Patent Abstract:
A weatherproof while-in-use electrical box assembly adapted for use on buildings that include a siding exterior or that will be finished with siding. The weatherproof electrical box assembly includes an electrical box with an integral siding block and a cover assembly adapted to receive large electrical plugs. The integral siding block provides a channel around the electrical box for accommodating siding. The channel enables the electrical box assembly to channel water to the bottom of the box and exterior of the siding where it will drip harmlessly to the ground. The cover assembly includes cord openings that enable closing of the cover plate while electrical cords are connected to electrical outlets within the electrical box. Cord inserts are provided for closing the cord openings when they are not in use. The tamperproof cover includes an arm adapted to accept a padlock for securing the cover to the electrical box.

Full Description:
This application claims the priority of U.S. Provisional Application Ser. No. 61/773,390 filed Mar. 6, 2013. 
    
    
     FIELD OF THE INVENTION 
     This invention relates to electrical boxes, and specifically to an electrical box with a siding block and a while-in-use cover. 
     BACKGROUND OF THE INVENTION 
     Electrical FS boxes for outdoor use are typically mounted on the exterior of buildings for providing convenient access to electrical outlets and other electrical devices such as switches and timers. Conventional FS boxes typically are a simple rectangular box configuration with a back wall and four side walls. When being mounted to a building, a rectangular hole must be cut in the substrate in order to mount the electrical box to the building. Cutting into the substrate creates a costly and time consuming repair job for the installer as he must typically caulk around the perimeter of the electrical box to seal against rain penetration between the box and the substrate. Although the caulk is meant to seal around the box, it is difficult to obtain a perfect seal making it likely that rain or water could seep behind the siding surrounding the box. Furthermore, cutting into the substrate can disrupt and damage the building&#39;s insulation layer that typically resides just under the substrate. There is also the problem of potentially damaging electrical wiring that is behind the area of the cut. 
     What is needed is an electrical box assembly that minimizes the need to cut a hole in the substrate and that accommodates siding in a manner that eliminates water seepage behind the siding. The electrical box assembly should be weatherproof, providing protection against rain and weather to a receptacle mounted therein while an electrical cord is plugged into the receptacle and also when the receptacle is not in use. The electrical box should furthermore include a cover member to accommodate large electrical plugs. The term “siding” as used herein includes stucco. 
     SUMMARY OF THE INVENTION 
     The invention is a weatherproof while-in-use electrical box assembly adapted for use on buildings that include a siding exterior or that will be finished with siding. The weatherproof while-in-use electrical box assembly includes an electrical box with an integral siding block and a cover assembly. The integral siding block provides a 360-degree channel around the electrical box for accommodating siding. The channel enables the electrical box assembly to channel water to the bottom of the box and exterior of the siding where it will drip harmlessly to the ground. The cover assembly is tamperproof and is adapted to receive large electrical plugs. The cover assembly includes cord openings that enable closing of the cover plate while electrical cords are connected to electrical outlets within the electrical box. The weatherproof electrical box assembly includes cord inserts for closing the cord openings when not in use to keep the assembly weatherproof when not in use. The tamperproof cover includes an arm adapted to accept a padlock for securing the cover to the electrical box thereby imparting a security function to the assembly. 
     OBJECTS AND ADVANTAGES 
     A first object is to eliminate the need for an installer to cut a large hole in the outer substrate of the house in order to install an electrical box on a building either covered with siding or under construction to be finished with siding. Cutting a large hole in the substrate can damage the insulation of a house and cause extra repair work for the contractor or homeowner. The present invention, by providing a siding block integral with the electrical box, eliminates the need for cutting a large hole in the substrate. The electrical box assembly of the present invention requires only a small hole to be made in the substrate in order to pull wiring into the box. 
     A second object of the invention is to provide an electrical box assembly that combines the utility of an FS box with an integral siding block for providing a 360-degree waterproof channel for accommodating siding around the periphery of the electrical box and channeling water away from the box and the surrounding siding. 
     A third object is to combine the functionality of a while-in-use cover with an FS style electrical box. 
     A further object is to provide a cover that is able to accept large electrical plugs of electrical cords while in use. 
     A further object of the invention is to provide tamperproof functionality to the electrical box assembly. The cover member is lockable to the electrical box portion of the assembly. 
     Another object is to provide smooth cord openings in the electrical box to eliminate fraying of electrical cords while the cords are plugged into the box. 
     Another object is to include reusable cord inserts to make the electrical box assembly weatherproof while the electrical box is not in use. 
     A further object is to enable installation of the electrical box assembly in either an old work situation or a new work situation. The electrical box assembly includes a removable base flange to convert the assembly so that it can be installed in an old work situation, wherein the siding is installed on the building. 
     These and other objects and advantages of the present invention will be better understood by reading the following description along with reference to the drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S) 
       Reference is made herein to the accompanying drawings, which are not necessarily drawn to scale, and wherein: 
         FIG. 1  is an isometric view of the preferred embodiment of an electrical box assembly with an integral siding block and a while-in-use cover in accordance with embodiments of the invention. 
         FIG. 2  is a front view of an electrical box which forms a portion of the electrical box assembly of  FIG. 1 . 
         FIG. 3  is a side view of the electrical box of  FIG. 2 . 
         FIG. 4  is an end view of the electrical box. 
         FIG. 5  is a sectional view of the electrical box taken along line  5 - 5  of  FIG. 2 . 
         FIG. 6  is a rear view of the electrical box. 
         FIG. 7  is a front isometric view of the electrical box. 
         FIG. 8  is a front isometric view of a while-in-use cover member box which forms a portion of the electrical box assembly of  FIG. 1 . 
         FIG. 9  is an isometric view of the electrical box assembly with the cover open. 
         FIG. 10  is a front elevation view of the electrical box assembly of  FIG. 1 . 
         FIG. 11  is a sectional view of the electrical box assembly taken along line  11 - 11  of  FIG. 10 . 
         FIG. 12  is an exploded isometric view of the electrical box assembly depicting the cover member separate from the electrical box. 
         FIG. 13  is an isometric view of an electrical box assembly according to the present invention with the cover member in the closed position. 
         FIG. 14  is a bottom view of the electrical box assembly of  FIG. 13 , with the cover in the closed position. 
         FIG. 15  is an isometric view of a second embodiment of the electrical box assembly of the present invention. 
         FIG. 16  is a front elevation of the electrical box assembly of  FIG. 15 . 
         FIG. 17  is a sectional view of the second embodiment of the electrical box assembly taken along line  17 - 17  of  FIG. 16 . 
         FIG. 18  is an isometric view of a cord opening plug which forms a portion of the electrical box assembly of  FIG. 1 . 
         FIG. 19  is a side view of the cord opening plug of  FIG. 18 . 
         FIG. 20  is an isometric view of the electrical box assembly of the present invention with the while-in-use cover closed and plugs installed in the cord openings. 
     
    
    
     DETAILED DESCRIPTION 
     With reference to  FIG. 1 , the present invention comprises an electrical box assembly  20  for mounting electrical components to the exterior of a finished building with siding installed on the exterior or to an unfinished building whose exterior that will be finished with siding. The electrical box assembly  20  includes an electrical box  22  with an integral siding block  24  and a while-in-use cover  26 . 
     Referring to  FIGS. 2-3 , the electrical box  22  includes four inner sidewalls  32 , four outer sidewalls  34 , and a back wall  36  that define the inner enclosure or cavity  38 . Outer sidewalls  34  are of a larger dimension D1 than the inner sidewalls  32  of dimension D2. Two bosses  40  extend from the inner surface  42  of the outer sidewalls  34 . A peripheral wall  44  extends between the inner sidewalls  32  and outer sidewalls  34 . Bosses  40  include component mounting bores  46  therein and a groove  48  adjacent the mounting bores  46  and extending fully across each boss  40 . 
     The electrical box  22  includes a plurality of apertures  50  in the back wall  36  with each of the apertures  50  including a surrounding peripheral wall  52  extending inward of the back wall  36 . The back wall  36  further includes a plurality of knockouts  56  therein. A base flange  58  extends from the entire periphery of the inner sidewalls  32 . The base flange  58  is coplanar with the back wall  36  and includes breakaway grooves  60  therein. A second flange  62  extends from the outer periphery of the outer sidewalls  34  and includes a wide base portion  64  and a smaller outer portion  66  that includes a beveled edge  68  and four truncated corners  70 . The outer sidewalls  34  include a front edge  72  and a peripheral wall  74  extending laterally outward around the entire outer periphery of the front edge  72 . 
     As shown in  FIG. 3 , electrical box  22  sidewalls  34  include a top end  76  and a bottom end  78 . Opposing outer sidewalls  34  of top end  76  include ears  80 , which are thick wall sections with apertures  82  therein. Bottom end  78  of the outer sidewalls  34  includes a leg  84  at one end. The leg  84  includes an aperture  86  therein. A tab  88  extends downward from the outer surface of one outer sidewall  34 . 
     Referring to  FIGS. 4 and 5 , base flange  58  in combination with inner sidewalls  32  and second flange  62  define a channel  90  that aides removal of water from around the electrical box assembly and the siding (not shown) installed around its periphery. The breakaway grooves  60  in the back wall  36  of electrical box  22  enable an installer to modify the electrical box  22  for installation on an existing structure or old work situation. By scoring with a utility knife or similar sharp blade, an installer can remove the base flange  58  from the electrical box  22 . With the base flange  58  removed, a rectangular hole, large enough to receive the inner sidewalls  32 , may be cut in the siding (not shown) to accommodate the electrical box. For new construction, the base flange  58  is retained with the box  22 , and the electrical box is secured to the substrate by driving nails through apertures  50  in back wall  36 . Base flange  58  underlies the siding and shields the substrate from rain or water penetration. Any rain or water falling in channel  90  will fall to the bottom of the electrical box channel  90  and from thence fall away from the siding. As shown in  FIG. 5 , the electrical box  22  includes an outer cavity  92  defined by peripheral wall  44  and outer sidewalls  34 . Outer cavity  92  is adapted to house an electrical component such as a duplex receptacle (not shown). The electrical component will seat flush against peripheral wall  44  and thus be recessed within the building wall that the electrical box  22  is secured to. Inner cavity  38  provides an enclosure for making wiring connections to the electrical component. 
     With reference to  FIG. 6 , the breakaway grooves  60  are formed around the entire periphery of the inner sidewalls  32 . Thus flange  58  may be removed by scoring, with a utility knife or similar sharp blade, along grooves  60  and then breaking away flange  58  from the remainder of the electrical box  22 . Such a modification would be made in an old work situation, in order to adapt the electrical box to fit within a smaller hole in the siding. The breakaway grooves  60  extend completely from side  59  to side  59  of the electrical box. 
     Referring to  FIGS. 8 and 9 , the cover  26  includes a front panel  94 , four sidewalls  96 , two ears  98  on opposing sidewalls, and apertures  101  in each ear  98  that are in axial alignment with one another. Sidewall panels  103  extend from three of the sidewalls  96 . The sidewall panels  103  and sidewalls  96  meet at a juncture  104 . An arm  105  extends from one end of the bottom sidewall  96   b  and includes an aperture  107  therein. A brace  109  extends from the bottom sidewall  96   b  to the arm  105 . The brace  109  is substantially planar and is orthogonal to the plane of the arm  105 . The cover  26  further includes a latch  111  with an opening  113  therein and two U-shaped openings  115  in the bottom sidewall  96   b . The cover  26  includes a beveled edge  117  at the juncture of the front panel  94  and each sidewall  96 . The ears  98  extend outward from the plane including the rear edge  102  of the sidewall panels  103 . 
     With reference to  FIG. 9 , cover member  26  is secured to electrical box  22  by bolts  119  extending through the ears  98  of the cover  26  and through the outer sidewall  34  of the electrical box. Cover  26  further includes a jam  121  including a flat abutment surface  123  extending from the inner surface  125  of the cover. Flat abutment surface  123  is in alignment with the juncture  104  between the cover sidewall  96  and the sidewall panel  103 . The jam  121  cooperates with brace  109  in leveling the cover  26  with respect to the front edge  72  of the electrical box  22 . When cover  26  is closed on electrical box  22 , aperture  107  in arm  105  of cover  26  is in axial alignment with aperture  86  in leg  84  of electrical box  22 . 
     Referring to  FIG. 11 , the cover member  26  is hinged to the electrical box  22  by bolts  119 . When the cover  26  is closed upon the electrical box  22 , brace  109  near the bottom of the box and flat abutment surface  123  of jam  121  each contact the front edge  72  of the electrical box  22  and maintain panel  94  of cover parallel with the front edge  72  of the electrical box  22 . 
       FIGS. 12 and 13  illustrate an alternative embodiment of the electrical box assembly  127  which includes an alternative means of connecting cover member  26  to the box. In this embodiment, electrical box  129  includes posts  131  integral with and extending from opposing sides of the outer sidewalls  34 . Ears  98  of cover member  26  are flexible and are slipped over the electrical box  129  and posts  131  wherein the cover becomes operatively hinged to the electrical box. 
     With reference to  FIG. 14 , with the cover  26  closed on the electrical box  22 , U-shaped openings  115  abut the front edge  72  of the electrical box  22  and form two smooth-walled while-in-use cord openings  133  through which electrical cords (not shown) can be passed. Closing of cover  26  upon electrical box  22  further causes latch  111  of cover to engage tab  88  of electrical box to snap lock the cover  26  to the box  22 . The electrical cord openings  133  are formed on the bottom sidewall  96   b  of the electrical box assembly at the juncture  132  of the cover  26  and the outer sidewall  34  of the electrical box  22 . As cover  26  is closed on the box  22 , tab  88  snaps through opening  113  in latch  111 . 
     With reference to  FIG. 15 , there is shown another alternative embodiment of the electrical box assembly  135 . Electrical box assembly  135  includes a horizontal electrical box  137  versus the vertical electrical box of the first embodiment. Additionally, horizontal electrical box assembly  135  includes shrouds  139  surrounding the U-shaped openings  115  in the cover  26 . When cover  26  is closed on electrical box  137 , aperture  107  in arm  105  of cover  26  is in axial alignment with aperture  86  in leg  84  of electrical box  137 . 
     Referring to  FIGS. 16 and 17 , the horizontal electrical box assembly  135 , similar to the first embodiment, includes an integral siding block  24  including a base flange  58 , a second flange  62 , and the inner sidewalls  32  defining a channel  90  for receiving siding (not shown) therein. After the horizontal electrical box assembly  135  is secured to a wall and siding is installed around the assembly, any rain falling within the channel  90  will fall to the bottom of the siding block  24  and fall away from the siding. As in the first embodiment, when the cover  26  is closed upon the electrical box  137 , brace  109  near the bottom of the box and flat abutment surface  123  of jam  121  each contact the front edge  72  of the electrical box  137  and align panel  94  of cover parallel with the front edge  72  of the electrical box  137 . 
     With reference to  FIGS. 18 and 19 , the electrical box assembly of the present invention includes cord opening plugs  141  that include a plug body  143  with two sides  145  and  147 . Three legs  149  extend from the plug body  143  including one leg on a first side  145  and two legs on the opposing side  147  that are installed at the U-shaped openings  115  in the bottom sidewall  96   b  of the cover  26  as shown in  FIG. 20 . The plugs  141  are preferably molded in one piece of plastic. The legs  149  define a gap  151  that is slightly larger than the thickness of the sidewall  96   b  surrounding the U-shaped openings  115 . The plugs  141  are supplied installed on the electrical box assembly  20  as shown in  FIG. 20 , but can be removed or subsequently installed by the homeowner as needed. When electrical cords (not shown) are connected to the receptacle within the box, the plugs are removed to provide cord openings for the cords. If the electrical cords are removed, the plugs  141  can be installed on the sidewall  96   b  at the U-shaped openings  115  in order to close the cord openings  133  (see  FIG. 14 ) thereby further waterproofing the box and also preventing insects from entering the cord openings. 
     With reference to  FIG. 11 , as a result of the wide sidewalls  96  of the cover  26 , the electrical box assembly  20  advantageously can accommodate large plugs (not shown) of electrical cords. The depth of the inside surface of the cover  26  from the front edge  72  of the electrical box  22 , shown as distance D3, is preferably at least 1.5 inches. Distance D4 in the figure, the distance between the mounting face of the electrical component and the inside surface of the cover  26  is preferably at least 2.75 inches. The volume within the cover member  26  is preferably at least 22 cubic inches. The inner cavity  38  preferably includes a volume of at least 17 cubic inches. Thus the depth of the outer cavity  92  of the electrical box is the difference between D3 and D4, which is at least 1.25″. This provides ample space for accommodating a f-inch long electrical plug within the outer cavity  92 . A large electrical plug as described herein is one that is over ¾-inch in length. 
     The electrical box  22  and cover plate  26  of the present invention may be manufactured of metal or plastic. Most preferably the electrical box  22  and cover plate  26  of the present invention are each molded of plastic in one piece. In the preferred embodiment of the electrical box, the siding block  24 , including the base flange  58  and second flange  62 , are thus an integral portion of the one-piece molded electrical box  22 . 
     The description of the present invention has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the invention. The embodiment was chosen and described in order to best explain the principles of the invention and the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated.

Technology Classification (CPC): 7