Patent Abstract:
A recessed electrical box including a flange having a rear surface formed to fit flush against siding. An inner cavity for accepting an electrical device extends well behind the flange. A removable cover is included for closing the inner cavity from the elements. The box is easily installed by forming a hole in the siding and sliding the box therein until the rear surface of the flange contacts the siding. The closeness of fit between the rear surface of the flange and the siding enables easy and rapid sealing between the box and the siding.

Full Description:
This application is a Continuation-In-Part of U.S. patent application Ser. No. 11/102,392, filed Apr. 8, 2005 and still pending, which is a Continuation-In-Part of U.S. patent application Ser. No. 11/070,344, filed Mar. 2, 2005 and still pending, which is a Continuation-In-Part of U.S. patent application Ser. No. 11/009,116 filed Dec. 10, 2004 and still pending, which is a Continuation-In-Part of U.S. patent application Ser. No. 10/863,942 filed Jun. 9, 2004 now U.S. Pat. No. 6,956,171. 

   FIELD OF THE INVENTION 
   This invention relates to electrical junction boxes and specifically to a recessed outlet box that can be easily retrofitted to the exterior siding of a building for accommodating and protecting a duplex outlet or other electrical device therein. 
   BACKGROUND OF THE INVENTION 
   Siding is commonly installed as the outer finish on the exterior of houses or other buildings. After a house has been built with the siding secured thereto, homeowners quite often find it necessary and desirable to mount additional electrical devices, such as duplex outlets, switches, and timers, to provide additional electrical services. 
   In several patent applications sharing common ownership and inventorship with the present application, including U.S. patent application Ser. Nos. 10/863,942, 11/009,116, 11/070,344, and 11/102,392, various electrical boxes were presented which provided the advantage of recessing the electrical device well behind the outer wall of the building. When mounted as a retrofit to a wall having siding installed thereon, recessed electrical boxes of the aforementioned patent applications included a flat rear surface of the box in contact with the siding. Although this provided an adequate means of recessing an electrical device well within a wall, the seal between the electrical box and the siding was not optimized. 
   What is needed therefore is a recessed electrical box that is easily retrofitted onto siding and with an optimal sealing surface between the electrical box and the wall surface. 
   SUMMARY OF THE INVENTION 
   The invention is a recessed electrical box having a flange with a rear surface formed to fit flush against siding. An inner cavity for accepting an electrical device extends well behind the flange. A removable cover is included for closing the inner cavity from the elements. The box is easily installed by forming a hole in the siding and sliding the box therein until the rear surface of the flange contacts the siding. The closeness of fit between the rear surface of the flange and the siding enables easy and rapid sealing between the box and the siding. 
   OBJECTS AND ADVANTAGES 
   One advantage of the recessed electrical box of the present invention is that it recesses an electrical device well within the wall of a structure. 
   The recessed electrical box furthermore provides the advantage of a mated fit between the box and the siding without the use of a gasket. 
   Another advantage provided by the electrical box of the present invention is that it can be rapidly retrofitted to a finished structure having siding installed thereon. 
   A further advantage is that the recessed electrical box provides a first enclosure that positions the electrical device within the exterior wall, thereby shielding the electrical device from impacts, and a second enclosure for shielding the face of the electrical device from rain and other environmental elements. 
   Yet another advantage is that the recessed electrical box of the present invention replaces traditional three-piece assemblies including electrical box, siding cover, and bubble cover assembly with a single one-piece assembly. 
   A further advantage is that a wide front flange is provided for covering mistakes or to cover a poorly cut mounting hole for a retrofit application. 
   The current recessed electrical box further provides, when used to house a duplex outlet, an electrical box and a spacious protective enclosure for protecting the plug ends of electrical cords. 
   A further advantage is that the electrical box and flange are molded integrally in one piece, thereby reducing production costs. 
   The electrical box furthermore includes integral bosses with threaded bores for accepting fasteners from an electrical device. 
   The electrical box of the present invention also provides a removable cover for added convenience. The cover is also a while-in-use cover that enables passage of electrical cords therethrough to allow connection of plug ends of the cords while the cover is closed. 
   The electrical box of the present invention provides an electrical junction box that is UL-listed to meet the requirements of the electrical code. It has the advantage of working on most popular siding types. 
   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. 

   
     DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a perspective view of a first and preferred embodiment of a recessed electrical box including a cover member for retrofit siding construction according to the present invention. 
       FIG. 2  is a sectional view of a spacer plate member used to fit the recessed electrical box to 5/16″ lap siding. 
       FIG. 3  is a sectional view of a spacer plate member used to fit the recessed electrical box to ⅝″ lap siding. 
       FIG. 4  is a sectional view of a spacer plate member used to fit the recessed electrical box to Dutch lap siding. 
       FIG. 5  is a front view of a spacer plate used for fitting the recessed electrical box to 5/16″ lap siding. 
       FIG. 5A  is a sectional view of the spacer plate of  FIG. 5  taken along line  5 A— 5 A. 
       FIG. 5B  is an end view of the spacer plate of  FIG. 5 . 
       FIG. 5C  is a sectional view of the spacer plate of  FIG. 5  taken along line  5 C— 5 C. 
       FIG. 6  is a perspective view of the recessed electrical box of  FIG. 1  without the cover member. 
       FIG. 7  is an exploded perspective view of a recessed electrical box, spacer member, cover member, electrical outlet, and faceplate in alignment prior to securement to a wall having siding thereon. 
       FIG. 8  is a front elevation view of a cover member that forms a portion of the recessed electrical box of the present invention. 
       FIG. 8A  is a sectional view of the cover member taken along line  8 A— 8 A of  FIG. 8 . 
       FIG. 8B  is a sectional view of the cover member taken along line  8 B— 8 B of  FIG. 8 . 
       FIG. 8C  is a bottom view of the cover member taken along line  8 C— 8 C of  FIG. 8 . 
       FIG. 9  is a front view of the electrical box assembly of  FIG. 1  without the cover. 
       FIG. 10  is a sectional view of the electrical box assembly taken along line  10 — 10  of  FIG. 9  and secured to siding on a structure. 
       FIG. 11  is a bottom view of the electrical box assembly of  FIG. 1  with the cover member in a closed position. 
       FIG. 12  is a perspective view of a second embodiment of the electrical box in which the back side of the flange has a profile to substantially match the profile of siding. 
       FIG. 13  is a sectional view of the electrical box assembly taken along line  13 — 13  of  FIG. 12 . 
   

   TABLE OF NOMENCLATURE 
   The following is a listing of part numbers used in the drawings along with a brief description: 
   
     
       
             
             
           
         
             
                 
             
             
               Part Number 
               Description 
             
             
                 
             
           
           
             
               20 
               recessed electrical box assembly 
             
             
               22 
               electrical box 
             
             
               24 
               spacer plate 
             
             
               26 
               cover member 
             
             
               28 
               sidewalls 
             
             
               30 
               flange 
             
             
               32 
               electrical device 
             
             
               34 
               faceplate 
             
             
               36 
               front surface of flange 
             
             
               38 
               back surface of flange 
             
             
               40 
               front surface of spacer plate 
             
             
               42 
               back surface of spacer plate 
             
             
               44 
               spacer plate for 5/16″ siding 
             
             
               46 
               spacer plate for ⅝″ siding 
             
             
               48 
               spacer plate for Dutch Lap siding 
             
             
               50 
               thin wall portion 
             
             
               52 
               peripheral wall of spacer plate 
             
             
               54 
               peripheral sidewall of cover member 
             
             
               56 
               bottom portion 
             
             
               58 
               U-shaped slot in cover member 
             
             
               60 
               aperture 
             
             
               62 
               ear 
             
             
               63 
               knockout 
             
             
               64 
               post 
             
             
               66 
               interior mounting surface 
             
             
               68 
               outer surface of building 
             
             
               70 
               securement arrangement 
             
             
               72 
               aperture in flange 
             
             
               74 
               fastener 
             
             
               76 
               siding 
             
             
               78 
               boss 
             
             
               80 
               threaded bore 
             
             
               81 
               device fastener 
             
             
               82 
               forward extending peripheral wall of electrical box 
             
             
               84 
               U-shaped slot in electrical box 
             
             
               86 
               bottom portion of peripheral wall of electrical box 
             
             
               88 
               circular cord opening 
             
             
               90 
               front edge of electrical box 
             
             
               94 
               inner surface 
             
             
               96 
               slope of inner surface 
             
             
               97 
               hole in siding and substrate 
             
             
               98 
               substrate 
             
             
               100  
               recessed electrical box assembly, 2 nd  embodiment 
             
             
               102  
               electrical box 
             
             
               104  
               rear peripheral wall 
             
             
               106  
               back surface of flange 
             
             
               108  
               flange 
             
             
               110  
               rear surface of rear peripheral wall 
             
             
               X 
               distance of sidewall from back surface of flange 
             
             
               Y 
               distance of interior mounting surface from back 
             
             
                 
               surface of flange 
             
             
               Z 
               amount of downward slope on inner surface of 
             
             
                 
               bottom sidewall 
             
             
                 
             
           
        
       
     
   
   DETAILED DESCRIPTION OF THE INVENTION 
     FIG. 1  depicts a preferred embodiment of a recessed electrical box assembly  20  according to the present invention. The recessed electrical box assembly  20  includes a box member or electrical box  22 , a spacer plate  24 , and a cover member  26 . The electrical box  22  includes sidewalls  28  and a peripheral flange  30  extending outwardly from the sidewalls  28 . 
     FIG. 7  depicts the electrical box assembly  20  with the electrical box  22 , spacer plate  24 , and cover member  26  exploded away from each other. The electrical box assembly  20  is used for mounting an electrical device  32 , such as the duplex outlet shown, substantially behind the outer surface of a building. The recessed electrical box assembly  20  accepts most single gang wiring devices, including ground fault receptacles, and standard indoor wall faceplates  34 , such as the one depicted in  FIG. 7 . The flange  30  includes a front surface  36  and a back surface  38 . 
   With reference to  FIGS. 2–4 , several embodiments of spacer plates are shown. Each spacer plate includes a front surface  40  and a back surface  42 . The back surface  42  of the spacer plate includes a profile shaped to match the profile of the siding it will be used with. Siding for houses and other structures typically is manufactured in several standard sizes. Some of the most popular siding types include ¼-inch lap siding, 5/16-inch lap siding, ½-inch lap siding, ⅝-inch lap siding, and Dutch Lap siding. The spacer plates in the present invention are therefore manufactured in several embodiments in order that the back surface  42  of the spacer plate will substantially match the profile of the siding it will be fitted to. The spacer plates in  FIGS. 2–4  therefore depict a spacer plate  44  (see  FIG. 2 ) for use with 5/16″ lap siding, a spacer plate  46  (see  FIG. 3 ) for use with ⅝″ lap siding, and a spacer plate  48  (see  FIG. 4 ) for use with Dutch Lap siding. 
   Referring to  FIGS. 5–5C , to save on material cost, the spacer plate  46  includes a thin wall portion  50  and a peripheral wall  52  which forms the siding profile on the back surface  42 . 
   With reference to  FIG. 10 , the front surface  40  of the spacer plate  46  includes a profile to match the profile of the back of the flange  30 , which preferably is flat to obtain a good seal between the back surface  38  of the flange  30  and the front surface  40  of the spacer plate  46  when they are secured together. It is preferable that the back surface  38  of the flange  30  joins the front surface  40  of the spacer plate  46  in a flush fit that forms a seal between the flange  30  and spacer plate  46 . 
   As shown in  FIGS. 8–8C , the cover member  26  is removable and includes a peripheral sidewall  54  thereon. A bottom portion  56  of the peripheral sidewall  54  includes U-shaped slots  58  (see  FIG. 8C ). Apertures  60  are provided in ears  62  extending from the peripheral sidewall  54  of the cover member  26  for securing the cover member  26  pivotally to the electrical box. As shown in  FIG. 6 , posts  64  are provided on the electrical box  22 . Removable wall sections or knockouts  63  are provided in the sidewalls  28  of the recessed electrical box  22 . 
   As shown in  FIG. 1 , the cover member  26  is pivotally connected to the box member  22  by the posts  64  extending through the apertures  60  in the peripheral sidewall  54  of the cover member  26 . The cover member  26  is preferably constructed of a flexible material, such as plastic, and the ears  62  of the cover member  26  can be easily biased outwards from their normal position and the ears  62  slipped over the posts  64  until the posts snap through the apertures  60 . 
   Reference is made to the sectional view of the electrical box  22  and spacer plate  24  in  FIG. 10 . The sidewalls  28  extend substantially beyond the back surface  38  of the flange  30  (see distance X in  FIG. 10 ). It is preferable that the sidewalls  28  of the electrical box  22  extend at least 2.0 inches, as represented by distance X, beyond the back surface  38  of the flange  30  to enable the sidewalls  28  to be recessed substantially behind the face of a building when the recessed electrical box assembly of the present invention is secured thereto. 
   As further shown in  FIG. 10 , the electrical box  22  includes an interior mounting surface  66  to allow for the mounting of an electrical device  32  within the box member  22 . Preferably, the interior mounting surface  66  is located substantially behind (see distance Y) the back surface  38  of the flange  30 . Positioning the interior mounting surface  66  substantially behind the back surface  38  of the flange  30  ensures that the electrical device  32  secured within the box  22  will be situated well within the outer surface  68  of the siding  76 , thereby protecting the electrical device  32  therein from damage by accidental impacts of lawn power equipment and the like. It is preferable that the interior mounting surface  66  be located at least 1.0 inch behind the back surface  38  of the flange  30  to provide superior protection to the electrical device  32  secured therein. 
   Referring to  FIG. 10 , the electrical box  22  further includes a securement arrangement  70  in the flange  30  including apertures  72  in the flange  30  and fasteners  74  for installing through the apertures  72  in the flange  30  and into the siding  76 . As shown in  FIG. 9 , there are preferably four apertures  72  in the flange  30 . The electrical box  22  further includes bosses  78  at the interior mounting surface  66 . The bosses  78  include threaded bores  80  for receipt of device fasteners  81  (see  FIG. 10 ) for securing the electrical device  32  thereto. 
   With reference to  FIG. 11 , the electrical box  22  further includes a forward extending peripheral wall  82  extending forward from the flange  30 . U-shaped slots  84  are provided in the bottom portion  86  of the forward extending peripheral wall  82 . When the cover member  26  is closed upon the electrical box  22 , as shown in  FIG. 11 , the U-shaped slots  58  in the cover member  26  are in alignment with the U-shaped slots  84  in the forward extending peripheral wall  82  thereby creating circular electrical cord openings  88  therein. Electrical cords (not shown) can therefore remain secured to the electrical device within the electrical box while the cover is closed, thereby protecting the electrical device and plug ends of the electrical cords against rain and other weather elements. 
   Referring to  FIG. 10 , the electrical box  22  further includes a front edge  90  at the forward end of the forward extending peripheral wall  82 . The bottom portion  86  of the sidewalls  28  of the electrical box  22  further includes an inner surface  94 . The inner surface  94  includes a slope  96 , designated by distance Z in  FIG. 10 , downwards on the inner surface  94  of the bottom portion  86  of the sidewall  28  from the interior mounting surface  66  to the front edge  90  of the box member  22 . This downward slope  96  is preferable to enable any rain or condensation that enters the electrical box assembly  20  to run downwards toward the front edge  90  and thence out of the box  22 . Preferably, the slope  96  from the interior mounting surface  66  to the front edge  90  is at least 0.020 inch. 
   With reference to  FIG. 6 , preferably the electrical box  22  and the flange  30  of the present invention are formed in one piece by injection molding of plastic. Preferably, the plastic is selected from the group including polycarbonate, polyvinyl chloride, polyethylene, or polypropylene. 
   Referring to  FIG. 8 , the cover member  26  is also preferably formed in one piece by injection molding of plastic. The material of construction of the cover member  26  includes plastic selected from the group including polycarbonate, polyvinyl chloride, polyethylene, or polypropylene. A most preferred material of construction of the cover member  26  is polycarbonate to impart high impact resistance to the cover member  26 . As the cover member  26  is exposed to impacts and functions to protect the electrical device secured therein, it is preferred that the cover member has high impact resistance. 
   Reference is made to  FIG. 10  for operation of the recessed electrical box assembly  20  of the present invention. The recessed electrical box assembly  20  is used to retrofit an existing building having siding  76  thereon with an electrical device  32  recessed inward from the outer surface  68  of the siding  76 . The recessed electrical box assembly  20  is installed by first cutting a hole  97  in the siding  76  and the substrate  98 , the hole  97  being large enough to accept the sidewalls  28  of the electrical box portion  22  of the recessed electrical box assembly  20 . The electrical box  22  is then inserted into the hole  97  until the back surface  42  of the spacer plate  46  is flush against the siding  76  and the back surface  38  of the flange  30  joins the front surface  40  of the spacer plate  46  in a flush fit. Fasteners  74  are then inserted through the apertures  72  in the flange  30  and tightened into the siding  76  and the substrate  98  to secure the recessed electrical box assembly  20  to the siding  76  and the substrate  98 . If the electrical box assembly  20  is installed in an area that will be exposed to the weather, caulking can be applied at the juncture of the electrical box  22  and the siding  76 . 
   A second embodiment of the recessed electrical box assembly  100  is shown in  FIGS. 12 and 13 . In this embodiment of the recessed electrical box, the electrical box  102  is provided in one piece, with a rear peripheral wall  104  extending from the back surface  106  (see  FIG. 13 ) of the flange  108  and the rear surface  110  of the rear peripheral wall  104  having a profile to match the profile of the siding it will be secured to. The advantage of this embodiment of the recessed electrical box assembly  100  is that the spacer plate of the first embodiment is eliminated. With reference to  FIG. 10 , in comparison with the second embodiment, the advantage of the first embodiment of the recessed electrical box assembly  20  is that it can be used for any particular style of siding by just providing a spacer plate  24  having the appropriate profile to match the profile of the siding on the structure. The first embodiment of the recessed electrical box assembly  20  therefore reduces stocking and inventory requirements as one electrical box  22  can be stocked and used with virtually any style of siding. Various embodiments of the spacer plate  44 ,  46 , or  48  such as shown in  FIGS. 2–4 , would be stocked and selected by the installer for the particular installation based upon the type of existing siding on the structure. 
   Having thus described the invention with reference to a preferred embodiment, it is to be understood that the invention is not so limited by the description herein but is defined as follows by the appended claims.

Technology Classification (CPC): 8