Abstract:
The present invention discloses a method and apparatus for locating a pre-wired electrically isolated power source. The invention includes a plurality of embodiments of encased receptacles combined with recessed electrical enclosures for mounting the receptacles. The recessed electrical enclosures allow for the input and output receptacles to be mounted externally to the enclosure, to create space internal to the enclosure, and for visual isolation of receptacle outlets and associated plugs/connectors that may also be present in the enclosure.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority to U.S. Provisional Application No. 61/516,768 filed 7 Apr. 2011 and U.S. Provisional Application No. 61/630,677 filed 16 Dec. 2011. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to a method and apparatus for locating a pre-wired electrically isolated power source. The invention includes a plurality of embodiments of encased receptacles and recessed electrical boxes for mounting these embodiments. 
     BACKGROUND OF THE INVENTION 
     Providing electrical power behind a wall structure currently requires the use of a standard electrical receptacle and wiring to be mounted internal to an electrically isolated box to prevent access to the internal wiring. Typically, an electrician is required to complete the installation which requires connecting into existing power and locating the new electrical receptacle and box. 
     The electrical box includes a cover plate flush mounted to the exterior wall leaving an opening for the power receptacle. 
     More recently, some electrical appliances, particularly flat screen televisions, are mounted directly to the wall, so that externally connected plugs protruding out of the wall plate interfere with mounting the television in flat abutment with the surface of the wall. 
     There exists a need for a method and apparatus for positioning in-wall power which can be accomplished by a lay person without the need of an electrician, and which provides electrically isolated receptacles, that are pre-wired, and can be mounted external to an electrical box, thereby creating space internal to the wall for isolating plugs and connectors. 
     SUMMARY OF THE INVENTION 
     The foregoing and other problems are overcome, and other advantages are realized, in accordance with the disclosed, alternative embodiments of these teachings. 
     The power solution of the present invention comprises pre-wired electrically isolated female and male receptacles combined with an integrated enclosure that can be used in applications where power must be supplied to a remote unit, such as a flat panel TV being hung on a wall (behind wall installation), or in a remote location where an integrated enclosure is necessary for installation and electrical isolation (trade show/outdoor exhibit where remote power is utilized on a temporary wall fixture). 
     For behind wall installations the invention may combine isolated power receptacles in combination with “Deep Box” mounting enclosures. The “deep box” enclosures allow for the input and output receptacles to be mounted deep inside a wall for visual isolation of receptacle outlets and associated plugs/connectors that may also be present in the enclosure. 
     In a behind wall installation, the integrated enclosures containing the female and male receptacles are separated behind a wall such that power can be supplied to the female end from an external source (such as an extension cord) which will supply power to a male receptacle mounted interior to the wall. The integrated enclosures for the receptacles are necessary to facilitate mounting in a variety of forms. Both the power input (female end) and power output (male end) integrated enclosures may contain a mounting frame for installation directly to a wall surface or onto any type of faceplate or in-wall enclosure, such as the “deep box” mounting enclosures of the present invention. 
     Alternatively, the integrated enclosures may be sold pre-mounted to any in-wall enclosure, including the “deep Box” enclosures of the present invention. Further, the integrated enclosed receptacles, interface wiring, and associated mounting frames or boxes (deep box or conventional electrical box) may be sold as a kit to facilitate easy installation. The electrical connection between the integrated enclosures may be separable via a snap plug or the like. 
     The integrated enclosures facilitate mounting of the power output and power input to a variety of electrical boxes including standard electrical boxes, flush mounted wall plates, and “deep boxes” disclosed in the present invention. Since the receptacles are encased and pre-wired, they are not required to be mounted internal to an electrical box for electrical isolation. This allows for the receptacles to be mounted externally to the electrical box enclosure, creating additional space within the box necessary for hiding connectors and the like. The encased receptacles may also be rough mounted to any wall surface. 
     The power input and power output integrated enclosure may be formed by overmolding, be a one piece boot, a two piece joinable encasement, or may comprise an integrated enclosure built around an overmolded connector. The receptacles are electrically connected within the integrated enclosure at the factory (pre-wired) and the electrical coupling between the enclosures can be ordered in specific lengths to meet the needs of a particular installation. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The foregoing aspects and other features of the present invention are explained in the following description, taken in connection with the accompanying drawings, wherein: 
         FIG. 1  illustrates an embodiment employing the principles of subject invention denoting encased receptacles as encased power input and power output with an electrical interface as any length necessary for a particular installation. 
         FIG. 2  illustrates the embodiment of  FIG. 1  having faceplates for connection to the encased receptacles. 
         FIG. 3  illustrates the embodiment of  FIG. 2  illustrating the installation of the encased receptacles, electrical interface, and faceplates in a wall. Also illustrated is an existing power receptacle with an extension cord for routing available power to the encased power input receptacle via an extension cord. 
         FIG. 4  illustrates an alternative embodiment for the design of the encased receptacles  10  and  20 . 
         FIG. 5  illustrates a mounting frame utilized in the current invention. 
         FIGS. 6-7  illustrates an IEC power receptacle integrated into the mounting frame of  FIG. 5 . 
         FIG. 8  illustrates a frame support member utilized in the current invention. 
         FIGS. 9-10  illustrates the assembled mounting frame and frame support member of  FIGS. 5 and 8 . 
         FIG. 11  illustrates a housing embodiment of the encased receptacles of the subject invention. 
         FIG. 12 , illustrates the assembled mounting frame and frame support member of FIGS.  7 , 8  and  11  prior to final assembly. 
         FIG. 13  illustrates a boot embodiment of the encased receptacle of the subject invention. 
         FIG. 16  illustrate a joinable section embodiment of the encased receptacle of the subject invention. 
         FIG. 17-19  illustrates a single gang recessed electrical box of the present invention. 
         FIG. 20-21  illustrates a double gang recessed electrical box of the present invention. 
         FIGS. 22-23  illustrates an alternative embodiment of a recessed electrical box of the present invention. 
         FIGS. 24-26  illustrates an encased receptacle of the present invention in combination with a recessed electrical box of the present invention. 
         FIG. 27  illustrates an encased receptacle of the present invention in combination with a recessed electrical box of the present invention mounted to a wall. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     While certain embodiments of the present invention have been illustrated and described herein, the present invention should not be limited to such illustrations and descriptions. It should be apparent to those skilled in the art that changes and modifications may be incorporated and embodied as part of the present invention and are within the scope of the claims. It is understood that the “deep box” embodiments disclosed can also be utilized with “low voltage” receptacles connected thereto. 
     As seen in  FIGS. 1-4 , the integrated enclosure in the form of an encased power output  10  and encased power input  20  are illustrated as connected by an electrical coupling  15 . 
     Coupling  15  contains the electrical connections between power input  20  and power output  10 , and may include solid copper conductors and combinations of hot, neutral and ground conductors encased in any electrical interface conduit as required by applicable building codes. 
     The assembled In-Wall power apparatus  30  is purchased for particular applications with a fixed length electrical coupling  15 . In the alternative, encased power input  20  and power output  10 , can each contain a fixed length electrical coupling to be connected on-site. Each coupling may be a mating connector or bare wire to be connected during installation. Such an embodiment would facilitate selling components separately. 
     The encased receptacle embodiment (both power input and power output) and coupling  15  are electrically insulated and pre-wired to meet applicable building codes and further to be installed by a laymen without the need for a licensed electrician. 
     The encased receptacles  10  and  20  further include mounting frames  60 A. The frames may be overmolded, or externally affixed to receptacles  10  and  20 . The Mounting frames include tabs  25  including tab connection holes  25 A,  25 B,  25 C, and  25 D. Although connection holes  25 A- 25 D are disclosed other connection holes could be included in tab  25 . In the preferred embodiment, the mounting frames  60 A are substantially co-planer with the front face of receptacles  10  and  20 . The selection of holes  25 A- 25 B in the embodiment of  FIG. 1-4  is to illustrate the utilization of faceplates  35  and  40 . Other mounting frames and tab configurations may be utilized to meet specific installation requirements. Encased standard NEMA, standard duplex, and non-standard custom receptacles require different dimensioned mounting frames and tabs. 
       FIG. 3  illustrates the power apparatus  30  of the present invention affixed to the surface of an exterior wall  45 . In the present example, a hole would be cut in the wall for placement of receptacle  10  in an elevated location on the wall  45 . Even without installing decorative faceplates  35  and  40 , the receptacles  10  and  20  can be installed, as is, in wall  45  by screwing or nailing into the receptacles  10  and  20  via holes  25 -thru  25 D into wall  45 . First, two holes would be made in wall  45 . Next, Receptacle  20  would be “fished” down to the first hole and receptacles  10  and  20  would be secured within the openings. Preferably, receptacle  20  would be at floor level out of view and in the vicinity of a live power outlet  50  as illustrated in  FIG. 3 . Live power would then be supplied to receptacle  20  via a conventional extension cord  55 . Power would then be available to receptacle  10  for powering, for example, a flat panel TV (not shown) mounted over receptacle  10 . 
     For a more decorative installation, faceplate  40  could be placed within the opening, connected to receptacles  10  and  20  via screw or nails through holes  25 D and  40 A, then faceplate  35  could be placed over receptacles  10  and  20  and connected over faceplate  40 , via screws or nails through holes  35 A and  25 B. Receptacles  10  and  20  would be accessible through opening  35 B of faceplate  35 . 
       FIG. 4  illustrates an alternative embodiment for the design of the encased receptacles  10  and  20 . 
     Other configurations of installations are possible, as described herein, such as recessed power input and power output within a walls interior surface. 
     An alternative embodiment of encased receptacles  10  and  20  in combination with recessed electrical boxes  120  is illustrated in  FIGS. 24-27 . It is understood that all embodiments of encased receptacles  10  and  20  described herein are mountable to all embodiments of the recessed electrical boxes described herein. 
     Various embodiments of recessed electrical boxes for encased power input  20  and power output  10  are contemplated, provided the encasement ensures electrical isolation and can meet applicable building codes. 
     As illustrated in  FIG. 12 , an encased receptacle is formed around an IEC power input connector  64 . It is contemplated by the present invention to include other connector types to be encased including standard NEMA, standard duplex, and non-standard custom connectors. Referring to  FIGS. 5 and 8 , a mounting frame  60  includes opposed tabs  25 , an opening  60 D to receive an IEC power receptacle  64  therein, and openings  60 B and  60 C to receive stanchions  65 A and  65 B of frame support member  65 . 
     As illustrated in  FIGS. 6 and 7 , IEC  64  fits snugly into opening  60 D, and includes a surface extension  64 A which may be further secured to frame  60  by any means known in the art such as gluing. Frame support member  65 , including stanchions  65 A and  65 B, snugly engage through openings  60 B and  60 C ( FIGS. 9-10 ), for engagement into housing apertures  80  ( FIG. 11 ), of housing  75 . As illustrated in  FIGS. 9-10 , stanchions  65 A and  65 B are snugly fit, and frame support member  65  and mounting frame  60  may require gluing or the like to remain securely affixed. 
     To assemble the integrated enclosure, screws or similar means  82  engage housing apertures  80 A and stanchion apertures  67  to couple housing  75  to frame support member  65 . 
     In an alternative embodiment a molded boot  90  ( FIG. 13 ) can be used to create an encased receptacle. In the above example, the boot  90  could be substituted for housing in glued or sealed contact with mounting frame  60  of receptacle  100 . As illustrated in  FIG. 13 , the boot  90  would include a rearward aperture  90 A for routing interface coupling  15 .  FIG. 13  illustrates a commercial power output receptacle  100  and boot  90 , however, it is understood that boot  90  can be used also in the application illustrated in  FIG. 12 . 
     In yet another alternative embodiment, as illustrated in  FIGS. 14-16 , first and second mirrored joinable sections,  110  and  115 , can be used to create the encased receptacle. The identical sections may include engagement tabs  115 A and  115 B. One of the tabs  115 A may engage a recess  65 AB of stanchions  65 A and  65 B while another tab  115 B slideably engages a stanchion support member  65 AC. This engagement allows for joinable sections  110  and  115  to be fixedly coupled to stanchions  65 A and  65 B while being joined together by screws  82 . It is understood that any combination of similar structure for engagement tabs and recesses can be used to fixedly couple the joinable sections. 
       FIGS. 17-19  illustrate various embodiments of recessed electrical boxes or “deep Boxes”, that can be utilized with the present invention. Referring to  FIG. 17-19 , the single gang recessed electrical box  120  includes an integrated face plate  122  with a flange  122 B that extends outward beyond the periphery of box  120 A. The box  120  includes wall mounting claws  124  that are adjustable to engage drywall or the like via positioning screws  122 A. The box includes connection apertures  120 B for securing any of the various embodiments of encased receptacles discussed herein. Opening  120 C is approximately dimensioned to the dimensions of the receptacle ends of the integrated enclosures after mounting over opening  120 C, and is smaller than opening  120 D. As illustrated in  FIG. 18 , recessed box  120  includes an interior surface that projects rearward of opening  120 D up to a rear panel  120 E. Rear panel  120 E extends inward from sides  120 F of the interior surface. 
     Since the electrical receptacles are electrically isolated and pre-wired in one of the various forms described herein, they can be mounted external to recessed electrical box  120 , as illustrated in  FIGS. 24-26 . This creates a deep opening within the wall, as illustrated in  FIG. 27 . 
     As illustrated in  FIG. 26 , a larger front opening  120 D is of sufficient length and width to allow access to the mounted receptacles  10  located inward of opening  120 D. As illustrated in  FIG. 27 , in the field, a hole would be cut in the wall at a dimension less than the periphery of face plate  122 , flange  122 B. Utilizing the engagement claws  124  against the interior wall mounting surface  45 B by turning the positioning screws  122 A, the claws would force the Flange  122 B against the wall for a secure fit. 
       FIG. 20-21  illustrates a double gang “deep box” having the same functionality for the respective elements as described above, and further illustrates multiple openings  120 C, in rear panel  120 E.  FIGS. 22-23  illustrate an alternative embodiment of the double gang recessed electrical box having the same functionality for the respective elements as described above.