Patent Publication Number: US-2023134979-A1

Title: Electrical box extender backer plate

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a non-provisional application claiming the benefit of priority under 35 U.S.C. § 119(e) to U.S. Provisional Application No. 63/273,332, filed Oct. 29, 2021, which is hereby incorporated by reference in its entirety. 
    
    
     FIELD 
     The present disclosure relates to a backer plate for use with an electrical box extender to enable the electrical box extender to function as a complete electrical box. 
     BACKGROUND 
     Industrial electrical boxes are widely used in industrial construction and may be mounted to, e.g., walls, ceilings, and/or floors. Typical industrial electrical boxes include a backplate, four walls extending perpendicularly from such backplate, and an open face. Conduits housing one or more electrical wires may be mounted to one or more of the four walls. The one or more electrical wires may extend through the industrial electrical box to another conduit, or alternatively may be attached to an electrical device mounted over the open face. For example, in certain applications, one or more electrical power lines extend through a conduit attached to one of the four walls of the electrical box and attach to an electrical outlet mounted over the open face of the electrical box. 
     Certain building codes generally provide that no more than a predetermined amount of electrical wires may be present in an electrical box of a certain size. Accordingly, if making modifications to an electrical system of a building includes adding more than the predetermined amount of electrical wires to the electrical box, the electrical box must be extended in size to accommodate such additional electrical wires. Electrical box extenders may then attach to the electrical box, thus increasing the size available to house the electrical wires. 
     SUMMARY 
     Discussed herein are various devices and systems related to creating an electrical box. 
     In one exemplary aspect, a backer plate is provided for use with an electrical box extender to form an electrical box, the backer plate including: a planar wall defining a perimeter, four edges along the perimeter, and four corners between adjacent edges, the planar wall further defining at least a first threaded opening located at a first corner of the four corners and a second threaded opening located at a second corner of the four corners, wherein the first and second threaded opening are configured to rotatably engage with a first and second threaded fastener, respectively, to fasten the electrical box extender to the planar wall of the backer plate to form the electrical box. 
     For example, the backer plate may be provided, wherein the four edges include a first edge, a second edge, a third edge, and a fourth edge, and wherein each of the first edge, the second edge, the third edge and the fourth edge are all equal in length. 
     For example, the backer plate may be provided, wherein the four edges of the backer plate forms a square shape that measures four inches by four inches, or 4 11/16 inches by 4 11/16 inches. 
     For example, the backer plate may be provided, wherein the first threaded opening and the second threaded opening each include an 8/32nd of an inch in diameter threading. 
     For example, the backer plate may be provided, wherein the planar wall defines a plurality of knockouts configured to receive one or more of an electrical conduit. 
     For example, the backer plate may be provided, wherein the planar wall defines a plurality of internal openings placed in between the plurality of knockouts, wherein each of a given internal opening from the plurality of internal openings includes a smaller area than each of a given knockout area from the plurality of knockouts. 
     In another exemplary aspect of the present disclosure, an electrical box assembly is provided. The electrical box assembly includes: a backer plate having a planar wall defining a perimeter, four edges along the perimeter, and four corners between adjacent edges, the planar wall further defining at least a first threaded opening located at a first corner of the four corners and a second threaded opening located at a second corner of the four corners; an electrical box extender separate from the backer plate, the electrical box extender including four wall and defining a first electrical box extender opening and a second electrical box extender opening; and a first threaded fastener extending through the first electrical box extender opening and engaged with the first threaded opening and a second threaded fastener extending through the second electrical box extender opening and engaged with the second threaded opening, the first and second threaded fasteners coupling the electrical box extender to the backer plate to form an electrical box. 
     For example, the electrical box assembly may be provided, wherein the four walls of the electrical box extender extend perpendicularly from the backer plate. 
     For example, the electrical box assembly may be provided, wherein the four walls of the electrical box extender extend perpendicularly from the four edges of the backer plate. 
     For example, the electrical box assembly may be provided, wherein the electrical box extender includes a first half and a second half, wherein both the first half and the second half each include a male end and a female end, wherein each of the female end and the male end together form one of the first electrical box extender opening or the second electrical box extender opening. 
     For example, the electrical box assembly may be provided, wherein the planar wall defines a plurality of knockouts configured to receive one or more of an electrical conduit. 
     For example, the electrical box assembly may be provided, wherein the planar wall defines a plurality of internal openings placed in between the plurality of knockouts, wherein each of a given internal opening from the plurality of internal openings includes a smaller area than each of a given knockout area from the plurality of knockouts. 
     For example, the electrical box assembly may be provided, wherein the four edges include a first edge, a second edge, a third edge, and a fourth edge, and wherein each of the first edge, the second edge, the third edge and the fourth edge are all equal in length. 
     For example, the electrical box assembly may be provided, wherein the four edges of the backer plate forms a square shape that measures four inches by four inches. 
     For example, the electrical box assembly may be provided, wherein the first threaded opening and the second threaded opening each include an 8/32nd of an inch in diameter threading. 
     In an exemplary aspect of the present disclosure, a method of forming an electrical box assembly is provided. The method includes: providing a backer plate including a planar wall defining a perimeter, four edges along the perimeter, and four corners between adjacent edges, the planar wall further defining at least a first threaded opening located at a first corner of the four corners and a second threaded opening located at a second corner of the four corners; providing an electrical box extender separate from the backer plate, the electrical box extender including four wall and defining a first electrical box extender opening and a second electrical box extender opening; and coupling the electrical box extender to the backer plate with a first threaded fastener extending through the first electrical box extender opening and engaged with the first threaded and with a second threaded fastener extending through the second electrical box extender opening and engaged with the second threaded opening. 
     For example, the method may be provided, wherein the four walls of the electrical box extender extend perpendicularly from the backer plate. 
     For example, the method may be provided, wherein the four walls of the electrical box extender extend perpendicularly from the four edges of the backer plate. 
     For example, the method may be provided, wherein the electrical box extender includes a first half and a second half, wherein both the first half and the second half each include a male end and a female end, wherein each of the female end and the male end together form one of the first electrical box extender opening or the second electrical box extender opening. 
     For example, the method may be provided, wherein the planar wall defines a plurality of knockouts configured to receive one or more of an electrical conduit. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which: 
         FIG.  1    is a perspective view of an electrical box in accordance with an exemplary aspect of the present disclosure. 
         FIG.  2    is a top, planar view of the exemplary backer plate used to form the electrical box of  FIG.  1   . 
         FIG.  3    is a perspective view of the exemplary backer plate. 
         FIG.  4    is a perspective, exploded view of a electrical box extender. 
         FIG.  5    is a perspective view of an assembled version of the electrical box extender of  FIG.  4    and fastened to the backer plate of  FIGS.  2  and  3   . 
         FIG.  6    shows another perspective view of the assembly of  FIG.  5   . 
     
    
    
     DETAILED DESCRIPTION 
     Reference will now be made in detail to present embodiments of the invention, one or more examples of which are illustrated in the accompanying drawings. The detailed description uses numerical and letter designations to refer to features in the drawings. Like or similar designations in the drawings and description have been used to refer to like or similar parts of the invention. 
     The word “exemplary” is used herein to mean “serving as an example, instance, or illustration.” Any implementation described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other implementations. Additionally, unless specifically identified otherwise, all embodiments described herein should be considered exemplary. 
     The singular forms “a”, “an”, and “the” include plural references unless the context clearly dictates otherwise. 
     Here and throughout the specification and claims, range limitations are combined and interchanged, such ranges are identified and include all the sub-ranges contained therein unless context or language indicates otherwise. For example, all ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other. 
     In general, the present disclosure is related to a backer plate that may be used with an electrical box extender to enable the electrical box extender to function as a complete, five-walled (all four side walls and back wall) electrical box. The exemplary backer plate of the present disclosure may be used with most electrical box extenders, such as the modular electrical box extender described in U.S. Pat. No. 9,806,507, issued Oct. 31, 2017, the entire contents of which are incorporated herein by reference. The exemplary backer plate includes threaded openings to allow for screws, bolts, studs or the like to pass through openings in the electrical box extender and engage with the threaded openings of the backer plate to fasten the electrical box extender to the exemplary backer plate and form the electrical box. 
     Throughout the written specification when referring to a threaded fastener, a threaded fastener is defined to be any fastener that has threads, such as screws, bolts, studs, rods, etc. 
     Further, as used herein, the term “electrical box extender” refers to any structure capable of attachment to an underlying electrical box to extend the internal volume of the assembly, or as in the case of the present disclosure, capable of attachment to a backer plate of the present disclosure to form an electrical box. 
     Referring now to the Figures,  FIG.  1    is a perspective view of an electrical box in accordance with an exemplary aspect of the present disclosure. The electrical box generally is formed using, and includes, a backer plate, an electrical box extender, and for the embodiment depicted, a cover plate. 
     Referring now to the Figures,  FIG.  1    is a perspective view of an electrical box  10  in accordance with an exemplary aspect of the present disclosure. The electrical box  10  generally is formed using, and includes, a backer plate  20 , an electrical box extender  12 , and for the embodiment depicted, a cover plate  84 . 
     The electrical box  10  of  FIG.  1    defines a coordinate system with x, y, and z-directions, each orthogonal to one another. The exemplary electrical box extender  12  depicted generally includes four walls, and more specifically four linear walls that extend perpendicularly from the backer plate  20 . 
     In particular, for the embodiment depicted, the electrical box extender  12  is configured as a modular electrical box extender made of a first half  14  (having two walls; only one depicted in  FIG.  1   ) and a second half  16  (also having two walls; only one depicted in  FIG.  1   ). Operation and assembly of the exemplary electrical box extender  12  will be described in more detail below. The first half  14  and the second half  16  may attach together via a means for fastening which could include a screw or bolt (with or without a nut), a nail, anchor, rivet, threaded rod (such as studs), glue, tape, Velcro, a magnet, a pin, a thread, etc., as understood by those of ordinary skill in the art. Depicted in the exemplary electrical box of  FIG.  1    is a threaded fastener  80 . 
     The electrical box  10 , when assembled to include the electrical box extender  12  and backer plate  20 , has a thickness T in the z-direction, a height L 2  in the y-direction, and a width L 1  in the x-direction. These lengths may be standard sizes as used in the art, or customized sizes to fit unique configurations such as square, hexagonal, octagonal, or rectangular electrical boxes In at least one embodiment, the dimensions L 1 , L 2 , and D may for example be 4 inches×4 inches×1½ inches. 
     Alternatively, in other embodiments, the dimensions L 1 , L 2 , and D may for example be 4½ inches×8⅝ inches×1⅝ inches, 4 11/16 inches by 4 11/16 inches by ½ inches, or any other suitable size. 
     The electrical box  12  may generally house a power outlet device  86 , a network connection device  90 , or the like. The cover plate  84  generally defines one or more openings to expose these devices, and may be fastened to one or more of these devices through fasteners  88 ,  92 . 
     Further, the electrical box extender  12  depicted generally includes knockouts  17 ,  18 , which may be removed to receive a conduit  22 . The knockouts  17 ,  18  may be circular in shape, and include various size diameter knockouts  17 ,  18  to accommodate various size conduits  22 . 
     The exemplary backer plate  20  is attached to a back of the assembled first half  14  and second half  16  electrical box extender  12 , or more specifically to an inner edge  96  of the electrical box extender  12 , so as to form the complete electrical box  10 . Although not expressly depicted, the exemplary backer plate  20  may receive electrical conduits  22  in the z-direction through knockouts  26  or  24  (not shown in  FIG.  1   ; see  FIG.  2   ). 
     Referring now to  FIG.  2   , the exemplary backer plate  20  includes a planar wall (not separately labeled), being generally flat. The exemplary backer plate  20  includes a plurality of knockouts  26  and  24 , wherein the knockouts  26  and  24  show different size knockouts to receive different size electrical conduits  22 . Examples of the diameters of the knockouts  26  and  24  may be ⅜ inches, ½ inch, ⅝ inches, ¾ inches, ⅞ inches, 1⅛ inch, 1⅜ inches, 1 inch. 
     These knockouts  26 ,  24  may form an “X” pattern, or other pattern configured to maximize the number of conduits  22  (not shown in  FIG.  2   ) that can fit within a perimeter  40  of the backer plate  20 . 
     The back plate  12  further defines a plurality of internal openings  34 ,  36 ,  32 . The internal openings  34 ,  36 ,  32  may be used for mounting the backer plate  20  to a surface, connecting the backer plate  20  to another device ordinarily used in combination with electrical boxes  10 , to mount internal electrical components of an electrical box such as the power outlet device  86  or the network connection device  90  (not shown in  FIG.  2   ) internally, or to provide an open space for tools to be inserted into, thus enabling access for an end of a tool into an electrical box  10  through the backer plate  20 . The internal openings  34 ,  36 , or  32  may additionally or alternatively be used for wiring such as to provide an opening for a ground wire to exit through the backer plate  20 . 
     In the exemplary embodiment depicted in  FIG.  2   , the planar wall of the backer plate  20  may further define four edges along the perimeter and four corners between adjacent edges. The four edges in the exemplary embodiment of  FIG.  2    includes a top edge  41  with respect to the x-y plane, a right edge  42 , a bottom edge  43 , and a left edge  44 . The lengths and overall shape determined by the combination of the four edges  41 ,  42 ,  43 ,  44 , may form the perimeter  40  of the backer plate  20 . The top and bottom edges  41 ,  43  may correspond to the length L 1  shown in  FIG.  1   , and the left and right edges  42 ,  44  may correspond to the height L 2  shown in  FIG.  1   . 
     Alternative configurations are contemplated such as six edges, eight edges, curved edges, one continuous circular curving edge, etc. 
     On the backer plate  20 , the internal openings  34 ,  36 , and  32  may be configured along the centerlines of the backer plate  20 , such that a relatively equal distance is placed between adjacent knockouts. For example, placing internal opening  32  a relatively equal distance from both a positive y-direction from knockout  24  and a negative y-direction from knockout  26 , or relatively equal upper and lower distances from knockouts  24  and  26  respectively. Internal opening  32  may be placed a distance L 3  away from a left edge  44  (in the x-direction) of the perimeter  40  of backer plate  20 , whereas internal opening  34  may be placed a different distance L 4  from the right edge  42  (in the x-direction) of the backer plate  20 , and internal opening  34  may have a different diameter compared to internal opening  32 . 
     Internal openings  36  on the other hand may all have the same diameter, and may have equal distances L 5  from a bottom edge  43  (in the y-direction) of the perimeter  40  as the distance L 5  from the top edge  41  (in the y-direction) of the perimeter  40  with respect to the bottom-most and top-most internal openings  36  respectively. The internal openings  36  may each be a distance L 6  from one another on the upper and lower portions of the backer plate (in the y-direction, not z-direction into page). Alternative configurations are contemplated. For example, internal openings  36  need not all be the same diameter, nor do any of the internal openings need to be placed along centerlines of the backer plate  20 . The internal openings could be randomly placed in areas between the knockouts  24 ,  26 . 
     As such, each of the internal openings  32 ,  34 , or  36  may be placed on the backer plate  20  in various amounts or patterns, configured to optimize the distances between internal openings, cutouts, or edges on the backer plate  20 . 
     Furthermore, the exemplary backer plate  20  includes two threaded openings, a first opening  30  located at a first corner (the lower left corner of the backer plate  20  in the embodiment depicted) and a second opening  31  located at a second corner (the upper right corner in the embodiment depicted; the second corner being an opposite side corner from the first corner). These threaded openings  30 ,  31  may be configured to be a distance L 7  from a y-direction perimeter  40  edge, and a distance L 8  from an x-direction perimeter  40  edge so as to match up or configure with an electrical box extender  12  (not shown) that may be used regularly in the industry. The distance L 7  and distance L 8  may each be less than 1 inch, such as less than 0.5 inches. 
     Moreover, the corners of the backer plate may be rounded corners  46  and have radius “r” so as to accommodate industry-used electrical box extenders  12  without creating inconvenient or cumbersome corners that extend further than the corners of an electrical box extender  12  used in the industry. The radius r may be less than 1.5 inches and at least 0.1 inches. 
       FIG.  3    provides a perspective view of the backer plate  20  of  FIG.  2   . As may be seen in  FIG.  2   , the backer plate  20  further defines a thickness “t”. The backer plate  20  is configured to be thick enough to refrain from bending under expected amounts of force (such as mounting, being fastened to an object, being tossed among a pile of other backer plates  20 , near-protruding wires from the inside of a makeshift electrical box  10 , etc.), while also minimizing the amount of space that the backer plate takes up on the backside of an electrical box extender  12 . These knockouts  24  and  26  can easily be punched out to define a knockout opening given an amount of force less than that required were there not indented portions, so as to easily receive an electrical conduit  22  (see in  FIG.  1   ) to give access for the electrical box  10  into the contents of the electrical conduit  22 . 
     Referring now to  FIG.  4   , the exemplary electrical box extender  12  of the electrical box  10  of  FIGS.  1  through  3    is shown as modular pieces, including the first half  14  and the second half  16 . This exemplary electrical box extender may be configured in a similar manner as the exemplary electrical box extender described in U.S. Pat. No. 9,806,507, issued Oct. 31, 2017, from which the entire contents of which are incorporated herein by reference. The first half  14  and the second half  16  are modular components that when twisted 180 degrees in the x-y plane so as to replace the other&#39;s position, the first half  14  and the second half  16  are interchangeable with one another. The first half  14  and the second half  16  when fastened together may create an electrical box extender  12 . When fastened together, the exemplary electrical box extender  12  may resemble what appears to be a square or rectangle. The exemplary electrical box extender  12  may have therefore have four walls that could be referred to as a top wall  51 , a right wall  52 , a bottom wall  53 , and a left wall  54 , all with respect to the x-y plane as can be seen in  FIG.  4   . The four walls  51 ,  52 ,  53 ,  54  may with their lengths and overall shape form an outer perimeter  50  of the electrical box extender  12 . 
     Alternative configurations are contemplated as many shapes of electrical box extenders  12  exist, such as square, rectangular, hexagonal, octagonal, circular, or even a combination of rectangular walls with circular walls, etc. as understood by those of ordinary skill in the art. 
     The first half  14  includes knockouts  18  and  19 , which may be similar in size to the knockouts  24  and  26  from the backer plate  20 . These knockouts  18  and  19  may be configured to have alternating diameters, all the same diameter, or all different diameters, or further, the knockouts  18  and  19  may be configured to have three knockouts per wall of electrical box extender. However, a different number of knockouts  18  and/or  19  is contemplated that may be configured to maximize the number of knockouts per wall of the electrical box extender  12  while maintaining industry-size receiving knockouts for electrical conduits  22 . Each of the first half  14  and the second half  16  have an outer edge  94  and an inner edge  96 . 
     The first half  14  has a female end  56  having a tab  60  defining an opening  64 , and the second half  16  has a male end  58  having a tab  62  defining an opening  66 . The opening  64  defined by the tab  60  of the female end  56  is configured to align with the opening  66  defined by the tab  62  of the male end  58  on the second half  16 . The first half  14  similar has a male end  58  configured in the same manner as the male end  58  of the second half  16 , and the second half  16  similarly has a female end  56  configured in the same manner as the female end  56  of the first half  14 . 
     In between the right wall  52  and the bottom wall  53  on the second half  16 , a second corner tab  74  is defined, extending inward from the second half corner  70 . A similar arrangement exists on the first half  14  from which the left wall  54  and the top wall  51  come together to form corner  68 . In the corner  68  of the first half  14 , a first corner tab  72  for the first half  14  is included, protruding inward from the first half corner  68 . Within each of the first corner tab  72  and the second corner tab  74 , a first opening  76  in the first corner tab and a second opening  78  in the second corner tab are each defined respectively for the first half  14  and the second half  16 . 
     Referring now to  FIGS.  5  and  6   , as noted above, the electrical box extender  12  is formed by the first half  14  and the second half  16 , and further the electrical box  10  can be formed by combining the first half  14  and second half  16 , further in combination with the backer plate  20 . 
     As can be seen in the exemplary electrical box  10  depicted, the electrical box further includes threaded fasteners  80  to couple the electrical box extender  12  to the backer plate  28  to form the electrical box  10 . More specifically, the exemplary electrical box  10  depicted includes a first threaded fastener  80  extending through the first electrical box extender opening (i.e., a first opening formed by a combination of openings  64 ,  66 ) and engaged with the first threaded opening  30  and a second threaded fastener  80  extending through the second electrical box extender opening (i.e., a second opening formed by a combination of openings  64 ,  66 ) and engaged with the second threaded opening  31  (see, e.g.,  FIG.  2   ), the first and second threaded fasteners  80  coupling the electrical box extender  12  to the backer plate  28  to form the electrical box  10 . 
     The threaded fasteners  80  may be inserted into openings  66  and  64  (when the openings  66  and  64  are overlapping) to fasten the first half  14  and the second half  16  together, and also fasten the electrical box extender  12  to the backer plate  20 , for example by aligning openings  64 ,  66  with opening  30  or opening  31  of the backer plate  20 . 
     As can be seen in  FIG.  5   , the corner tabs  72  and  74  may include a means for fastening  82  such as a threaded fastener to attach a cover plate  84  ( FIG.  1   ) to the electrical box  10  if so desired. The means for fastening a cover plate  84  to the electrical box extender  12  can be any of the means for fastening that were previously mentioned, although in the exemplary model depicted in  FIG.  5   , threaded fasteners  82  are what may be inserted into first opening  76  and second opening  78  to attach to a cover plate  84 . 
     Further, it is contemplated that the first opening  76  and second opening  78  may receive a means for fastening to fasten an additional electrical box extender (not shown) on top of the electrical box extender  12  depicted. The system of the additional electrical box extender attached to the electrical box extender  12  would be on the outer edge  94  of the electrical box extender  12 . 
     As shown in  FIGS.  5  and  6   , the exemplary backer plate  20  provides a snug fit to the back of the electrical box extender  12 . When using a first half  14  and a second half  16 , which often have non-threaded openings  64  and  66 , in this instance it may be important for the backer plate  20  to have the openings  30 ,  31  be threaded if the means for fastening the electrical box extender  12  to the backer plate  20  is to function via a threaded fastener. 
     In alternative configurations, it is contemplated that the means for fastening may be other than that of a threaded fastener, and that in this instance the first and second openings  30 ,  31 , need not be threaded, and the threaded fasteners  80  could instead be any of nails, anchors, rivets, glue, tape, Velcro, magnets, pins, threads, etc. 
     The backer plate  20  provides a way to create an electrical box  10  when, e.g., no leftover electrical boxes  10  can be found, and electrical box extenders  12  and/or first half  14  and second half  16  may be found in excess. 
     It will be appreciated that in certain exemplary aspects, a method of forming an electrical box assembly may be provided. 
     The method may include providing a backer plate having a planar wall defining a perimeter, four edges along the perimeter, and four corners between adjacent edges, the planar wall further defining at least a first threaded opening located at a first corner of the four corners and a second threaded opening located at a second corner of the four corners. As used herein, the term “providing” does not require forming or manufacturing a component. 
     The method may further include providing an electrical box extender separate from the backer plate, the electrical box extender including four wall and defining a first electrical box extender opening and a second electrical box extender opening. 
     Further, still, the method may include coupling the electrical box extender to the backer plate with a first threaded fastener extending through the first electrical box extender opening and engaged with the first threaded and with a second threaded fastener extending through the second electrical box extender opening and engaged with the second threaded opening. 
     This written description uses examples to disclose the present disclosure, including the best mode, and also to enable any person skilled in the art to practice the disclosure, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the disclosure is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.