Patent Publication Number: US-11038300-B1

Title: Extendable electrical outlet enclosure

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of the filing date of U.S. Provisional Patent Application 62/772,110 entitled “Horizontal Surface Enclosures” to Jeffrey P. Baldwin that was filed on Nov. 28, 2018, the disclosure of which is hereby incorporated herein by this reference. 
     TECHNICAL FIELD 
     Aspects of this document relate generally to an extendable electrical outlet enclosure. 
     BACKGROUND 
     Electrical outlet enclosures are used to contain an electrical outlet and its wiring. Electrical enclosures help to keep the outlet free of water, direct, and other contaminants. In addition, the electrical enclosure provides a layer of separation between electrical wiring and the materials surrounding the electrical outlet. This reduces the risk of fire or electrical shock as a result of contact with the electrical wiring. However, in each situation in which an outlet is used, there may be differing amounts of electrical wiring that need to be contained within the electrical enclosure. A need exists for electrical outlet enclosures that are extendable to accommodate different amounts of wiring while still providing the benefits of an electrical outlet enclosure expressed above. 
     SUMMARY 
     Aspects of this document relate to electrical outlet enclosures which may comprise a tubular main body having a first end and a second end opposite the first end, the main body having an electrical device support extending inward from a wall of the main body between the first end and the second end, the electrical device support defining a separation between an electrical plug section adjacent the first end and a wiring section adjacent the second end, the second end comprising at least one screw boss connected to the wall of the main body and accessible to the second end, a bezel surrounding an opening at the first end and removably coupled to the first end, a cap configured to removably mount to the bezel within the opening to cover the electrical plug section, at least one extension tube having an outer wall, each of the at least one extension tube having a leading end with at least one leading screw boss connected to the outer wall and accessible to the leading end, and a trailing end with at least one trailing screw boss connected to the outer wall and accessible to the trailing end, the at least one trailing screw boss out of alignment with the at least one leading screw boss, wherein the at least one leading screw boss is configured to align and couple with the at least one boss of the main body, and a back plate having at least one cord receiver aperture extending therethrough and at least one mounting screw aperture extending therethrough, wherein the at least one screw aperture of the back plate is positioned to align with the at least one trailing boss of the at least one extension tube and the at least one cord receiver aperture is configured to allow wiring to extend from the electrical enclosure, wherein the electrical enclosure is configured to assemble with the bezel and cap connected to the first end of the main body, the at least one extension tube leading boss connected to the at least one boss of the second end of the main body with a screw, the back plate connected to the extension tube with a screw through the at least one screw aperture and the at least one trailing boss, and an electrical device coupled to the main body at the electrical device support. 
     Particular embodiments may comprise one or more of the following features. The at least one extension tube may comprise a first extension tube and a second extension tube and the at least one trailing boss of the first extension tube is configured to align with the at least one leading boss of the second extension tube. The at least one cord receiver aperture may be two cord receiver apertures. 
     Aspects of this document relate to electrical outlet enclosures which may comprise a tubular main body having a first end and a second end opposite the first end, the main body having an electrical device support extending inward from a wall of the main body between the first end and the second end, the electrical device support defining a separation between an electrical plug section adjacent the first end and a wiring section adjacent the second end, the second end comprising at least one screw boss connected to the wall of the main body and accessible to the second end, a bezel surrounding an opening at the first end and removably coupled to the first end, a cap configured to removably mount to the bezel within the opening to cover the electrical plug section, at least one extension tube having an outer wall, each of the at least one extension tube having a leading end with at least one leading screw boss connected to the outer wall and accessible to the leading end, and a trailing end with at least one trailing screw boss connected to the outer wall and accessible to the trailing end, wherein the at least one leading screw boss is configured to align and couple with the at least one boss of the main body, and a back plate having at least one mounting screw aperture extending therethrough, wherein the at least one screw aperture of the back plate is positioned to align with the at least one trailing boss of the at least one extension tube, wherein the electrical enclosure is configured to assemble with the bezel and cap connected to the first end of the main body, the at least one extension tube leading boss connected to the at least one boss of the second end of the main body with a screw, the back plate connected to the extension tube with a screw through the at least one screw aperture and the at least one trailing boss, and an electrical device coupled to the main body at the electrical device support. 
     Particular embodiments may comprise one or more of the following features. The at least one extension tube may comprise a first extension tube and a second extension tube and the at least one trailing boss of the first extension tube is configured to align with the at least one leading boss of the second extension tube. Each of the at least one trailing screw boss may be out of alignment with each of the at least one leading screw boss. The back plate may further comprise at least one cord receiver aperture configured to allow wiring to extend through the electrical enclosure. The at least one cord receiver aperture may be two cord receiver apertures. 
     Aspects of this document relate to electrical outlet enclosures which may comprise a tubular main body having a first end and a second end opposite the first end, the main body having an electrical device support extending inward from a wall of the main body between the first end and the second end, the electrical device support defining a separation between an electrical plug section adjacent the first end and a wiring section adjacent the second end, a bezel surrounding an opening at the first end and removably coupled to the first end, at least one extension tube having an outer wall, each of the at least one extension tube having a leading end and a trailing end, wherein the leading end of one of the at least one extension tube is configured to align and couple with the second end of the main body, and a back plate, wherein the back plate is configured to align and couple with the second end of one of the at least one extension tube, wherein the electrical enclosure is configured to assemble with the bezel connected to the first end of the main body, the leading end of one of the at least one extension tube connected to the second end of the main body, the back plate connected to the trailing end of one of the at least one extension tube, and an electrical device coupled to the main body at the electrical device support. 
     Particular embodiments may comprise one or more of the following features. The second end of the main body may have at least one screw boss connected to the outer wall and accessible to the second end, the leading end of the at least one extension tube having at least one leading screw boss connected to the outer wall and accessible to the leading end, and the trailing end of the at least one extension tube having at least one trailing screw boss connected to the outer wall and accessible to the trailing end. The at least one screw boss of the second end may be configured to align with the at least one leading screw boss of the at least one extension tube. The back plate may have at least one mounting screw aperture extending therethrough, wherein the at least one screw aperture of the back plate is positioned to align with the at least one trailing boss of the at least one extension tube. The at least one extension tube may comprise a first extension tube and a second extension tube and the at least one trailing boss of the first extension tube is configured to align with the at least one leading boss of the second extension tube. Each of the at least one trailing screw boss may be out of alignment with each of the at least one leading screw boss. The back plate may further comprise at least one cord receiver aperture extending therethrough, configured to allow wiring to extend through the electrical enclosure. The at least one cord receiver aperture may be two cord receiver apertures. A cap configured to removably mount to the bezel within the opening to cover the electrical plug section. 
     The foregoing and other aspects, features, applications, and advantages will be apparent to those of ordinary skill in the art from the specification, drawings, and the claims. Unless specifically noted, it is intended that the words and phrases in the specification and the claims be given their plain, ordinary, and accustomed meaning to those of ordinary skill in the applicable arts. The inventors are fully aware that he can be his own lexicographer if desired. The inventors expressly elect, as their own lexicographers, to use only the plain and ordinary meaning of terms in the specification and claims unless they clearly state otherwise and then further, expressly set forth the “special” definition of that term and explain how it differs from the plain and ordinary meaning. Absent such clear statements of intent to apply a “special” definition, it is the inventors&#39; intent and desire that the simple, plain and ordinary meaning to the terms be applied to the interpretation of the specification and claims. 
     The inventors are also aware of the normal precepts of English grammar. Thus, if a noun, term, or phrase is intended to be further characterized, specified, or narrowed in some way, then such noun, term, or phrase will expressly include additional adjectives, descriptive terms, or other modifiers in accordance with the normal precepts of English grammar. Absent the use of such adjectives, descriptive terms, or modifiers, it is the intent that such nouns, terms, or phrases be given their plain, and ordinary English meaning to those skilled in the applicable arts as set forth above. 
     Further, the inventors are fully informed of the standards and application of the special provisions of 35 U.S.C. § 112(f). Thus, the use of the words “function,” “means” or “step” in the Detailed Description or Description of the Drawings or claims is not intended to somehow indicate a desire to invoke the special provisions of 35 U.S.C. § 112(f), to define the invention. To the contrary, if the provisions of 35 U.S.C. § 112(f) are sought to be invoked to define the inventions, the claims will specifically and expressly state the exact phrases “means for” or “step for”, and will also recite the word “function” (i.e., will state “means for performing the function of [insert function]”), without also reciting in such phrases any structure, material or act in support of the function. Thus, even when the claims recite a “means for performing the function of . . . ” or “step for performing the function of . . . ,” if the claims also recite any structure, material or acts in support of that means or step, or that perform the recited function, then it is the clear intention of the inventors not to invoke the provisions of 35 U.S.C. § 112(f). Moreover, even if the provisions of 35 U.S.C. § 112(f) are invoked to define the claimed aspects, it is intended that these aspects not be limited only to the specific structure, material or acts that are described in the preferred embodiments, but in addition, include any and all structures, materials or acts that perform the claimed function as described in alternative embodiments or forms of the disclosure, or that are well known present or later-developed, equivalent structures, material or acts for performing the claimed function. 
     The foregoing and other aspects, features, and advantages will be apparent to those of ordinary skill in the art from the specification, drawings, and the claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Implementations will hereinafter be described in conjunction with the appended drawings, where like designations denote like elements, and: 
         FIG. 1  is a top perspective view of an assembled extendable electrical outlet enclosure with the cap removed; 
         FIG. 2  is an exploded view of the electrical enclosure of  FIG. 1 ; 
         FIG. 3A  is a side view of the electrical enclosure of  FIG. 1  with the cap in place, showing section lines  4 - 4 ; 
         FIG. 3B  is a top view of the electrical enclosure of  FIG. 3A ; 
         FIG. 3C  is a bottom view of electrical enclosure of  FIG. 3A ; 
         FIG. 4  is section view of the electrical enclosure of  FIG. 3A  taken along section line  4 - 4 ; 
         FIG. 5  is a bottom perspective view of the electrical enclosure of  FIG. 1 ; 
         FIG. 6  is a perspective view of two possible implementations of a back plate for the electrical enclosure of  FIG. 1  that can be used with any embodiment disclosed in the Application; 
         FIG. 7  is a perspective view of the electrical enclosure of  FIG. 1  with the back plate removed, showing the internal configuration of an assembled extendable electrical outlet enclosure; 
     
    
    
     Skilled artisans will appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of implementations. 
     DETAILED DESCRIPTION 
     This document features an extendable electrical outlet enclosure. There are many features of an electrical enclosure and method implementations disclosed herein, of which one, a plurality, or all features or steps may be used in any particular implementation. 
     In the following description, reference is made to the accompanying drawings which form a part hereof, and which show by way of illustration possible implementations. It is to be understood that other implementations may be utilized, and structural, as well as procedural, changes may be made without departing from the scope of this document. As a matter of convenience, various components will be described using exemplary materials, sizes, shapes, dimensions, and the like. However, this document is not limited to the stated examples and other configurations are possible and within the teachings of the present disclosure. As will become apparent, changes may be made in the function and/or arrangement of any of the elements described in the disclosed exemplary implementations without departing from the spirit and scope of this disclosure. 
       FIG. 1  depicts a top perspective view of a non-limiting implementation of an extendable electrical outlet enclosure  10 . The extendable electrical outlet enclosure  10  is designed to be modular so that a different size extendable electrical enclosure  10  can be implemented in each new situation, depending on the needs of the particular outlet and its location and installation.  FIG. 2  shows an exploded view of the electrical enclosure  10  of  FIG. 1 . In the implementation shown, the electrical enclosure  10  comprises a main body  12 , a bezel  14 , a cap  16 , at least one extension tube  18 , and a back plate  20 . These main components of the electrical enclosure  10  are configured to align and couple with the bezel  14  and cap  16  connected to a first end  22  of the main body  12  and the at least one extension tube  18  connected to a second end  24  of the main body  12 . The back plate  20  is then connected to the at least one extension tube  18 . Inside of the main body, an electrical device  27  can be coupled to the main body  12  at an electrical device support  28 . Each of the individual components may be coupled with the adjacent component using one or more screws  31 . 
       FIG. 3A  shows a side view of the electrical enclosure  10  of  FIGS. 1 and 2 . The main body  12  has a first end  22  and a second end  24  that is opposite the first end  22 . In addition, the main body  12  has a wall  26  that extends between the first end  22  and the second end  24 .  FIG. 3B  shows a top view of the electrical enclosure  10  with the cap  16  in place. The cap  16  functions to obscure a view of the electrical device  27  when the electrical device  27  is not in use by covering an opening  29  of the main body  12 .  FIG. 3C  shows a bottom view of the electrical enclosure  10 . 
       FIG. 4  depicts a cross-sectional view of the electrical enclosure  10  taken along the section line  4 - 4  shown in  FIG. 3A , and  FIG. 2  depicts an exploded view. The main body  12  may have a bezel support  25  at the first end  22  of the main body  12 . The bezel support  25  extends radially outward from the first end  22  and provides a surface to which the bezel  14  is configured to attach, surrounding the opening  29  at the first end  22  of the main body  12 . The cap  16  is configured to removably mount to the bezel  14 , thus covering the opening  29  when the electrical device  27  is not in use. An electrical device support  28  extends radially inward from the wall  26  towards the center line of the main body  12 . The electrical device support  28  defines a separation between an electrical plug section  30  and a wiring section  32 . The electrical plug section  30  is adjacent to the first end  22 , while the wiring section  32  is adjacent to the second end  24 . When an electrical device  27  has been installed within the electrical enclosure  10 , an electrical plug can be coupled with the electrical device  27  through the electrical plug section  30 . Power may be supplied to the electrical device  27  through wiring that is coupled with the electrical device  27  through the wiring section  32 . The main body  12  may have at least one screw boss  34  connected to the wall  26  at the second end  24  (shown in  FIG. 2 ). 
     The at least one extension tube  18  may be one extension tube, two extension tubes, or more than two extension tubes. Each of the at least one extension tube  18  has an outer wall  36  extending between a leading end  38  and a trailing end  40 . The leading end  38  may have at least one leading screw boss  42  connected to the outer wall  36  and accessible at the leading end  38 . The trailing end  40  may have at least one trailing screw boss  44  connected to the outer wall  36  and accessible at the trailing end  40 . The at least one leading screw boss  42  may be configured to align and couple with the least one screw boss  34  of the main body  12  using a screw  31 . 
     The back plate  20  may be the same shape as the cross section of the tubular main body  12  and the at least one extension  18 . The back plate  20  may have at least one cord receiver aperture  46  extending therethrough (see also  FIG. 5 ). Alternatively, the back plate  20  may have no cord receiver aperture (see  FIG. 6 ), or exactly two cord receiver apertures  46  (see  FIG. 6 ). The at least one cord receiver aperture  46  is configured to allow wiring to extend from the electrical enclosure  10 . The back plate  20  may also have at least one mounting screw aperture  48  extending therethrough. The at least one mounting screw aperture  48  is configured to align with the at least one trailing boss  44  of the at least one extension tube  18 . 
     In implementations having more than one extension tube  18 , the leading screw boss  42  of the first extension tube  18  is configured and positioned to align and couple with the at least one screw boss  34  of the main body  12 . The leading screw boss  42  of each succeeding extension tube  18  is configured and positioned to align and couple with the at least one trailing screw boss  44  of the preceding extension tube  18 . The at least one mounting screw aperture  48  of the back plate  20  is configured and positioned to align and couple with the at least one trailing screw boss  44  of the last extension tube  18 . For example, in an implementation with two extension tubes, the at least one leading screw boss  42  of the first extension tube  18  is configured to align and couple with the at least one screw boss  34  of the main body  12 , the at least one leading screw boss  42  of the second extension tube  18  is configured to align and couple with the at least one trailing screw boss  44  of the first extension tube  18 , and the at least one mounting screw aperture  48  of the back plate  20  is configured to align and couple with the at least one trailing screw boss  44  of the second extension tube  18 . In situations where more wiring is attached to the electrical device  27 , it is beneficial to have more extension tubes  18  because this creates more space within the electrical enclosure  10  to hold the wiring. Therefore, each specific situation will determine the number of extension tubes  18  that could be used beneficially. 
       FIG. 7  depicts a perspective bottom view of the electrical enclosure of  FIG. 1  with the back  20  plate removed, showing the internal configuration of an assembled electrical enclosure  10 . In the implementation shown, each extension tube  18  has leading screw bosses  42  that are out of alignment with the trailing screw bosses  44  of the same extension tube  18 . This allows easier access to the leading screw bosses  42  with a tool when the electrical enclosure  10  is assembled. 
     In a particular use example, an electrical outlet enclosure  10  for in-floor installation is to be installed into a floor. In a first installation, the floor is shallow, for example, framed with only 2×4 studs or to be formed with a shallow concrete pour, and an installer does not have a lot of room to install the electrical outlet enclosure  10 . In this first situation, the installer uses only the main body  12 , bezel  14 , cap  16 , the back plate  20  with cord receiver apertures  46 , and at least one screw  31  to attach the back plate  20  to the at least one screw boss  34  of the main body  12 . In a second installation, the floor is a little deeper and more space is needed within the electrical outlet enclosure  10 , for example framed with 2×6 studs or to be formed with a deeper concrete pour. In this second situation, the installer could use the main body  12 , bezel  14 , cap  16 , a first extension tube  18 , the back plate  20  with cord receiver apertures  46 , and a screw  31  to attach the extension tube  18  leading screw boss  42  to the screw boss  34  of the main body  12 , and a screw  31  to attach the back plate  20  to the trailing screw boss  44  of the extension tube. In a third installation, for example, the floor is deep and an installer has plenty of room for whatever depth of the electrical outlet enclosure  10  the installer desires. In this third situation, the installer could use the main body  12 , bezel  14 , cap  16 , two or more extension tubes  18 , the back plate  20  with cord receiver apertures  46 , and the screws  31  to attach the extension tubes  18  leading screw boss  42  to the screw boss  34  of the main body  12  and to the trailing screw boss  44  of the extension tube(s) respectively, and a screw  31  to attach the back plate  20  to the trailing screw boss  44  of the extension tube. Although the embodiments illustrated show only two extension tubes  18 , and it is currently contemplated that most products sold will include two extension tubes  18 , it will be understood by those of ordinary skill in the art that one or more extension tubes  18  may be used and in particular installations, it may be desirable to use three or even four or more extension tubes  18  for an installation, attaching them to each other to form the electrical outlet enclosure  10  as the first two are attached and described herein. 
     It will be understood that extendable electrical enclosure implementations are not limited to the specific assemblies, devices and components disclosed in this document, as virtually any assemblies, devices and components consistent with the intended operation of an extendable electrical enclosure may be utilized. Accordingly, for example, although particular electrical enclosures, covers, lids, sleeves, latches, snap-fit couplers, hinges, frames, enclosures, bubble covers, housings, joints, protrusions, ledges, clamps, grooves, ridges, couplers, fasteners, power sockets, and other assemblies, devices and components are disclosed, such may include any shape, size, style, type, model, version, class, measurement, concentration, material, weight, quantity, and/or the like consistent with the intended operation of an electrical enclosure implementation. Implementations are not limited to uses of any specific assemblies, devices and components; provided that the assemblies, devices and components selected are consistent with the intended operation of an extendable electrical enclosure. 
     Accordingly, the components defining any electrical enclosure implementations may be formed of any of many different types of materials or combinations thereof that can readily be formed into shaped objects provided that the components selected are consistent with the intended operation of an electrical enclosure implementation. For example, the components may be formed of: polymers such as thermoplastics (such as ABS, Fluoropolymers, Polyacetal, Polyamide; Polycarbonate, Polyethylene, Polysulfone, and/or the like), thermosets (such as Epoxy, Phenolic Resin, Polyimide, Polyurethane, Silicone, and/or the like), any combination thereof, and/or other like materials; glasses (such as quartz glass), carbon-fiber, aramid-fiber, any combination thereof, and/or other like materials; composites and/or other like materials; metals, such as zinc, magnesium, titanium, copper, lead, iron, steel, carbon steel, alloy steel, tool steel, stainless steel, brass, tin, antimony, pure aluminum, 1100 aluminum, aluminum alloy, any combination thereof, and/or other like materials; alloys, such as aluminum alloy, titanium alloy, magnesium alloy, copper alloy, any combination thereof, and/or other like materials; any other suitable material; and/or any combination of the foregoing thereof. 
     For the exemplary purposes of this disclosure, sizing, dimensions, and angles of electrical enclosure implementations may vary according to different implementations. 
     Various electrical enclosure implementations may be manufactured using conventional procedures as added to and improved upon through the procedures described here. Some components defining electrical enclosure implementations may be manufactured simultaneously and integrally joined with one another, while other components may be purchased pre-manufactured or manufactured separately and then assembled with the integral components. Various implementations may be manufactured using conventional procedures as added to and improved upon through the procedures described here. 
     Accordingly, manufacture of these components separately or simultaneously may involve extrusion, pultrusion, vacuum forming, injection molding, blow molding, resin transfer molding, casting, forging, cold rolling, milling, drilling, reaming, turning, grinding, stamping, cutting, bending, welding, soldering, hardening, riveting, punching, plating, and/or the like. If any of the components are manufactured separately, they may then be coupled with one another in any manner, such as with adhesive, a weld, a fastener (e.g. a bolt, a nut, a screw, a nail, a rivet, a pin, and/or the like), wiring, any combination thereof, and/or the like for example, depending on, among other considerations, the particular material forming the components. 
     It will be understood that the assembly of extendable electrical enclosures are not limited to the specific order of steps as disclosed in this document. Any steps or sequence of steps of the assembly of electrical enclosures indicated herein are given as examples of possible steps or sequence of steps and not as limitations, since various assembly processes and sequences of steps may be used to assemble electrical enclosures. 
     The electrical enclosure implementations described are by way of example or explanation and not by way of limitation. Rather, any description relating to the foregoing is for the exemplary purposes of this disclosure, and implementations may also be used with similar results for a variety of other applications requiring an extendable electrical enclosure.