Abstract:
An adjustable electrical box including a box having a back wall bounded by a top and bottom wall and a pair of opposed sidewalls. The pair of sidewalls and the top and bottom walls are joined to form a continuous perimeter wall having an opening. A bracket is fixedly secured to the perimeter wall and extends outwardly therefrom for attaching said box to a support structure. A frame is telescopically received in said box opening. An adjustment device is rotatably secured to the frame and engagable with the perimeter wall of the box, wherein activation of the adjustment device causes the frame to move relative to the box.

Description:
FIELD OF THE INVENTION  
       [0001]     The present invention relates to an electrical outlet box, more specifically, an electrical box being adjustable to accommodate a variety of installation situations.  
       BACKGROUND OF THE INVENTION  
       [0002]     Electrical boxes are commonly employed in order to provide a termination for electrical connections to electrical components such as outlets and switches. Electrical boxes may be in the form of outlet boxes, junction boxes, floor boxes and switch boxes and may be located in walls, floors or ceilings or any location in which an electrical termination takes place. Electrical boxes are typically secured to a support structure such as a wall stud or ceiling joist and then covered with a covering material such as gypsum board, plaster, paneling or other type of covering material.  
         [0003]     During new construction when electrical wiring is installed, electrical boxes are attached to the support structures in the desired location. When a box is secured to a support structure this typically fixes the position of the electrical box and does not provide for movement thereof. For proper installation, the front edge of the electrical box is typically desired to be substantially flush with the covering material. For interior construction, when wall covering material having standard thicknesses is used, such as gypsum board, electrical boxes may include a fixed offset such that the front of the box extends beyond the support structure a certain distance. Therefore, when the covering is attached the front of the box is substantially flush with the front surface of the wall covering. This fixed offset, however, requires that the installer know the thickness of the wall covering at the time of installation. The position can not be easily adjusted to accommodate for covering materials of irregular thickness or situations in which the covering thickness is changed after the electrical box is installed.  
         [0004]     In order to accommodate changes or variations in covering thicknesses, various adjustable electrical boxes have been derived. U.S. Pat. No. 5,289,934 to Smith, et al. discloses an adjustable mounting assembly for an electrical outlet box. In this patent, the electrical box is attached to a bracket which moves relative to the electrical box. With the bracket fixed to the support structure, adjustment results in the entire box moving. Accordingly, installation of such a box requires an installer to ensure that there is enough play in the electrical wiring such that movement does not cause undue stress on the wiring.  
         [0005]     U.S. Pat. No. 3,834,658 discloses an outlet box with an adjustable mounting. As in the &#39;934 patent, the outlet box includes a bracket which is movably attached thereto. The bracket is fixably secured to a support structure such as a wall stud and the box may be moved relative to the bracket.  
         [0006]     U.S. Pat. No. 5,042,673 is directed to an electrical box extension. The electrical box extension attaches to flanges located on a standard outlet box. In order to adjust the position of the extension, four (4) adjustment screws must be rotated in order to move the extension relative to the electrical box. Therefore, considerable effort must be employed in order to adjust the extension to the proper position. If a number of such boxes need to be installed in a job, the time and expense just for adjusting the extension becomes significant.  
         [0007]     Accordingly, it would be desirable to provide an adjustable electrical box in which the outlet box remains fixed to a support structure and the front face of the assembly may be easily and quickly adjusted in order to be flush with the covering material.  
       SUMMARY OF THE INVENTION  
       [0008]     It is an advantage of the present invention to provide an electrical box having a degree of adjustability.  
         [0009]     It is another advantage of the present invention to provide an electrical box having an electrical box fixedly secured to a support structure and a frame member movable relative thereto.  
         [0010]     It is still another advantage of the present invention to provide an adjustable electrical box having an adjustment device disposed between the electrical box and the frame in order to affect relative movement therebetween.  
         [0011]     In the efficient attainment of these and other advantages, the present invention provides an adjustable electrical box including a box having a back wall bounded by a top and bottom wall and a pair of opposed sidewalls. The pair of sidewalls and the top and bottom walls are joined to form a continuous perimeter wall having an opening. A bracket is fixedly secured to the perimeter wall and extends outwardly therefrom for attaching said box to a support structure. A frame is telescopically received in the box opening. An adjustment device is rotatably secured to the frame and engagable with the perimeter wall of the box, wherein activation of the adjustment device causes the frame to move relative to the box.  
         [0012]     In a preferred embodiment, the adjustment device includes a member rotatably secured to the frame. The frame and the box include a cooperating projection and groove arrangement to guide movement of the frame relative to the box. The adjustment device may further include only one threaded member engagable with the box such that rotation of the one threaded member moves the frame between a fully retracted position and a fully extended position.  
         [0013]     A preferred form of the adjustable electrical box, as well as other embodiments, objects, features and advantages of this invention will be apparent from the following detailed description of illustrative embodiments thereof, which is to be read in conjunction with the accompanying drawings. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0014]      FIG. 1  is top perspective view of an adjustable electrical box of the present invention.  
         [0015]      FIG. 2  is an exploded top perspective view of the electrical box of  FIG. 1 .  
         [0016]      FIG. 3  is an exploded first side perspective view of the electrical box of  FIG. 1 .  
         [0017]      FIG. 4  is an exploded second side perspective view of the electrical box of  FIG. 1 .  
         [0018]      FIG. 5  is a front elevational view the electrical box of  FIG. 1  showing the adjustable electrical box attached to a support structure.  
         [0019]      FIG. 6  is an elevational view of the electrical box of  FIG. 1  showing the adjustable electrical box installed. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0020]     The present invention includes an electrical box for accommodating a variety of electrical components such as wires, outlets, switches, etc. The electrical box may be secured to a support structure such as a wall stud, which is typically covered by a material such as gypsum board, plaster or paneling. For proper instillation it is desirable to have the front of the electrical box to be generally flush with the front surface of the covering material. This permits a face plate to be properly placed on the box, which provides a secure covering to the box and its components. The electrical box of the present invention is adjustable to accommodate the variations in the support member and/or thickness in covering material such that the front of the box can be placed adjacent to the front surface of a wall covering material.  
         [0021]     Referring to  FIGS. 1 and 2 , the adjustable electrical outlet box  10  includes a box  12  having a frame  14  telescopically received therein. An adjustment device  16  extends between the frame and box  12  and permits for movement of the frame relative to outlet box  12 . Box  12  includes a back wall  18  bounded by a top wall  20  and bottom wall  22  and a pair of opposed sidewalls  24  and  26 . The top, bottom and pair of sidewalls are joined together to form a continuous perimeter wall  28  ending in an edge  29 . Edge  29  defines an opening  30  into which electrical components and/or wires may extend. Box  12  may be formed of a plastic or polymer material of the type typically used to make electrical boxes.  
         [0022]     Referring additionally to  FIGS. 3 and 6 , sidewall  24  may include a flange  31  extending above edge  29 . A mounting bracket  32  extends generally outwardly from flange  31 . Mounting bracket  32  has a mounting surface  34  that abuts a support structure  80  when box  12  is mounted thereto. Bracket  32  includes a plurality of apertures  36  for accommodating mechanical fasteners. Mounting bracket  32  is configured such that it may be placed against the front of support structure  80 , such as a wall stud, and be attached thereto with mechanical fasteners  88 , such as screws and nails. In order to position box  12  against support structure  80 , sidewall  24  may include a pair of standoffs  33 , which cooperate with flange  31  to form a uniform mounting surface. Standoffs  33  and flange  31  project outwardly from sidewall  24  and provide a pocket  35  in which adjustment device  16  may extend. Box  12  may also include a plurality of knock-outs  38  formed on the perimeter wall. For example, the knock-outs  38  may be formed on the top and bottom wall  28  in order to permit electrical wiring to enter box  12 .  
         [0023]     Referring to  FIGS. 2 and 5 , the present invention also provides an additional means of securing electrical box  12  to a support structure. Such securement device  40  includes a pair of ears  42  extending outwardly from the top  20  and bottom  22  of outlet box  12 . The ears  42  include slots  44  which accommodate fasteners  46 . Such fasteners may be frictionally held within slots  44 . This frictional retention may be overcome by hammering fasteners  46  into support structure  44  upon installation.  
         [0024]     Telescopically received within box opening  30  is frame  14 . With reference to  FIGS. 2-4 , frame  14  has an outer wall  48  having a configuration substantially similar to the configuration of perimeter wall  28 . For example, in the preferred embodiment, perimeter wall  28  and outer wall  48  both have a rectangular opening. However, it is in the contemplation of the present invention that the electrical box and frame may be formed in a variety of shapes. Outer wall  48  has a front  50  portion having a collar  52  which ends in a rim  54 . Collar  52  extends outwardly from outer wall  48  forming a ridge  56 . Located on the interior of outer wall  48  and adjacent rim  54  are a pair of electrical component attachment points  58 . Attachment points  58  may include apertures  60  for receiving a threaded fastener in order to secure an electrical component  61  to frame  14  ( FIG. 5 ).  
         [0025]     In order to move frame  14  relative to outlet box  12 , the present invention includes an adjustment device  16  extending therebetween. Adjustment device  16  is preferably disposed at a position between the top wall  20  and bottom wall  22  of box  12 . In the preferred embodiment, adjustment device  16  includes a threaded member  62  rotatably secured to frame  14 . Threaded member  62  extends from frame  14  and is threadedly received within an aperture  64  formed in sidewall  24  of electrical box  12 . Aperture  64  may be integrally formed with sidewall  24 . Rotation of threaded member  62  in one direction advances the threaded member into aperture  64  causing frame  14  to move in toward electrical box  12 . Frame  14  may be moved into box  12  until frame ridge  56  engages perimeter wall edge  29  such that frame  14  is in a fully retracted state. In this retracted state, rim  54  is generally flush with mounting bracket front surface  34 . Rotation in the opposite direction results in threaded member  62  moving out of aperture  64  resulting in frame  14  moving away from electrical box  12  to a fully extended state. Rotation may preferably be achieved by using a standard screwdriver, which engages threaded member  62 . Adjustment device  16  in addition to permitting movement between box  12  and frame  14 , retains frame  14  to box  12 , such that the position of the frame is fixed relative to box  12 , unless threaded member  62  is rotated.  
         [0026]     With reference to  FIGS. 1 and 3 , threaded member  62  is preferably rotatably secured to frame  14  such that an upper portion  66  of threaded member  62  is disposed adjacent rim  54  to facilitate access thereto by an installer. In order to achieve the rotatable securement, a portion of collar  52  may be formed to include an indentation  68 . Indentation  68  includes a slotted opening  69  which is adapted to permit the upper portion  66  of threaded member  62  to snap in to indentation  60  and be rotatably retained therein. The upper end or head portion  66  of threaded member  62  is generally flush with the front portion of frame  14  such that it is easily accessible by an installer even when covering material  82  is installed.  
         [0027]     In order to assist in guiding the movement of frame  14  relative to electrical box  12 , the present invention includes a guide  70  ( FIG. 1 ). The guide  70  preferably includes a cooperating rail and slot arrangement. In the preferred embodiment shown in  FIG. 4 , electrical box  12  includes on the top and bottom wall  20 ,  22  a slot  72  extending from edge  29  toward back wall  18 . Frame  14  includes on outer wall  48  a pair of rails  74  which are adapted to ride within slots  72 . Guide  70  permits for uniform movement of frame  14  relative to electrical box  12  and assists in smooth operation when the adjusting member  16  is operated. It is within the contemplation of the present invention that the frame  14  could include the slots and box  12  could support the rails. It is also with in the contemplation of the present invention that frame  14  and box  12  could be configured with other cooperating structures so as to maintain alignment and insure proper operation.  
         [0028]     In the preferred embodiment, only one threaded member is required in order to move frame  14  relative to box  12 . The present invention by using only one member permits for fast and efficient method of adjusting the electrical box assembly  10 . In contrast, devices of the prior art include as many as four (4) threaded members, each having to be rotated generally to the same degree in order to permit smooth movement of the telescoping member.  
         [0029]     Referring to  FIGS. 5 and 6 , the adjustable electrical box of the present invention is preferably installed by positioning box  12  adjacent a support structure  80  such that mounting bracket  32  abuts the front face of support structure  80  fasteners such as nails or screws may be inserted in apertures  36  to secure box  12  to support structure  80 . Fasteners  46  of securement device  40  may be driven into support structure further securing box  12 . A covering material  82  such as gypsum board may be placed over the support structure  80 . An opening  84  in covering material may be made to align with electrical box  10 . Adjustment device  16  may be actuated to extend frame  14  such that rim  54  is substantially flush with a front surface  86  of covering material  80 . The present invention permits the outlet box  12  to be fixedly secured to a support structure and only the frame moves. The bracket is fixed to the box; therefore, a sturdy connection to the support structure is achieved.  
         [0030]     In the preferred embodiment, frame  14  is configured such that it may travel approximately  1{fraction (3/4)} inches relative to box 12 without becoming removed from box 12. This dimension is for exemplary purposes only and is not intended to be limiting. This degree of movement permits electrical box assembly 10 to be used in a wide variety of applications since a variety of covering materials may be accommodated. In addition, the adjustment feature allows for variations in support member 80 and box 12 placement thereon to be accommodated. Once box 12 is secured to a support structure, an installer need not be overly concerned about the mounting depth of the box or the thickness of any covering material. Once the covering material is placed over the box with the appropriate opening formed in the covering material, the adjustment device 16 can be activated in order to extend or retract frame rim 54 such that it is flush with the front face of the covering material.    
         [0031]     Although the illustrative 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 effected therein by one skilled in the art without departing from the scope or spirit of the invention.