Patent Publication Number: US-4837406-A

Title: Face plate and electrical component assembly

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to electrical components that are housed in boxes, and in particular, to arrangements for quickly and correctly mounting electrical components within an electrical box. 
     2. Description of the Prior Art 
     Outlets and switches are presently mounted in electrical boxes in much the same way that they have been for decades. First, the electrical box is nailed to a stud in the wall or to a joist in the floor or ceiling. Wire is pulled through conduits positioned within the walls, floors and ceilings and through each electrical box. Sheet rock is then typically placed on the studs or joists to form the wall or ceiling surfaces. Templates are used to cut a hole in the sheet rock so that the interior of the box and the electrical wiring is accessible. 
     In installing electrical components, such as an outlet or a switch , an end portion of the insulation from an end portion of the wires is removed, the wire mounting screws of the outlet are backed off, the wires are attached to the screws, and the screws are tightened. The outlet is then secured to the box by two screws. The face plate is then attached to the outlet by yet another screw. 
     As is readily apparent, the above procedure involves a good deal of labor. 
     In addition, since the electrical boxes are fastened to the studs prior to attaching the sheet rock, the front edge of the box may not be aligned properly with the sheet rock wall. Variations in the position of the electrical box relative to the sheet rock occur frequently, causing outlets and switches to be tilted or cocked and sometimes to be drawn too far into the box. When the outlet or switch is drawn too far into the box, attaching a face plate to the outlet or switch can become a problem. 
     A number of patents describe various methods and structures for more efficiently mounting electrical boxes. These patents include: 
     
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Inventor       Patent No.                                                 
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Warthen          867,624                                                  
Smith          3,488,428                                                  
Robinson et al 3,662,085                                                  
Brown          3,770,872                                                  
Hoehn          4,105,862                                                  
Mengeu         4,281,773                                                  
Borja et al    4,295,003                                                  
Nattel         4,306,109                                                  
Haslbeck et al 4,315,100                                                  
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     Other patents have also described various methods and structures for correcting the problem of variations in mounting electrical boxes within walls. These patents include: 
     
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Inventor     Patent No.                                                   
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Goodsell     4,336,416                                                    
Jaberg       2,410,287                                                    
Strand       1,862,324                                                    
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     SUMMARY OF THE INVENTION 
     The present invention includes an assembly having an electrical component, such as an outlet or a switch, that is mountable within an electrical box and has means for adjustably, adhesively securing it in place. The assembly provides for a quick and efficient manner of mounting the electrical component within a box and for compensating for variations in mounting of the box with respect to the wall surface. The assembly of the present invention utilizes a conventional outlet or switch construction and preferably a conventional face plate such that after the installation has been completed, the face plate and switch or outlet may be dissassembled in a conventional manner. 
     The assembly as shown includes the face plate and the electrical component secured to each other conventionally by a face plate screw or screws. The electrical component includes two conventional mounting screws that extend away from the electrical component and a back surface of the face plate. The assembly further includes means for adhesively mounting the assembly to the electrical box and said means for adhesively mounting are threadably engaged by the two mounting screws. The electrical box has an interior for accepting the electrical component and for housing wiring that is to be attached to the electrical component. The assembly is slid into the electrical box and the adhesive is permitted to cure, securing the assembly to the box. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a front view of the assembly of the present invention. 
     FIG. 2 is a cross sectional view taken along the line 2--2 of FIG. 1 of the device of the present invention. 
     FIG. 3 is a side view of the assembly of the present invention. 
     FIG. 4 is a front view of a portion of the electrical box of the present invention illustrating the boss and bore for receiving the plug. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The device of the present invention is indicated generally at 10 in FIGS. 1 and 2. The device 10 of the present invention includes an electrical box 12 and a face plate and electrical component assembly 14, as best illustrated in FIG. 2. The device of the present invention permits quick and efficient mounting of an electrical component, such as an outlet or a switch, along with a face plate to an electrical box in a quick and efficient manner. In addition, the device of the present invention compensates for variations in mounting of an electrical box with respect to the wall surface. 
     Referring to FIGS. 1-3, the assembly 14 includes a standard face plate 16 and a standard electrical component 18, such as an outlet or a switch. Although a duplex outlet 18 is specifically shown in the drawings, it will be understood that switches and other electrical components that are mounted in a conventional manner in electrical boxes are includable within the scope of the present invention. 
     The face plate 16 is secured to the duplex outlet 18 by a face plate screw 20. In the case of a switch, there are typically two face plate screws that attach the face plate to the switch. 
     Regardless of whether the electrical component is a duplex outlet or a switch, the component typically includes first and second ear members 22 and 24 through which electrical component mounting screws 26 and 28 extend for mounting the component to a conventional electrical box. The screws 26 and 28 threadably engage first and second cylindrical plugs 30 and 32, which are used to secure the assembly 14 to the electrical box 12, as will be described subsequently. 
     In the prior art, the electrical component is first wired by backing off terminal screws of the electrical component, attaching the wires around the screws, tightening the screws, and then securing the electrical component to the electrical box with screws 26 and 28. The face plate 16 is then mounted to the electrical component by face plate screws. 
     In the present invention the electrical component is wired in much the same way as in the prior art. However, the face plate and electrical component are one assembly 14 and are secured to the electrical box by adhesive in contrast to the prior art method of using mounted screws to initially secure the electrical component and then the face plate. 
     The electrical box 12 of the present invention is for the most part a conventional type of electrical box. As illustrated in FIGS. 2 and 4, the box has a back wall 34, a top wall 36, a bottom wall 38 and side walls 40 and 42. As will be understood, although a rectangular box is shown in the drawings, the present invention includes within its scope electrical boxes having other configurations. The electrical box 12 further includes first and second bosses 43 and 45 having plug receiving holes 44 and 46 for receiving the plugs 30 and 32, all respectively. The holes 44 and 46 are disposed adjacent the bottom and top walls 38 and 36 of the box 12 so that the holes are positioned to receive the plugs 30 and 32. The plugs 30 and 32 are secured to bosses 43 and 45 by a suitable adhesive. 
     Preferably, the box 12 is made of the same type of material as the prior art electrical boxes. The material may be metal, however, plastic or fiberglass if preferred. The plugs 30 and 32 preferably are also made of plastic. Since the plugs 30 and 32 are secured to the box 12 by an adhesive, the plugs and the box should be made of materials that permits adhesive bonding to each other. 
     In use, the box 12 of the present invention is mounted to a stud of a wall or to a joist of a floor or ceiling in a conventional manner. The sheet rock is then placed over the stud or wall and a template is used to cut a hole in the sheet rock to expose the front opening and interior of the box. Referring to FIG. 2, the box 12 is shown nailed to a stud 50. As illustrated in FIG. 2, a front edge of the box 52 is not correctly positioned with respect to the sheet rock 54. A gap 55 between the front edge of the box and the ears 22 and 24 of the electrical component 18 occurs. In the prior art, the screws 26 and 28 were typically tightened into the box causing the electrical component to be installed too deeply within the box, thereby causing problems in mounting the face plate onto the electrical component. 
     Using the present invention, the assembly 14 is mounted by applying adhesive to the plugs 30 and 32 or within the holes 44 and 46 and sliding the plugs 30 and 32 within the holes 44 and 46. The face plate abuts against the sheet rock and acts as a stop to correctly position the depth of the plugs within the holes. The adhesive is permitted to cure. Of course, prior to attaching the assembly 14 to the electrical box 12, wires 56 and 58 are attached to the terminal screws 60 of the electrical component in a conventional manner. 
     It will be appreciated that once the adhesive is cured, the face plate and the electrical component are removable from the box in a conventional manner. The face plate is removed by backing off the face plate screws 20 and the electrical component is removed by backing off the screws 26 and 28 from the plugs 30 and 32. The component 18 can be reinstalled by turning in the screws 26 and 28 into the holes 27 and 29 of the plugs 30 and 32 with the plugs now acting as support posts and being secured to become part of the box. 
     The sub-assembly of the electrical component screws 26 and 28 and plugs 30 and 32 can be used for compensating for box mounting differences, without the face plate, if plastic ears 22 and 24 on the component rest on the outer surface of the sheet rock or wall board. These form surfaces that engage the outer surface of the wall board to position the plugs prior to gluing. 
     Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention.