Abstract:
A recessed electrical outlet assembly for recessing a duplex receptacle or similar electrical device within a wall. The recessed electrical outlet assembly includes an electrical box and a frame member. The electrical box includes sidewalls and a back wall defining a cavity therein. The cavity is capable of receiving an electrical device therein. The frame member includes a laterally extending flange and a rearward-extending collar that is received within the sidewalls of the electrical box. Alignment tabs are provided on the sidewalls of the electrical box to enable easy alignment against a stud in either a new work or retrofit situation. Bosses provided on the outer sidewalls of the electrical box are angled away from the sidewalls and toward the front of the electrical box and include captive fasteners to simplify the installation of the recessed electrical outlet assembly to a wall.

Description:
This application is a Continuation-In-Part of U.S. patent application Ser. No. 11/356,590 filed Feb. 16, 2006 now U.S. Pat. No. 7,166,801 and still pending, which is a Continuation-In-Part of U.S. patent application Ser. No. 11/264,857, filed Nov. 2, 2005 and now U.S. Pat. No. 7,045,713, which is a Continuation-In-Part of U.S. patent application Ser. No. 11/246,985, filed Oct. 7, 2005 and now U.S. Pat. No. 7,064,271, which is a Continuation-In-Part of U.S. patent application Ser. No. 11/185,256, filed Jul. 20, 2005 and now U.S. Pat. No. 7,115,820, which is a Continuation-In-Part of U.S. patent application Ser. No. 11/102,392, filed Apr. 8, 2005 and now U.S. Pat. No. 7,151,219, 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 and 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, all of which are commonly owned by the assignee of the present invention and the entire contents of which are incorporated herein by reference. 

   FIELD OF THE INVENTION 
   This invention relates to assemblies for the mounting of electrical devices and specifically to a recessed electrical outlet assembly that includes an electrical box portion and a frame member for recessing 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, 6,956,171, 7,005,578, 7,045,713, 7,064,271, 7,115,820, and 7,151,820 and in co-pending U.S. application Ser. No. 11/356,590, 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 were directed primarily to recessing electrical devices on the exterior surface of a structure. Although the aforementioned patents and patent applications provide an apparatus for recessing an electrical box on the exterior of a structure, there is also a need for recessing an electrical outlet on an interior wall of a structure. 
   Accordingly, the present invention provides a two-piece recessed electrical outlet assembly that includes a first portion that comprises an electrical box for mounting in an interior wall and housing and protecting an electrical outlet and its associated wiring. A second portion of the recessed assembly includes a frame member for covering the electrical box and a portion of the interior wall surrounding the box to obscure that portion of the wall surrounding the electrical box. 
   SUMMARY OF THE INVENTION 
   The invention is a recessed electrical outlet assembly for recessing a duplex receptacle or similar electrical device within a wall. The recessed electrical outlet assembly includes an electrical box and a frame member. The electrical box includes sidewalls and a back wall defining a cavity therein. The cavity is capable of receiving an electrical device therein. The frame member includes a laterally extending flange and a rearward-extending collar that is received within the sidewalls of the electrical box. Alignment tabs are provided on the sidewalls of the electrical box to enable easy alignment against a stud in either a new work or retrofit situation. Bosses provided on the outer sidewalls of the electrical box are angled away from the sidewalls and toward the front of the electrical box and include captive fasteners to simplify the installation of the recessed electrical outlet assembly to a wall. 
   OBJECTS AND ADVANTAGES 
   A first object of the recessed electrical outlet assembly of the present invention is to provide an electrical box that positions an electrical device behind the wall surface, thereby recessing the electrical device and enabling cabinets, wall clocks, appliances, and the like to be positioned close to the wall without interference or obstruction from the electrical device. 
   A second object is to provide a recessed electrical outlet assembly that shields the electrical device and any electrical cords plugged therein from splashing water, grease, or other household hazards. 
   A further object is to provide a recessed electrical outlet assembly that provides a recessed area within the wall to hold the plug ends of electrical cords while they are in use, thereby recessing the plug ends away from the wall and from interference with the device they are providing electrical feed to. 
   Another object of the present invention is to provide a two-piece recessed electrical outlet assembly that includes bosses with captive fasteners for easing the installation task. 
   A further object of the present invention is to provide a two-piece recessed electrical outlet assembly in which the captive fasteners are angled outwards with respect to the sidewalls of the box and angled toward the front of the box to make them more easily accessible to an installer in a retrofit situation. 
   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 outlet assembly according to the present invention along with a duplex outlet and its complementary faceplate. 
       FIG. 2  is a front view of the electrical box portion of the recessed electrical outlet assembly of  FIG. 1 . 
       FIG. 3  is a side view of the electrical box as viewed from the left side of  FIG. 2 . 
       FIG. 4  is an end view of the electrical box as viewed from the bottom end of  FIG. 2 . 
       FIG. 5  is a sectional view of the electrical box taken along line  5 - 5  of  FIG. 4 . 
       FIG. 6  is a front view of a frame member that forms a portion of the recessed electrical outlet assembly of  FIG. 1 . 
       FIG. 7  is a side view of the frame member as viewed from the left side of  FIG. 5 . 
       FIG. 8  is an end view of the electrical box as viewed from the bottom end of  FIG. 5  and with a portion of the frame member cut away to show a sectional view of a collar portion. 
       FIG. 9  is an exploded side view of the frame member portion in alignment with a sectional side view of the electrical box portion to which it will be secured to form a recessed electrical outlet assembly according to the present invention. 
       FIG. 10  is the side view of  FIG. 9  but with the frame member secured to the electrical box to form the recessed electrical outlet assembly of the present invention. 
       FIG. 11  is a perspective view of the recessed electrical outlet assembly of the present invention secured to a wall stud and with a duplex outlet and its complementary faceplate installed therein. 
   

   TABLE OF NOMENCLATURE 
   The following is a listing of part numbers used in the drawings along with a brief description: 
   
     
       
             
             
           
             
             
           
         
             
                 
             
             
               Part Number 
               Description 
             
             
                 
             
           
           
             
                 
             
           
        
         
             
               20 
               recessed electrical outlet assembly 
             
             
               22 
               electrical box 
             
             
               24 
               frame member 
             
             
               26 
               front sidewall portion 
             
             
               28 
               rear sidewall portion 
             
             
               30 
               duplex receptacle 
             
             
               32 
               faceplate 
             
             
               34 
               peripheral sidewall of frame member 
             
             
               35 
               aperture in flange 
             
             
               36 
               flange 
             
             
               38 
               open rear end 
             
             
               40 
               fastening arrangement 
             
             
               41 
               boss in front sidewall of electrical box 
             
             
               42 
               bore 
             
             
               44 
               fastener 
             
             
               46 
               mounting arrangement 
             
             
               48 
               boss 
             
             
               50 
               captive fastener 
             
             
               52 
               axis 
             
             
               54 
               outer surface of front sidewalls 
             
             
               56 
               leg 
             
             
               58 
               head of fastener 
             
             
               59 
               front edge of front sidewall portion 
             
             
               60 
               rear edge of front sidewall portion 
             
             
               62 
               lateral wall 
             
             
               64 
               rear edge 
             
             
               66 
               rear wall 
             
             
               68 
               alignment tab 
             
             
               70 
               rear edge of alignment tab 
             
             
               72 
               outer surface of rear sidewalls 
             
             
               74 
               rib 
             
             
               76 
               axis 
             
             
               78 
               recessed area 
             
             
               80 
               recessed peripheral wall 
             
             
               81 
               knockout 
             
             
               82 
               front face 
             
             
               84 
               arrangement for securing an electrical device 
             
             
               86 
               device mounting boss 
             
             
               88 
               front face of boss 
             
             
               90 
               central opening of frame member 
             
             
               92 
               inner chamfered edge 
             
             
               94 
               outer chamfered edge 
             
             
               96 
               stud 
             
             
               98 
               front face of stud 
             
             
               102 
               fastener for electrical device 
             
             
               104 
               fastener for faceplate 
             
             
               106 
               sheetrock 
             
             
               108 
               plug end of electrical cord 
             
             
               110 
               push-in connector 
             
             
               D 
               distance flange extends outward from peripheral sidewall 
             
             
               W 
               outer width across peripheral wall of frame member 
             
             
               H 
               outer height across peripheral wall of frame member 
             
             
               W1 
               inner width across front sidewalls of electrical box 
             
             
               H1 
               inner height across front sidewalls of electrical box 
             
             
               θ 
               angle of fastener with respect to outer surface of sidewall 
             
             
               θ 1   
               angle of fastener with respect to front edge of sidewall 
             
             
                 
             
           
        
       
     
   
   DETAILED DESCRIPTION OF THE INVENTION 
   With reference to  FIG. 1 , a preferred embodiment is shown of the present invention, which is a recessed electrical outlet assembly  20  including an electrical box  22  and a frame member  24 . The electrical box  22  includes a front sidewall portion  26  and a rear sidewall portion  28 , with the front sidewall portion  26  being of larger width and height than the rear sidewall portion  28 . In  FIG. 1 , a duplex receptacle  30  and a faceplate  32  are shown in alignment with the electrical box  22 . The frame member  24  includes a peripheral sidewall  34  and a lateral flange  36  with the peripheral sidewall  34  terminating in an open rear end  38 . A fastening arrangement  40  for securing the frame member  24  to the electrical box  22  includes apertures  35  in the flange  36  of the frame member  24 , a boss  41  including a bore  42  therein in the front sidewall  26  of the electrical box  22 , and a fastener  44  for securing through the apertures  35  of the frame member  24  into the bore  42  of the electrical box  22 . 
   As shown in  FIG. 2 , the electrical box portion  22  of the recessed electrical outlet assembly includes a mounting arrangement  46  for securing the electrical box to a stud (not shown). The mounting arrangement  46  includes bosses  48  integral with the front sidewall  26  of the electrical box  22  and a captive fastener  50  held frictionally within each of the bosses  48 . As shown by axis  52 , the axial orientation angles each captive fastener  50  away from the outer surface  54  of the front sidewall  26  by angle θ. Integral legs  56  offset each boss  48  from the outer surface  54  of front sidewall  26  and the axial orientation directs the head  58  of the captive fastener  50  away from the front sidewall  26  to render the captive fastener  50  easily reachable by an installer. 
   Referring to  FIG. 3 , the front sidewalls  26  of the electrical box  22  include a front edge  59  and a rear edge  60 . A lateral wall  62  extends inward from the rear edge  60  of the front sidewalls  26 . The rear sidewalls  28  extending rearward from the lateral wall  62  to a rear edge  64  and a rear wall  66  extends from the rear edge  60  thereby closing the rear end of the electrical box  22 . 
   As shown in  FIG. 3 , the electrical box  22  includes one or more alignment tabs  68  extending along the outer surface  54  of the front sidewalls  26 . The alignment tabs  68  extend rearward from the front edge  59  of the electrical box  22 . The alignment tabs  68  include rear edges  70  which are planar with the front edge  59  of the electrical box  22 . The rear sidewalls  28  include an outer surface  72  and one or more ribs  74  extending along the outer surface  72 . The ribs  74  extend rearward from the lateral wall  62  of the electrical box  22 . 
   With reference to  FIG. 4 , as shown by axis  76 , the captive fasteners  50  are at an angle θ 1  of between 5 and 15 degrees with respect to the front edge  59  of the electrical box  22 . The ribs  74  extend along the rear sidewall portion  28  and provide an extended surface area for fitting flush against a stud (not shown) that the electrical box  22  will later be secured to. As shown in  FIG. 4 , the rear sidewalls  28  of the electrical box  22  include one or more recessed areas  78  therein, with each recessed area  78  including a recessed peripheral wall  80  therein. The recessed area  78  includes a knockout  81  or removable wall portion, which can be removed to allow insertion of an electrical fitting therein or passage of electrical cables (not shown) to the electrical box. 
   With reference to  FIG. 5 , the lateral wall  62  of the electrical box  22  includes a front face  82  and an arrangement  84  for securing an electrical device (not shown) to the electrical box  22  such that it is mounted planar with the front face  82  of the lateral wall  62 . The arrangement  84  for securing an electrical device includes device mounting bosses  86  molded integrally within the electrical box  22 . The device mounting bosses  86  terminate in a front face  88  that is planar with the front face  82  of the lateral wall  62 . 
   Referring to  FIGS. 6-8 , the flange  36  of the frame member  24  extends outward from the peripheral sidewall  34  of the frame member  24  by a distance D of at least 0.5 inch. The frame member  24  includes a central opening  90 , an inner chamfered edge  92  at the juncture of the peripheral sidewall  34  and the flange  36 , and an outer chamfered edge  94  around the outer periphery of the flange  36 . The outer width W across the peripheral sidewall  34  of the frame member  24 , as shown in  FIG. 8 , and the outer height H across the peripheral sidewall  34  of the frame member  24 , as shown in  FIG. 7 , are slightly smaller than the inner width W 1  and inner height H 1  (see  FIG. 2 ) of the front sidewall portion  26  of the electrical box  22  to enable the peripheral sidewall  34  of the frame member  24  to be telescopically received within the front sidewall portion  26  of the electrical box  22 , as shown in  FIGS. 9 and 10 . 
   Reference is made to  FIGS. 1 and 11  for an understanding of the operation of the recessed electrical outlet assembly  20  of the present invention. The recessed electrical outlet assembly  20  is used for recessing an electrical device, such as a duplex receptacle, within the wall of a structure. In certain locations, such as behind a cabinet which requires a wall outlet for illuminating a light, it would be advantageous to recess the electrical outlet so that the plug ends of the electrical cord at the outlet does not interfere with placing the cabinet against the wall. The description for operation of the recessed electrical outlet assembly presented herein is for interior use in new construction, in which the wall studs are exposed and prior to securing sheet rock to the wall. As shown in  FIG. 1 , the electrical box  22  is placed against a wall stud  96  and aligned with the front face  98  of the stud by sliding the box  22  backwards until the rear edge  70  of the alignment tabs  68  (see  FIG. 4 ) are flush against the front face  98  of the stud  96 . The alignment tabs  68  align the front edge  59  of the electrical box 0.5 inch from the face  98  of the stud  96 , which is the proper distance to align the front edge  59  of the box  22  with the eventual surface of the wall for conventional ½ inch thick sheetrock. 
   With reference to  FIG. 11 , after the box  22  is aligned properly with the stud  96  by the alignment tabs  68 , the captive fasteners  50  within the bosses  48  of the mounting arrangement  46  are driven into the wall stud  96  thereby securing the electrical box  22  to the stud  96 . The captive fasteners  50  are easily accessible by the installer as a result of their offset from the outer surface  54  of the front sidewall  26  and the axial orientation of the captive fasteners  50  with the head of the fastener  50  oriented toward the front of the electrical box  22  and outward from the front sidewall  26 . 
   After the electrical box  22  is secured to the wall stud  96 , see  FIG. 1 , an electrical device such as the duplex receptacle  30  shown in  FIG. 1  can be secured to the electrical box  22  by fasteners  102  secured into the device mounting bosses  86  within the box  22 . A faceplate  32  can then be secured to the duplex receptacle  30  by a fastener  104  as shown in  FIG. 1 . Frame member  24  is then secured to the electrical box  22  by driving the fasteners  44  of the fastening arrangement  40  through the apertures  35  in the flange  36  of the frame member  24  and into the bores  42  that are integral with the front sidewalls  26  of the electrical box  22 . 
   With reference to  FIG. 11 , after the frame member  24  is secured to the electrical box  22 , flange  36  of the frame member  24  is secured flush against the front edge  59  of the electrical box  22  and also flush with the wall or outer face of the sheetrock  106 . After the sheetrock  106  is installed, the recessed electrical outlet assembly  20  provides an electrical device  30  that is recessed a substantial distance from the face of the wall, thereby providing plenty of space to accommodate the plug ends  108  of electrical cords and thus preventing them from interfering with placement of the cabinet, electrical appliance, or similar object. 
   Although a specific example is described herein for the installation of the recessed electrical outlet assembly on an interior wall that has been newly constructed, it should be emphasized that the recessed electrical outlet assembly also could be used on exterior walls or on old work interior walls. For existing interior walls, a hole would be cut in the wall adjacent to a wall stud. Although the captive fasteners shown herein are nails, they could also be screws that would be more easily driven into the wall stud in an old work application. 
   As shown in  FIG. 11 , the recessed area  78  in the rear sidewall portion  28  enables the use of electrical fittings or connectors such as the Black Button™ push-in connector  110  for connecting non-metallic cable to electrical boxes, which is available from Arlington Industries of Scranton, Pa. The recessed area  78  permits use of the connectors without projecting from the sidewall and interfering with placement of the electrical box in locations where space is tightly restricted. 
   The electrical box  22  and frame member  24  portions of the recessed electrical outlet assembly of the present invention may be constructed of metal or plastic. In a preferred embodiment, the electrical box  22  and frame member  24  are each molded in one piece of plastic. 
   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.