately to accommodate wiring for low voltage dimming applications, or other desired applications. In certain exemplary embodiments, grommets  150  are inserted into the openings  145   a ,  145   b , to reinforce the openings  145   a ,  145   b  and/or shield wiring (not shown) from the sharp edges of the openings  145   a ,  145   b . In certain embodiments, the grommets  150  are constructed from plastic. In certain other embodiments, the grommets  150  are constructed from rubber. 
     In certain exemplary embodiments, the voltage divider  130  is constructed of steel or aluminum, and the thickness of the top wall  130   a  and the side wall  130   b  is about 0.016 inch. In certain other exemplary embodiments, the voltage divider  130  is constructed of a vulcanized fiber and molded polymeric material, and the thickness of the top wall  130   a  and the side wall  130   b  is about 0.028 inch. However, those of ordinary skill in the art will recognize that other thicknesses, both lesser and greater, for both the steel/aluminum embodiment and the vulcanized fiber/molded polymeric embodiment are within the scope of the exemplary embodiments. 
     Referring now to  FIG. 2 , a perspective view of an electrical box  100  coupled to a lighting fixture  250  is shown. The electrical box  100  is the same as that described above with regard to  FIG. 1 , except as specifically stated below, and for the sake of brevity will not be repeated herein. 
     The lighting fixture  250  includes line voltage wiring  255  and low voltage wiring  260  coupled to a ballast (not shown). The line voltage wiring  255  and low voltage wiring  260  extends from the lighting fixture  250  to the box  100  through a flexible electrical conduit  265 . The flexible electrical conduit  265  is coupled to the side wall  105   c , and provides a pathway for the wiring  255 ,  260  from the fixture  250  into the cavity  115  of the box  100 . 
     Once inside the cavity  115  of the box  100 , the low voltage wiring  260  extends through the opening  145   b  of the voltage divider  130  and into a space  115   a  formed by the voltage divider  130  and the side walls  105   a ,  105   b . In alternative embodiments, the low voltage wiring  260  extends through the opening  145   a  of the voltage divider  130  and into the space  115   a . The line voltage wiring  255  remains in the cavity  115  outside of the space  115   a , and therefore is separated from the low voltage wiring  260 . As a result, separation between the line voltage wiring  255  and the low voltage wiring  260  is maintained for the purposes of connecting each to their respective power sources (either directly or through intermediate connections). The line voltage wiring  255  includes a connector  255   a  at an end thereof, and can be electrically coupled to a power source (not shown). The low voltage wiring  260  includes a connector  260   a  at an end thereof, and can be electrically coupled (via intermediate wiring) to a dimmer switch (not shown) or other low voltage system. In certain alternative embodiments, additional line voltage wiring (not shown) can extend through any one of the knockouts  120  of the box  100 , and into other electrical boxes (not shown). 
     When access to the cavity  115  of the box  100  is necessary, a cover (not shown) removably secured to the front side of the box  100  is opened to allow access to the cavity  115 . When access to the cavity  115  of the box  100  is no longer necessary or when the fixture  250  is operating, the cover is re-secured to the front side of the box  100  to close off the box  100  and prevent access to the line voltage wiring  255  and the low voltage wiring  260  housed therein. 
     Referring to  FIG. 3 , a perspective view of an electrical box  300  is shown. The electrical box  300  is the same as that described above with regard to  FIG. 1 , except as specifically stated below, and for the sake of brevity will not be repeated herein. 
     The box  300  also includes a voltage divider  330  positioned therein. The voltage divider  330  includes a first end  330   a  and a second end  330   b . The voltage divider  330  also includes a curved portion  330   c  extending between the first end  330   a  and the second end  330   b . The first end  330   a  is coupled to the side wall  105   a  at a position such that at least one knockout  120   a  remains between the first end  330   a  and the side wall  105   d  of the box  300 , and at least one knockout  120   b  remains between the first end  330   a  and the side wall  105   b  of the box  300 . In certain exemplary embodiments, the side wall  105   a  includes only one knockout  120   b  that remains between the first end  330   a  and the side wall  105   b  of the box  300 . The second end  330   b  is coupled to the side wall  105   b  at a position about midway along the length of the side wall  105   b . In certain exemplary embodiments, the voltage divider  330  is integral to the side walls  105   a ,  105   b . In alternative embodiments, the voltage divider  330  includes flanges (not shown) extending orthogonally from the first end  330   a  and the second end  330   b , respectively. The flanges or the first end  330   a  and the second end  330   b  themselves are secured to the box  300  by any means known to one having ordinary skill in the art, including, but not limited to, screws, adhesives, and welding. 
     The curved portion  330   c  of the voltage divider  330  includes circular openings  145   a ,  145   b , for receiving low voltage wiring (not shown) therethrough. In certain alternative embodiments, the curved portion  330   c  may include only one opening  145   a . Any number of openings may be included in the voltage divider  330 , as deemed appropriate by one having ordinary skill in the art. 
     Referring to  FIG. 4 , a perspective view of an electrical box  400  is shown. The electrical box  400  is the same as that described above with regard to  FIG. 1 , except as specifically stated below, and for the sake of brevity will not be repeated herein. 
     The box  400  includes a voltage divider  430  positioned therein. The voltage divider  430  includes a first end  430   a  and a second end  430   b . The voltage divider  430  also includes a flat planar portion  430   c  extending between the first end  430   a  and the second end  430   b  and having a width that is equal to or substantially equal to the depth of the box  400 . The first end  430   a  is coupled to the side wall  105   a  at a position such that at least one knockout  120   a  remains between the first end  430   a  and the side wall  105   d  of the box  400 , and at least one knockout  120   b  remains between the first end  430   a  and the side wall  105   b  of the box  400 . In certain exemplary embodiments, the side wall  105   a  includes only one knockout  120   b  that remains between the first end  430   a  and the side wall  105   b  of the box  400 . The second end  430   b  is coupled to the side wall  105   b  at a position about midway along the length of the side wall  105   b . In certain exemplary embodiments, the voltage divider  430  is integral to the side walls  105   a ,  105   b . In alternative embodiments, the voltage divider  430  includes flanges (not shown) extending orthogonally from the first end  430   a  and the second end  430   b , respectively. The flanges or the first end  430   a  and the second end  430   b  themselves are secured to the box  400  by any means known to one having ordinary skill in the art, including, but not limited to, screws, adhesives, and welding. 
     The flat portion  430   c  of the voltage divider  430  includes circular openings  145   a ,  145   b , for receiving low voltage wiring (not shown) therethrough. However, one of ordinary skill in the art will recognize that any number of openings  145 , including a single opening, in the voltage divider  430  is within the scope of the exemplary embodiments based on particular design needs. 
     Referring now to  FIG. 5 , a perspective view of an exemplary voltage divider  500  for retrofitting into an existing electrical box is shown. The voltage divider  500  includes a top wall  530   a , a side wall  530   b , an optional base wall  530   c , and an attachment wall  530   d , collectively referred to as walls  530 , arranged in a rectangular shape. Those of ordinary skill in the art will recognize, however, that the alternative voltage dividers of  FIGS. 2-4  are modifiable in a similar manner as described with regard to voltage divider  500  of  FIG. 5  for other retrofit options. The top wall  530   a  of the voltage divider  500  includes a circular opening  545   a , and the side wall  530   b  includes a circular opening  545   b . The openings  545   a ,  545   b  are sized to function as a passageway for wiring (not shown), such as low voltage wiring, from a cavity  115  of a junction box  100  (such as that taught and described in  FIG. 1 ) to the interior of the voltage divider  500 . In one exemplary embodiment, the low voltage wiring is used for low voltage dimming applications. 
     The attachment wall  530   d  includes a circular opening  545   d  sized approximately equal to or greater than a knockout (not shown) and generally positioned to line up with the knockout in the existing electrical box when inserted therein. In certain exemplary embodiments, the attachment wall  530   d  includes a flange  535  extending generally upward past the intersection of the top wall  530   a  and the attachment wall  530   d , where the flange  535  is orthogonal to the top wall  530   a . The flange  535  includes an opening  570  configured to receive a screw, or other attachment device. 
     In one exemplary embodiment, the voltage divider  500  is placed in a corner of the existing electrical box such that the attachment wall  530   a  is flush against a side wall of the existing electrical box, and the circular opening  545   d  is aligned with a knockout in the side wall of the existing electrical box. The flange  535  is secured to an interior of the side wall of the existing electrical junction box using an attachment device, such as a screw. Once the voltage divider  500  is placed in the existing electrical box, low voltage wiring (not shown) can be drawn from the electrical box through one of the openings  545   a ,  545   b , and into the space defined by the walls  530 . The low voltage wiring can then be electrically connected to an external dimmer switch. The presence of the voltage divider  500  in the existing electrical box allows the user to effectively separate low voltage wiring from line voltage wiring for the purposes of making connections to voltage sources for both therein, and keeping those connections points separate. 
     In certain exemplary embodiments, the voltage divider  500  is constructed from one of steel, aluminum, vulcanized fiber and molded polymeric material, or the like. In certain embodiments, the voltage divider  500  has a shape other than rectangular. For instance, the shape of the voltage divider  500  in certain alternative embodiments is one of triangular, pentagonal, curved, or asymmetric. One having ordinary skill in the art will recognize that the voltage divider may have any shape suitable for use in an electrical box, while effectively separating connection points between low voltage wiring and line voltage wiring, and allow users to run multiple sets of line voltage wiring through the electrical box to other electrical boxes. 
     The particular embodiments disclosed herein are illustrative only, as the invention may be modified and practiced in different but equivalent manners apparent to those having ordinary skill in the art and having the benefit of the teachings herein. While numerous changes may be made by those having ordinary skill in the art, such changes are encompassed within the spirit and scope of this invention as defined by the appended claims. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular illustrative embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit of the present invention as defined by the claims below. The terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee.