Abstract:
One aspect of the invention is an outlet box frame for installation in a hole in a floor structure. The hole having a perimeter and defining an internal wall surface in said floor structure. The frame including a walled member, at least one flange portion and a unitary retaining screw guide. The walled member being sized for insertion within the hole. The at least one flange portion extending outward from the walled member, wherein once installed at least a portion of the flange extends from the walled member past the internal wall surface. The unitary retaining screw guide supports a retaining screw. The screw guide being supported from the walled member and configured to receive the retaining screw therein. Upon installation, the retaining screw inserted in the retaining screw guide engages the hole wall without significant penetration thereof, providing at least pullout resistance of the frame from the hole. Alternatively, the outlet box frame may include the retaining screw.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/914,064 filed on Apr. 26, 2007. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    The present invention relates generally to an electrical outlet box assembly, which houses power and/or communication lines and/or fixtures. More specifically, the present invention relates to an outlet box frame assembly having a frame, which includes a guide for holding one or more anchoring screws that provide support for the outlet box within a hole in a floor structure. 
         [0003]    It is well known to use electrical outlet boxes to terminate or couple electrical wires and cables. Such outlet boxes permit the insertion of electrical wires into the box, which can pass through the box or terminate therein to electrical fixtures, such as switches and receptacles in an electrical outlet box. It has also become necessary to pass through or terminate communications wires for such purposes as data, voice and signal transmission and networking computers. While terminations of electrical wires are required to be housed in an electrical box, not all wires and cables are required to use an electrical box. Nonetheless, aesthetics, mechanical safety and convenience have dictated the need to place communication and other wires or cables in close proximity to the electrical terminations. 
         [0004]    In office spaces and other commercial environments it is often desirable to have access to electrical outlets or other electrical connections at locations located a distance from standard wall outlets. In order to safely accommodate such situations, floor boxes and/or ceiling boxes are typically used. These boxes may be located in the floor or ceiling, near or at the location, such as under a work cubicle or near a piece of machinery, where the connection is needed. 
         [0005]    One type of floor box, referred to as a poke-through floor box, is designed to be supported within a hole in a poured concrete floor. Contemporary poke-through floor boxes generally include a so-called “self-anchoring” assembly, which secures the poke-through structure within the hole in the floor structure. Generally, these self-anchoring assemblies employ a ring-shaped spring or retaining clip with one or more radially protruding elements. The retaining clip engages and bites into the surrounding wall structure of the hole as the assembly is inserted therein, in order to anchor the assembly in-place. However, due to the design and configuration of these retaining rings, the poke-through assembly is extremely difficult to remove or freely reposition once installed. In fact, removing or repositioning the assembly after installation can destroy the retaining clip and damage the poke-through assembly. Additionally, employing a retaining ring adds cost to the overall assembly, as they have to be custom manufactured for the particular type of floor box. 
         [0006]    Accordingly, there is a need for an outlet box assembly that overcomes the shortcoming set forth above. In particular, there is a need for a floor box anchoring assembly that is easily adjusted after installation. Such an improved assembly is preferably inexpensive and installed easily. 
       SUMMARY OF THE INVENTION 
       [0007]    One aspect of the present invention is an outlet box frame for installation in a hole in a floor structure. The hole having a perimeter and defining an internal wall surface in the floor structure. The frame includes a walled member, at least one flange portion and a unitary retaining screw guide for supporting a retaining screw. The walled member is sized for insertion within the hole. The at least one flange portion extends outward from the walled member toward and past the internal wall of the hole. Also, the screw guide is supported from the walled member and configured to receive the retaining screw therein. During and/or upon installation, the retaining screw is inserted in the screw guide and engages the internal wall surface of the hole without significantly penetrating it. Thus, the screw resists pullout and/or rotation of the frame relative to the hole. 
         [0008]    Additionally, the outlet box frame can include a cover-mounting portion for securing an outlet box cover relative to the walled member. Also, the outlet box assembly can include the retaining screw disposed in the screw guide. The retaining screw can further provide rotational resistance for the frame relative to the hole. Further, a first portion of the screw guide can be configured to hold at least a central shaft portion of the retaining screw upon installation. Additionally, a second portion of the screw guide can be configured to hold a portion of the retaining screw remote from the central shaft portion. The first and second portions of the screw guide can be integrally formed. 
         [0009]    Another aspect of the present invention is an outlet box assembly for installation in a hole in a floor structure. The assembly including a screw anchor and a frame. The frame allowing power and/or communication cables to pass therethrough. Also, the frame includes an external wall portion, at least one flange portion and a screw guide for supporting the screw anchor. The external wall portion covering a portion of the internal wall of the hole. The at least one flange portion extending from the external frame wall toward and past the internal wall of the hole. The screw guide disposed below the flange and configured to receive the retaining screw therein. Upon installation, the retaining screw disposed partially within the screw guide engages the internal wall of the hole without significant penetration thereof. The wall engagement by the screw prevents or resists pullout and/or rotation of the frame from the hole. 
         [0010]    Yet another aspect of the present invention is an outlet box assembly for installation in a hole in a floor structure, where the hole defines internal walls that extend from an upper surface of the floor structure. The assembly includes a first and second frame element. The first frame element supports an outlet box cover. Also, the first frame element includes at least one protruding portion, wherein upon installation the protruding portion extends beyond the internal walls of the hole for engaging at least a portion of the floor upper surface. The second frame element extends from the first frame element. Upon installation the second frame element is substantially disposed within the hole. The second frame element includes a screw guide for supporting a retaining screw. The screw guide is configured to receive the retaining screw therein. Also, upon installation the retaining screw inserted in the screw guide engages the internal walls of the hole without significant penetration thereof. Thus, the screw resists pullout and/or rotation of the frame elements relative to the hole. 
         [0011]    Further, the assemblies described above can include an intumescent member disposed below the frame for resisting heat transfer through the hole. Also, the flange portion can be integrally formed with the external frame wall. Additionally, the assemblies can include additional features from those described above, such as those recited above for the outlet box frame. 
         [0012]    The preferred embodiments of the outlet box frame and assembly of the present invention, as well as other objects, features and advantages of this invention, will be apparent from the following detailed description, which is to be read in conjunction with the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0013]      FIG. 1  is bottom perspective view of an electrical box assembly including a radially protruding anchor screw in accordance with the present invention. 
           [0014]      FIG. 2  is a top perspective view of the assembly shown in  FIG. 1 , with the cover and lower conduit assemblies removed. 
           [0015]      FIG. 3  is a top plan of the assembly shown in  FIG. 2 . 
           [0016]      FIG. 4   a  is a side section view of the assembly shown at A-A in  FIG. 3 . 
           [0017]      FIG. 4   b  is a side section view of an alternative assembly to that shown in  FIG. 4   a.    
           [0018]      FIG. 5  is a partially exploded top perspective view of the assembly shown in  FIG. 2 . 
           [0019]      FIG. 6  is a partially exploded top perspective view of an outlet box frame with two anchor screws in accordance with the present invention. 
           [0020]      FIG. 7  is a partially exploded bottom perspective view of the assembly shown in  FIG. 6 . 
           [0021]      FIG. 8  is a top perspective view of the lower assembly elements shown in  FIG. 5 . 
           [0022]      FIGS. 9   a,    9   b  and  9   c  are side, top perspective and bottom views, respectively of an alternative assembly in accordance with the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0023]    Referring first to  FIG. 1 , the outlet box assembly  10 , formed in accordance with the present invention, is shown. The outlet box assembly  10  shown includes a furniture feed design, which is preferably intended to allow wires or cables to pass therethrough between floors, without an electrical fixture or device mounted therein. However, one of ordinary skill in the art would understand that this design can be modified to provide a bracket that supports and/or accommodates electrical fixtures, such as switches or receptacles, and/or communication fixtures, such as data plugs, coaxial connectors, fiber optic connectors and the like, which provide for termination of voice, data or signal wires. 
         [0024]    The assembly  10  particularly includes a mounting frame  100  with at least one screw guide for supporting a removeably installed anchor screw. The anchor screw tip  59  is shown radially protruding from the assembly. The frame  100  can be made of various materials, however, it is preferably made of die-cast zinc, aluminum or other metals and suitable materials for the particular application. 
         [0025]    Additionally, the assembly preferably includes a cover  200 , intumescent member  210 , and lower assembly elements  220 ,  230 ,  240 ,  241 . In the particular example shown, the assembly  10  is made in a circular or cylindrical configuration. However, it should be understood that the assembly is preferably formed or adapted to the shape and size of the hole in which it is intended. Also, although the details and alternative designs for the cover  200 , intumescent member  210  and lower assembly elements  220 ,  230 ,  240 ,  241  are not fully elaborated herein, it should be understood that such elements can vary from the exemplary designs shown. While the preferred embodiment is described in the context of a concrete floor installation, the invention is suitable for installations in structures comprised of other materials and configurations. 
         [0026]      FIGS. 2 through 8  show further details of the frame  100  and other assembly structures. In particular, the frame  100  preferably includes a flange  110  that radially protrudes from the upper edge of a substantially annular ring or wall member  120 . While wall  120  can be a continuous unitary member, it can also be formed with cutouts, apertures or protrusions that otherwise interrupt its generally uniform annular shape. Also, integrated into the combined structures of the flange  110  and the wall  120 , the frame  100  can include mounting portion  102  intended to secure the cover  200  to the frame  100 . As particularly shown in  FIG. 6 , the mounting portion  102  preferably includes one or more reinforcing structures  112 ,  113  and an aperture  114  for receiving a screw or other fastener. Also, while the upper surface of the mounting portion  102  is shown flush with the rest of the upper surface of the flange  110 , either a vertically recessed or protruding surface for the mounting portion  102  could alternatively be provided. 
         [0027]    As particularly shown in  FIGS. 4   a  and  4   b,  the wall  120 ,  121  is preferably suitable sized to fit inside the hole  22  in the floor structure  20  in which it is installed. In contrast, the flange  110 ,  111  radially extends outwardly past the diameter of the hole  22 , providing an overhang. Thus, flange  110 ,  111  preferably prevents the frame  100 ,  101  from completely falling into the hole, at least during the installation process. The flange  110 ,  111  can rest on the upper surface of the floor  20  as shown or be supported by an intermediate washer, gasket or other structure (not shown). 
         [0028]    Additionally as shown in  FIGS. 2 and 3 , the flange  110 ,  111  can include further protruding portions  115  that extend radially beyond the normal diameter of the flange  110 ,  111 . Such protruding portions  115  can serve as handles during installation or even mate with the design of the cover  200  to prevent relative rotational movement there between. It should be understood, however, that while flange  110 ,  111  is shown to be a continuous annular member, it can alternatively be formed by two or more radial protrusions that are circumferentially spaced from one another. 
         [0029]    The frame  100 ,  101  also preferably includes an inner platform or bracket  130 ,  131  which can provide a support structure and means for securing the lower assembly elements  210 ,  220 ,  230 ,  240 ,  241  thereto. Additionally, bracket  130 ,  131  preferably provides support for the anchor screw guide  140 ,  141 . As shown, at least an upper portion of the screw guide  140 ,  141  is formed as a recess in the bracket  130 ,  131 . In this way, the head of anchor screw  50  when installed in the screw guide  140 ,  141  can also be recessed below the upper surface of bracket  130 ,  131 . Such a configuration preferably avoids interference of the anchor screw  50  with the cover or other structures mounted in the frame  100 ,  101 . 
         [0030]    The anchor screw guide  140 ,  141  is preferably designed to receive and guide a screw  50 , which serves as an anchor for the assembly  10  within the hole, preferably preventing pullout and rotation of the assembly  10 . The screw guide  140 ,  141  is preferably formed as a unitary element. The cost of most suitable screws  50  should be significantly less expensive than the traditional stamped steel retaining ring. The anchor screw  50  is generally inserted into the screw guide  140 ,  141  from above the frame  100  at an angle. The screw guide  140 ,  141  is designed to allow at least the tip  59  of the anchor screw  50  to radially protrude outside the perimeter or diameter of the annular wall  120 . In fact, preferably the anchor screw  50  should protrude far enough outside the annular wall  120  to allow the screw tip  59  to fully engage and bite, dig or wedge into or bias against the wall surface  22  of the hole in which it is installed. This type of biting engagement is not intended to significantly penetrate the wall surface  22 . Preferably, the screw tip  59  only slightly breaks the surface  22  in order to provide an enhanced frictional engagement. This type of biting engagement serves not only to vertically secure, but also to center the overall assembly  10  within the hole. Additionally, the engagement of screw tip  59  will not only resist the overall assembly from being pulled-out of the hole, but will also preferably resist rotation of the assembly  10  within the hole. The examples shown in  FIGS. 4   a  and  4   b  illustrate the biting engagement in a concrete floor installation. Such an application preferably uses a sharply pointed screw tip  59 . However, a more blunt screw tip  59  could be used for softer surfaces  22 . Also, the length of the screw is preferably selected to suit the particular application. Additionally, suitable metallic or ceramic washers could be used in combination with the anchor screw  50  as desired. While metal washers are less expensive, ceramic washers could provide a thermal barrier or heat dissipating effect if the assembly  10  were subjected to a spiking thermal event, such as a fire. 
         [0031]    Additionally shown in  FIGS. 2 and 5 , frame  100  is preferably secured to the intumescent member  210  and some of the lower assembly elements  220  (not all shown) through axial bolts  250 . Preferably, the bracket  130  is provided with an aperture  132  for receiving and securing an upper portion of the bolts  250 . Also, because the screw guides  140 ,  141  vertically project beyond the lower portion of the frame wall  120 , the adjacent intumescent member  210  is preferably provided with cups or recesses  215  for accommodating these projecting structures. Further, the intumescent member  210  is preferably provided with at least one aperture or slot  216 . The aperture  216  is preferably formed to allow the anchor screw  50  to pass beyond the outer diameter of the intumescent member  210  and bitingly engage the wall surface  22  of the hole in which the assembly  10  is installed. Although aperture  216  is shown as a vertical slot, it should be understood that such an aperture could be almost any other size or shape. Providing a slot  216  that is open at the upper surface of the intumescent member  210 , allows a technician to separate the frame  100  from the intumescent  210  without fully removing the anchor screw  50 . Alternatively, no aperture  216  need be provided, as the installer can either pre-drill a hole on-sight or punch/screw the anchor screw through the outer wall of recess  215 . 
         [0032]    An embodiment of the screw guide  140 , is shown in  FIG. 4   a.  This embodiment is preferably provided with a recess in the bracket  130 , which includes upper support surface  142  and two sidewalls  144  (also shown in  FIG. 6 ). The upper support portion  142  is designed to initially receive the screw  50  and support the upper end of the screw shaft. Preferably, when the screw tip  59  is properly engaged with the wall  22  of the hole  20 , the screw head is also engaged with the upper surface of the upper support portion  142 . However, the depth of the recess in the bracket  130  is preferably sufficiently deep such that even if the screw head is not fully seated against the upper surface of the upper support portion  142 , the screw head will preferably not protrude upwardly beyond the surface of bracket  130 . Additionally, the screw guide  140  is preferably provided with a lower support portion  148 . The anchor screw  50  also penetrates the lower support portion  148 . The shaft of the anchor screw  50  is thus provided with further support closer to the screw tip  59 , preventing an overstressed cantilever condition at the base of the screw head and distributing the shear stresses across the anchor screw  50 . 
         [0033]    Another embodiment of the screw guide  141 , is shown in  FIG. 4   b.  This embodiment combines the upper and lower support portions into a single support portion  143  preferably disposed on an outer wall  148  of screw guide  141 . As illustrated, this embodiment may require selection of a shorter anchor screw  50 . 
         [0034]    Preferably, the support portions  142 ,  143  and outer wall  148 ,  149  are respectively provided with screw apertures  145 ,  146 ,  147 . Preferably, the central axis of the apertures  145 ,  146 ,  147  is angled at forty-five degrees from the plane of the upper surface of the floor  20 . Alternatively, the apertures can be configured for other desired angles, such as angles smaller or greater than forty-five degrees. Thus, the apertures  145 ,  146 ,  147  can ensure the screw anchor is installed at the desired angle. Also, it should be understood that any one or all of the support portions  142 ,  143 ,  148 ,  149  could be formed without a pre-formed aperture, thus allowing the installer to either drill a hole or simply punch the anchor screw  50  through that portion of the frame  100 ,  101 . Thus, without a pre-formed aperture  145 ,  146 ,  147 , the installer dictates the angle between the screw anchor and the surrounding structures. 
         [0035]    Another embodiment of the present invention is illustrated in  FIGS. 9   a ,  9   b  and  9   c.  The assembly  12  includes frame  102  and cover  202 . This embodiment demonstrates a non-circular design for frame  102  as an alternative to the more traditional annular design described above. It should be understood that although the above designs illustrate and describe assemblies with circular or annular shapes, and particularly perimeters, when viewed from the top, such assemblies can be formed in other geometric shapes. Also, the overall shape of the perimeter can include protrusions and/or be asymmetric. The frame  102  preferably includes a wall member  122  that is formed into a hexagonal shape when viewed from above or below (as shown in  FIG. 9   c ) is an example of such a non-circular design. While such a frame is preferably formed of galvanized steel, other suitable materials could alternatively be used. 
         [0036]    The assembly  12  preferably further includes an alternative screw guide  149  design. In particular, screw guide  149  is preferably formed by a section of material partially cutout and bent outwardly away from the wall member  122 . Such a cutout leaves an aperture  129  in a portion of wall member  122  and a protruding tab that serves as the screw guide. The protruding tab  149  preferably includes a threaded aperture  159  for receiving anchor screw  50  as shown in  FIG. 9   c.  It should be understood that while frame  102  is shown with tab  149  bent outwardly and a pre-formed screw aperture  159 , these features can be formed or finalized just prior to installation. For example, the tab  149  can be formed by perforations through the wall  122 , but not bent away therefrom. In this way the installer would push out the tab  149  with a simple tool to an appropriate angle, as shown in  FIG. 9   a.  Additionally, the threaded aperture  159  can alternatively be left to the installer to drill or otherwise form during or prior to installation. 
         [0037]    Additionally, although assembly  12  is also shown as a furniture feed design, it should be understood that a bracket could be formed therein to support and secure fixtures or lower assembly elements. Such a bracket could be disposed either above or below the tab  149 , as suited for a particular application. 
         [0038]    Although preferred embodiments of the present invention have been described herein with reference to the accompanying drawings, it is to be understood that the invention is not limited to those precise embodiments and that various other changes and modifications may be affected herein by one skilled in the art without departing from the scope or spirit of the invention, and that it is intended to claim all such changes and modifications that fall within the scope of the invention.