Patent Publication Number: US-2022224091-A1

Title: Back-to-back two-gang electrical box

Description:
FIELD OF THE INVENTION 
     The present disclosure relates electrical boxes, and more particularly, to a back-to-back electrical box for indoor and outdoor applications. 
     BACKGROUND 
     Various electrical boxes for indoor and outdoor use are known. Electrical boxes can be single gang to accommodate one outlet or switch, or multi-gang to accommodate two or more outlets or switches. 
     Multi-gang boxes are generally arranged to position outlets or switches side-by-side. For example, the Hubbell HBL985 wall box is a two-gang box for delivering power, data, or AV side-by-side. These wall boxes are typically mounted with the outlets or switches facing outward from a wall. When outlets are side-by-side, one outlet may be blocked when an oversized plug is used. Further, it may be difficult to use outlets facing outward from a wall when they are located behind furniture or in tight spaces. 
     Some devices exist for mounting outlets on outdoor posts, however, most only accommodate single outlets our side-by-side outlets, such as B-K Lighting Receptacle Bollards and Legrand Outdoor Charging Stations. U.S. Pat. No. 7,234,670, assigned to Arlington Industries, describes one post that allows for outlets to be mounted opposite one another. However, the post is limited in its applications and cannot be mounted in different configurations. 
     The present invention solves these and other problems in the prior art. 
     SUMMARY 
     An object of the present invention is to provide an improved electrical box having a variety of electrical and data interface devices (i.e., outlets/receptacles, switches, etc.) positioned on opposite sides. A further object of the present invention is to provide an improved electrical box which can be mounted both vertically and horizontally. 
     In one exemplary embodiment according the present disclosure, an electrical box is provided including a central housing with a first side opening, a second side opening opposite the first side opening, and a rear opening, each of the first and second side openings configured to receive an electrical or data interface device, a first extension compartment around the first side opening, the first extension compartment including a first door, and a second extension compartment around the second side opening, the second extension compartment including a second door. In some embodiments, an exterior cover extends at least partially over the central housing, the first extension compartment, and the second extension compartment. 
     The first side opening may include a first electrical or data interface device and the second side opening may include a second (e.g., different) electrical or data interface device. In some embodiments, the first interface device is a high voltage electrical outlet or switch, and the second interface device is a low voltage data or audio/visual (AV) outlet. 
     The electrical box may have a rear side including the rear opening and a front side opposite the rear side, wherein the rear opening is configured to attach to a mount box. In some embodiments, each of the first and second doors are hingedly attached to edges of the front side. The mount box may be a multi-gang box or a single-gang mount box. When a single-gang mount box is used, the electrical box may include a mud ring at least partially closing the rear opening of the central housing around an opening of the single-gang mount box. 
     In some embodiments, the central housing includes a slot extending therethrough on the front side. A barrier may be positioned in the slot extending through the central housing and at least partially into the mount box. In some embodiments, the mount box is mounted in a wall and the electrical box is mounted against the wall. In some embodiments, the mount box is mounted on a top of a pedestal, and the electrical box is mounted against the top of the pedestal. 
     In another exemplary embodiment according the present disclosure, an electrical box is provided including a central housing with a first side opening, a second side opening opposite the first side opening, and a rear opening configured to attach to a mount box, each of the first and second side openings configured to receive an electrical or data interface device, a recess on a front side of the central housing including holes to receive fasteners for attaching the central housing to the mount box, and a slot in the recess extending into the central housing. 
     In some embodiments, a barrier extends through the slot and the rear opening at least partially into the mount box. A removable cover may be positioned within the recess. 
     The electrical box according to embodiments of the present disclosure is adapted to accommodate dual voltage and can be mounted in a vertical orientation (e.g., wall mounting) or a horizontal orientation (e.g., on a pedestal) on a standard single or two gang boxes. The electrical box is particularly suitable for outdoor applications, such as outside a home or business or in an outdoor recreational area such as a beach or park. For example, the electrical box may be mounted in the horizontal orientation in an outdoor recreational area or other public space for charging devices. The electrical box has indoor applications as well. For example, the electrical box can be used indoors for receptacles which are located behind beds to comply with NEC requirements (e.g., Article 210-60(b) of NEC 2014), such as in health care facilities. With the electrical box disclosed herein, a bed can be up against the box and the plug/receptacle connection is protected. 
     The electrical box according to the present disclosure provides consumers with the capability of installing multi-voltage devices with a provided barrier (e.g., mounted to Hubbell&#39;s two-gang box HBL985) or with single voltage devices where no barrier is required. If one power output is blocked by an oversize plug, the box provides consumers additional opportunity to use another side. In some embodiments, the electrical box includes a mud ring for power distribution applications. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       A more complete appreciation of the present disclosure and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein: 
         FIG. 1  is an isometric view of an electrical box according to an exemplary embodiment of the present disclosure mounted to a two-gang box; 
         FIG. 2  is a top view of the electrical box shown in  FIG. 1 ; 
         FIG. 3  is a front view of the electrical box shown in  FIG. 1 ; 
         FIG. 4  is an isometric view of the electrical box shown in  FIG. 1  with a first door in an open position; 
         FIGS. 5A and 5B  are side views of the electrical box shown in  FIG. 1  with first and second doors in open positions; 
         FIG. 6  is an isometric view of an electrical box according to an exemplary embodiment of the present disclosure mounted in a vertical configuration on a wall; 
         FIG. 7  is an isometric view of an electrical box according to an exemplary embodiment of the present disclosure mounted in a horizontal configuration on a pedestal; 
         FIG. 8A  is an isometric view of an electrical box according to an exemplary embodiment of the present disclosure mounted to a two-gang box with an exterior cover removed; 
         FIG. 8B  is a front view of the electrical box shown in  FIG. 8A  with a slot cover removed; 
         FIG. 9  is an isometric view of the electrical box shown in  FIGS. 8A-8B  with a first extension compartment removed; 
         FIG. 10  is an isometric view of the electrical box shown in  FIG. 9  with a central housing removed; 
         FIG. 11  is a rear isometric view of a central housing of an electrical box according to an exemplary embodiment of the present disclosure mounted to a two-gang box; 
         FIG. 12  is an exploded view of the central housing and the two-gang box shown in  FIG. 11 ; 
         FIG. 13  is a top view of an electrical box according to an exemplary embodiment of the present disclosure mounted to a single-gang box; 
         FIG. 14  is a rear isometric view of the electrical box shown in  FIG. 13 ; 
         FIG. 15  is an isometric view of the electrical box shown in  FIG. 13  with an exterior cover and a first extension compartment removed; and 
         FIG. 16  is an isometric view of the electrical box shown in  FIG. 15  with a central housing removed. 
     
    
    
     DETAILED DESCRIPTION 
     The present disclosure may be understood more readily by reference to the following detailed description of the disclosure taken in connection with the accompanying drawing figures, which form a part of this disclosure. It is to be understood that this disclosure is not limited to the specific devices, methods, conditions, or parameters described and/or shown herein, and that the terminology used herein is for the purpose of describing particular embodiments by way of example only and is not intended to be limiting of the claimed disclosure. 
     Also, as used in the specification and including the appended claims, the singular forms “a,” “an,” and “the” include the plural, and reference to a particular numerical value includes at least that particular value, unless the context clearly dictates otherwise. Ranges may be expressed herein as from “about” or “approximately” one particular value and/or to “about” or “approximately” another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another embodiment. It is also understood that all spatial references, such as, for example, horizontal, vertical, top, upper, lower, bottom, left and right, are for illustrative purposes only and can be varied within the scope of the disclosure. 
       FIG. 1  shows an electrical box  100  according to an exemplary embodiment of the present disclosure mounted to a two-gang box  50 .  FIGS. 2 and 3  illustrate top and front views of the electrical box  100  shown in  FIG. 1 . The electrical box  100  has a rear side adjacent to the box  50 , an opposite front side, and top and bottom sides. In this exemplary embodiment, the two-gang box  50  may be, for example, a Hubbell HBL985 or any other suitable multi-gang (e.g., two-gang) box. A further described below, the electrical box  100  may alternatively be mounted to a single-gang box (see  FIGS. 13-16 ). The box  50  may be secured at least partially within a wall or pedestal. 
     The electrical box  100  may further include an exterior skin or cover  110 , a first end with first door  120 , and second end opposite the first end with a second door  130 . The cover  110  extends over the front, top, and sides of the electrical box  100 . The cover  110 , and/or the doors  120 , 130  and other components of the electrical box  100 , may be manufactured from a corrosion resistant metal such as aluminum (e.g., cast aluminum), stainless steel or other material suitable for outdoor use, or plastic or metal for indoor use. In some embodiments, the cover  110  can be different colors. 
     As shown in  FIGS. 3 and 4 , the first and second doors  120 , 130  may be hingedly attached to the electrical box  100  and/or cover  110  with hinges including springs  122 , 132  to bias the doors  120 , 130  closed. Preferably the doors  120 , 130  are hinged at an outside edge at the front of the electrical box  100 . Therefore, the doors  120 , 130  open from the wall outward when the electrical box  100  is vertically mounted, or upward from the ground when horizontally mounted, to protect the switch or outlets and the mating plugs or connector devices while in use from the elements. 
     As shown in  FIG. 4 , the electrical box  100  includes a first extension compartment  140  or recessed frame with an interior cavity exposed when the door  120  is opened. The first extension compartment  140  may include cable cutouts  142 , 144  on two or more of its sidewalls to route a cord  152  (having a plug  154 ) when the door  120  is fully closed. The electrical box  100  may include plugs  145  that snap into the cutouts  142 , 144  when not in use. A second extension compartment  160  (shown in  FIGS. 8A-10 ) has the same features. The exterior cover  110  may also have corresponding tabs  112  that are removable (e.g., break off) to reveal the cutouts  142 , 144 . 
       FIG. 5A  is a side view of the first end of the electrical box  100  with the first door  120  in an open position. In the exemplary embodiment, the cavity of the first extension compartment  140  surrounds and encloses a high voltage electrical power outlet  150 .  FIG. 5B  is a side view of the second end of the electrical box  100  with the second door  130  in an open position. In the exemplary embodiment, the cavity of the second extension compartment  160  surrounds and encloses a low voltage data or audio/visual (AV) outlet. The outlets shown herein are only exemplary. A variety of electrical and data interface devices may be installed in the electrical box  100 . Examples include, without limitation, high voltage electrical power outlets, electrical switches, data, or audio/visual outlets (e.g., ethernet, coaxial, telephone, HDMI), and combined power and data outlets (e.g., USB, USB-C, etc.). 
     The electrical box  100  according to an exemplary embodiment of the present disclosure may be mounted in vertical and horizontal configurations.  FIG. 6  is an isometric view of the electrical box  100  mounted in a vertical configuration on a wall  200 . The vertical configuration can, for example, be used indoors for receptacles which are located behind beds to comply with NEC requirements, such as in health care facilities.  FIG. 7  is an isometric view of the electrical box  100  mounted in a horizontal configuration on top of a pedestal  220 . 
       FIG. 8A  is an isometric view of the electrical box  100  mounted to a two-gang box  50  with the exterior cover  110  removed to illustrate the internal components. The electrical box  100  includes a central back-to-back housing  180  with a first end and opening and a second opposite end and opening. The central housing  180  is secured to the box  50  with a gasket in between. Extension compartments  140 , 160  are secured over the outlets  150 , 170  and to respective ends of the central housing  180  with gaskets in between. 
     The central housing  180  may have top and bottom cutouts  181  to reduce material and form a partial backstop on each side for outlets or switches. As shown in  FIGS. 8A and 8B , the central housing  180  may also include a removable (e.g., snap in) cover  182  to allow access to fasteners (e.g., four fasteners  183 ) for securing the central housing  180  to the box  50 .  FIG. 8B  shows the electrical box  100  with the cover  182  removed. Removal of the cover  182  also reveals a vertical slot  185  for the insertion and inspection of a barrier between the two outlets  150 , 170 . The slot  185  extends into the central housing  180  allowing a barrier to be placed between the first and second side openings of the central housing  180  and out through the rear opening. As one skilled in the art will understand, a barrier is used particularly when the voltages are different between the two outlets  150 , 170 , such as when one outlet  150  is high voltage electrical power and the other outlet  170  is low voltage data or audio/visual (AV). 
       FIG. 9  is an isometric view of the electrical box  100  shown in  FIG. 8A  with the first extension compartment  140  removed and a first side opening  184  of the central housing  180  exposed. The outlet  150  is secured into the first side opening  184  of the central housing  180 . The central housing  180  includes connection mechanisms, such as threaded holes  188  (see  FIG. 11 ), to receive fasteners  151  (e.g., screws) to attach the outlets  150 , 170 . A gasket  186  is positioned around the first side opening  184  of the central housing  180 . 
       FIG. 10  is an isometric view of the electrical box  100  shown in  FIG. 9  with a central housing  180  removed. The gasket  52  between the central housing  180  and the box  50  is shown. A gasket  186  positioned around a second side opening (opposite the first side opening  184 ) of the central housing  180  is also shown. A barrier  54  extends between the first and second outlets  150 , 170  and into the box  50 . The barrier  54  may be inserted and inspected via the slot  185  behind the removable cover  182 . 
       FIG. 11  is a rear isometric view of the central housing  180  of the electrical box  100  mounted to a two-gang box  50 , with sidewalls of the box  50  removed for clarity.  FIG. 12  is an exploded view of the central housing  180  and the two-gang box  50  shown in  FIG. 11 . The central housing  180  includes a rear opening engaging with the box  50 . The gasket  52  surrounds the rear opening of the central housing  180 . Each side of the central housing  180  has two or more holes  188  for receiving fasteners  151  to attach the outlet  150  (or other electrical or data interface device). The central housing  180  also includes holes  190  for receiving fasteners to attach the extension compartment  140  to the central housing  180 . There may also be a hole  192  for receiving a grounding fastener. 
     As discussed above, the electrical box  100  may be mounted to a single or multi-gang boxes.  FIG. 13  is a top view of an electrical box  100  according to an exemplary embodiment of the present disclosure mounted to a single-gang box  60 .  FIG. 14  is a rear isometric view of the electrical box  100  shown in  FIG. 13 . 
       FIGS. 15 and 16  are isometric views of the electrical box  100  shown in  FIG. 13  with portions removed to illustrate the internal components. The same central housing  180  may be used for a single-gang box  60  and secured together with fasteners under a removable cover  182 . A gasket  62  is positioned between the box  60  and the central housing  180 . Further, when a single-gang box  60  is used, an optional mud ring  66  may be provided to close the opening, at least partially, between the box  60  and the rear opening of the central housing  180 . 
     As shown throughout the drawings, like reference numerals designate like or corresponding parts. While illustrative embodiments of the present disclosure have been described and illustrated above, it should be understood that these are exemplary of the disclosure and are not to be considered as limiting. Additions, deletions, substitutions, and other modifications can be made without departing from the spirit or scope of the present disclosure. Accordingly, the present disclosure is not to be considered as limited by the foregoing description.