Abstract:
The present invention concerns a dual hinge recess weatherproof outdoor electrical box assembly for shielding and protecting electrical components from moisture. The electrical box assembly includes an electrical box having a plurality of hinge sockets, an adapter plate that is recessed in the electrical box, and a cover having a plurality of hinge pins for operable engagement with the hinge sockets.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
   This application claims the benefit of U.S. Provisional Application No. 60/858,978 filed Nov. 14, 2006, the contents all of which are incorporated herein by reference. 

   FIELD OF THE INVENTION 
   The present invention generally relates to a hinged electrical box assembly, and more particularly to a dual hinge weatherproof electrical box assembly. 
   BACKGROUND OF THE INVENTION 
   Generally, electrical box assemblies are used for a variety of applications and provide a termination point for electrical wires for connection to an electrical component. Depending on the application and location, electrical box assemblies can be mounted on or in a wall in either a horizontal or vertical orientation. Once mounted, electrical wires are installed and connected to the electrical component. Typically, a face plate is provided that covers a top opening of the electrical box that may prevent damage to electrical components included therein. 
   Some electrical box assemblies include a cover that permits the box to be mounted in a location where it can be exposed to wet conditions. For example, some electrical boxes are mounted outdoors and provide electrical power for lighting and power equipment, even though the electrical box may be exposed to moisture. 
   Although some of these assemblies include a cover that can operate to inhibit some moisture from entering the box and causing damage, moisture remains a problem in that the electronic components are positioned adjacent the face plate. As such, there exists a need for an improved weatherproof outdoor box assembly. Furthermore, it would be desirable to provide an improved weatherproof dual hinge electrical box assembly that includes a cover which is adapted to be opened when the box is oriented in either the horizontal or vertical direction. 
   SUMMARY OF THE INVENTION 
   The present invention concerns a dual hinge recess weatherproof outdoor electrical box assembly for shielding and protecting electrical components from moisture. The electrical box assembly includes an electrical box having a plurality of hinge sockets, an adapter plate that is recessed in the electrical box, and a cover having a plurality of hinge pins for operable engagement with the hinge sockets. 
   The adapter plate of the present invention is substantially planar, and includes a perimeter bounded by a substantially rectangular side edge. Preferably, the adapter plate is recessed inside the outlet box and includes at least one aperture for receiving an electrical component. The adapter plate may include one or more tabs that extend from a back surface of the adapter plate and engage a back portion of the box. Upon engagement with the back portion of the box, the adapter plate is removably secured to the box. 
   The electrical box includes a face plate having a first hinge socket and a second hinge socket each extending respectively from a side edge of the box and are configured in a substantially orthogonal orientation. The electrical box also includes at least one knockout for receiving and attaching an electrical wire to an electrical component. For example, in one preferred embodiment, a bottom portion of the electrical box includes a V-shaped slot that is adapted to receive electrical wires for attachment to electrical components. In another embodiment, a back wall of the electrical box includes one or more knockouts that are adapted to receive electrical wires for attachment to an electrical component. In yet other embodiments, both the V-shaped slot and the back wall knockouts are included on the electrical box. 
   The cover of the present invention includes a front wall, an opposed open end and a substantially rectangular side wall defining a cover interior. Preferably, the side wall includes a rim bounding the open end. The cover also includes at least one access port through the side wall adjacent the open end for providing separate passageways into the interior of the cover. For example, an electrical cord may be set in each of the separate passageways. 
   Preferably, the cover includes a first hinge pin and a second hinge pin extending respectively from the side wall adjacent the open end in substantially orthogonal orientation; and the cover being pivotally affixed to the box by operative engagement of the hinge socket with the hinge pin of corresponding orientation and movable between an open and a closed position and wherein the hinge pin and the hinge socket that are not in operative engagement are not aligned. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a perspective view of the electrical connector box and attached cover in a vertical open position, the adapter plate being shown detached from the electrical connector box. 
       FIG. 2  is a perspective view of the electrical connector box and attached cover in a vertical open position, the adapter plate being recessed in the electrical connector box. 
       FIG. 3  is a perspective view of the electrical connector box and attached cover in a vertical closed position. 
       FIG. 4  is a perspective view of the electrical connector box and attached cover in a horizontal open position, the adapter plate being shown recessed in the electrical connector box. 
       FIG. 5  is a perspective view of the electrical connector box and attached cover in a horizontal closed position. 
       FIG. 6  is a rear perspective view of the electrical connector box. 
   

   Like reference symbols in the various drawings indicate like elements. 
   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
   Referring now to  FIGS. 1-6 , an electrical box assembly  10  according to the present invention is disclosed. The electrical box assembly  10  includes an electrical connector box  28  having a face plate  32  attached thereto, a box cover  12  removably attached to the face plate  32 , and an adapter plate  42  that is removably secured to a recessed inside portion of the electrical connector box  28 . 
   The electrical connector box  28  of the present invention is a generally rectangular box-like member that includes a generally flat backwall  29  (see  FIG. 6 ) with a continuous sidewall member (indicated generally at  34 ) upstanding therefrom. The sidewall member  34  includes a pair of oppositely disposed endwall portions  34 B,  34 C and a pair of oppositely disposed sidewall portions  34 A,  34 D. The front edges of the endwall portions  34 B,  34 C and sidewall portions  34 A,  34 D preferably define a generally planar open front for the electrical connector box  28 . 
   As shown in  FIG. 6 , the back wall  29  of the electrical connector box  28  includes one or more knockouts  62 A,  62 B for receiving and attaching an electrical wire to an electrical component installed in the box  28 . In one preferred embodiment, the electrical connector box  28  includes one or more a V-shaped slots  64 A,  64 B that also may be adapted to receive electrical wires for attachment to electrical components positioned in the box  28 . Preferably, as shown in  FIG. 6 , the V-shaped slots  64 A,  64 B are formed on the back wall  29  and end wall portions  34 B,  34 C of the box  28 . Of course, it will be appreciated by one skilled in the art that one or more knockouts and V-shaped slots may be included on the electrical connector box  28 . 
   As shown in  FIG. 6 , in one preferred embodiment, the back edges of the endwall portions  34 B,  34 C are preferably joined to sidewall portions  34 A,  34 D, respectively, to define a recess area  52  that provides clearance for one or more tabs  44  extending from the adapter plate  42 . 
   Referring now to  FIGS. 1 ,  2  and  4 , the adapter plate  42  of the present invention is shown. The adapter plate  42  is a generally rectangular member having a substantially planar rectangular top surface that is perimetrically bounded by an outer wall  47 . The outer wall  47  of the adapter plate  42  is of dimensions suitable for insertion and attachment to an inside recessed portion of the box  28 . As shown in  FIGS. 1 and 2 , the adapter plate includes openings  48  for attaching an electronic component (not shown) to the adapter plate  42 . For example, in one preferred embodiment, openings  48  are provided on the adapter plate  42  that are adapted to accept a screw to fasten an electronic component to the adapter plate  42 . Preferably, the electronic component lies on top of the adapter plate  42 . Afterwards a typical cover plate (not shown) covers both the electrical component and opening  46  in the normal fashion. 
   In one preferred embodiment, as shown in  FIG. 1 , the adapter plate  42  includes one or more tabs  44  extending perpendicularly from a back surface of the adapter plate  42 . The distal end of each tab  44  may be used to secure the adapter plate  42  to an internal portion of the box  28 . For example, in one preferred embodiment, as shown in  FIGS. 1 and 6 , recessed area  52  of the box  28  forms a shoulder  36  on an interior portion of the box  28 . The shoulder  36  preferably includes an opening  38  that is adapted to receive the distal end of one of the tabs  44 . Upon insertion of the distal end of one of the tabs  44  into the opening  38 , the tab, and thereby the adapter plate  42  is engageably locked and secured to the shoulder  36  of the electrical connector box  28 . Preferably, one of the distal ends of the tabs  44  is press-fit into the opening  38  and is releasably locked to a back portion of the opening  38 . 
   One advantage of securing the adapter plate  42  to the shoulder  36 , as shown in  FIGS. 2 and 4 , is that electrical components are thereby recessed in the box  28  and not positioned adjacent the face plate  32 . As a result, electrical components may be further protected from any moisture accumulating on the inside cover area  16  of the cover  12  and face plate  32 . Of course, it will be appreciated by one skilled in the art that other techniques may be used to secure the adapter plate  42  to the shoulder  36  of the box. For example, the adapter plate  42  may be secured to an internal portion of the box  28  via screws or via incorporating mechanical structure located on both the plate and the internal wall of the box. 
   The adapter plate  42  of the present invention is configured to accommodate any number of electrical components. For example, the adapter plate  42  can accommodate a single duplex receptacle mounted to threaded opening  48 . Of course, it will be appreciated by one skilled in the art that the adapter plate  42  can also accommodate a variety of different components including GFCI receptacles or switches secured atop adapter plate  42 . To finish installation, a typical cover plate is then installed over the electrical component in the usual manner. 
   In one preferred embodiment, the face plate  32  of the present invention is rigidly mounted to the open front of the electrical box  28  and is used to mount the electrical box assembly  10  on or in a wall. For example, as shown in  FIG. 1 , openings  40  are provided on the face plate  32  that allow the assembly  10  to be secured to a wall using fasteners, such as but not limited to, nails, screws and bolts. Preferably, the face plate  32  has a substantially planar rectangular top surface. The perimeter of the face plate  32  is generally greater than the perimeter of the box  28 . For example, as shown in the figures, in one preferred embodiment, a back surface of the face plate  32  is attached to the front edges of the endwall portions  34 B,  34 C and sidewall portions  34 A,  34 D of the box  28  resulting in the perimeter of the face plate  32  being larger than the perimeter of the box  28 . 
   As shown in the Figures, the face plate  32  preferably includes a vertical hinge socket  24  and a horizontal hinge socket  30  each extending respectively from a side edge of the box  28  and are configured in a substantially orthogonal orientation. Preferably, each of the hinge sockets  24 ,  30  is formed in an arched structure having an interior portion adapted to concentrically receive a hinge pin  23  or  26  of the cover  12 . 
   Preferably, the face plate  32  also includes one or more face plate locking members  50 A,  50 B that may be used to lock the cover  12  to the face plate  32 . Details of locking the cover  12  to the face plate  32  are discussed in connection with  FIG. 3 . 
   The cover  12  of the present invention is a generally rectangular box-like member having a substantially planar rectangular inner surface  16  that is perimetrically bounded by an outer wall  14 . As shown in  FIGS. 1 and 2 , the outer wall  14  is comprised of four substantially planar side walls having two sets of substantially parallel sides. The outer wall  14  extends around and help define inner surface  16  and includes an outwardly flanged rim  15  extending from an end thereof. Preferably, the rim  15  is integrally formed on the cover  12  as a single piece component and operates to channel away any water that may fall on the cover  12  when the cover  12  is in the closed position. 
   In one preferred embodiment, as shown in  FIGS. 1 and 2 , the outer wall  14  of the cover  12  is configured to include one or more conventional plug knockouts  18 ,  22  of a type generally known in the art. Preferably, the knockouts  18 ,  22  are a partially cut through opening or removable wall section that create an opening through which a wire may pass for electrical connection to an enclosed electrical component. 
   Preferably, the outer wall  14  of the cover  12  is configured to include a vertical cover hinge pin  23  and a horizontal cover hinge pin  26  for pivotal engagement with the vertical hinge socket  24  and the horizontal hinge socket  30  of the face plate  32 , respectively. For example, as shown in  FIG. 1 , the vertical hinge socket  24  is mounted on the face plate  32  such that the interior portion of the socket  24  is oriented towards the front of face plate  32 . By mounting the vertical hinge socket in this way, the vertical cover hinge pin  23  can be rotatably engaged to the hinge socket  24 . The cover  12  can thereby be pivoted to rotate into an open or closed position. 
   The cover  12  of the present invention also includes a locking device  20  that may be positioned in operative engagement with the face plate locking members  50 A,  50 B. As is well known in the art, the cover  12  may be formed of a variety of materials. For example, in one preferred embodiment, the cover  12  is integrally formed of an injection molded, high impact synthetic plastic material, such as for example, clear Lexan. 
   A perspective view of the cover  12  pivotally engaged to the face plate  32  in a closed vertical orientation is shown in connection with  FIG. 3 . In one preferred embodiment, the locking devices  50 A and  50 B extend from diagonally opposed sides of the face plate  32  and are adapted to be fastened to the cover locking device  20 . As shown in the  FIG. 3  example, when the electrical box assembly  10  is in the vertical closed position, the locking device  50 B is in locking engagement with the cover locking device  20 . As will be described and shown in connection with  FIG. 4 , the cover  12  can also be pivotally engaged to the face plate  32  in a horizontal orientation. 
   As shown in  FIGS. 1 and 3 , in one preferred embodiment, the cover locking device  20  comprises a stanchion  74  supporting an annular ring  76 . The face plate locking device  50 B comprises a support stanchion  70 , an annular ring  72 , and a locking tab  78 . The annular ring  76  of the cover  12  is adapted to align concentrically with the complementary structure on the face plate locking device  50 A or  50 B, and provides a passage through which a conventional lock shank of a padlock or other locking device (not shown) may be inserted. The lock can be a padlock, opened by key or combination. 
   In operation, when the cover  12  is pivotally engaged to the face plate  32  and rotated to the vertical closed position, the cover locking device  20  passes the face plate locking device  50 B and the locking tab  78  is elastically deformed laterally away from the locking device  50 B until the cover  12  is in the fully closed position. Once the cover  12  is fully closed, the locking tab  78  flexes back to its original position to releasably secure the cover  12  on the face plate  32 . At the same time, the annular rings  72 ,  76  are concentrically aligned to permit insertion of a lock such as a pad lock. To open the cover  12 , the locking tab  78  is manually bent away from the locking device  50 B thereby permitting opening of the cover  12 . By providing the cover  12  and face plate  32  with a snap closure mechanism, the cover  12  can be closed securely and tightly, thus maintaining a tight seal between the cover  12  and face plate  32 . 
   Referring now to  FIGS. 4 and 5 , the electrical box assembly  10  arranged in an open and closed horizontal orientation, respectively, is shown. As shown in  FIG. 4 , the cover  12  is rotated 180 degrees from the vertical orientation depicted in  FIGS. 1 and 2  with respect to face plate  32 . In the horizontal orientation, the horizontal hinge pin  26  and horizontal hinge socket  30  are pivotally engaged. While in the horizontal position, the vertical hinge socket  24  and pin  23  are positioned along opposite parallel sides of the face plate  32  and cover  12 , respectively. Such arrangement prevents the unused hinge components from interfering with the opening and closing of the cover  12 . Furthermore, as shown in  FIG. 5 , in the horizontal closed position, the cover locking device  20  engages with the face plate locking device  50 A. The face plate locking device  50 B is not engaged in the horizontal orientation. 
   It should be understood that to affix the cover  12  to the face plate  32 , either hinge socket  24 ,  30  is pivotally engaged to the corresponding horizontal  26  or vertical  23  hinge pin respectively. Furthermore, either set of hinges  24 ,  30  can be selectively engaged without the need to modify the adapter plate  42 , face plate  32  or the cover  12 . It should also be understood that other intermating structure are equally suitable such that the described pin and socket interconnection is not the only structure usable for securing the cover  12  to the face plate  32 . Further, either inter-mating structure may be formed on either face plate  32  or cover  12 . 
   For example, in one preferred embodiment, the pin structure described is secured to the face plate and the socket structure described previously is secured to the cover. Bayonet, ball, as well as male/female structures are equally suitable for this purpose. Furthermore, there is no necessity that the intermating structure on the face plate  32  be the same nor is there any necessity that the intermating structure on the cover  12  be the same. It is only necessary that the respective intermating structure on the cover and face plate be configured to engage each other. 
   In the preferred embodiment of the present invention, the face plate and cover are mounted such that the cover opens by pivoting in an upward direction. For example, the face plate may be mounted to the box with either a vertical or horizontal hinge socket positioned at the top wherein the corresponding cover hinge pin is pivotally engaged to that socket. Alternately, it is also possible to open the cover in a downward or lateral direction by positioning a hinge socket at the bottom or side of the face plate respectively, and pivotally engaging the corresponding hinge socket. Either orientation can be achieved without any modification to the positioning of the adapter plate. 
   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.