Abstract:
A device and method for configuring a recessed electrical box for the mounting of electrical components at a shallow depth with respect to the mounting surface. The device and method includes a spacer for adjusting the depth at which an electrical component is mounted within a recessed electrical box. The spacer includes a frame member with side members and end members that define an opening therein. A front face on the spacer is adapted to accept the mounting of two electrical components thereto. A rear face on the spacer is adapted to fit flush against the peripheral wall of a recessed electrical box assembly. Two arms extending from each end member of the spacer include apertures therein for acceptance of fasteners for mounting the electrical components. The spacer enables an installer to mount an electrical component at a shallow depth within a recessed electrical box.

Description:
This application claims the priority of U.S. Provisional Application Ser. No. 61/767,566 filed Feb. 21, 2013. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to the installation of electrical components and specifically to a spacer for depth adjustment of electrical components in a recessed electrical box. 
     BACKGROUND OF THE INVENTION 
     There is a continuing need to provide electrical boxes which recess electrical components within the wall of a structure. Electrical components are commonly mounted on walls and similar surfaces to provide various electrical services in the home. It is beneficial to recess some electrical components, such duplex receptacles, deep within the wall in order to provide adequate space for the plug ends of electrical cords that will be plugged into the duplex receptacle. Other components such as switches are typically mounted at a shallow depth in order to provide easy access for users to manipulate the switch. 
     Recessed electrical boxes are used to mount electrical components deep within the wall. However, in many situations it is necessary to mount the electrical component at a shallow depth within the recessed electrical box. In the current state of the art, the recessed electrical box is limited to mounting electrical components at a single depth within the wall. 
     Accordingly, there is a need for a device and method for configuring a recessed electrical box to mount electrical components shallow or deep within the wall, as desired by the installer. Such a device and method would increase the usability of the recessed electrical box and make it unnecessary to stock two types of box, one for the shallow mounting of components and one for deep mounting of components with respect to the wall. 
     BRIEF SUMMARY OF THE INVENTION 
     The current invention is a device and method for configuring a recessed electrical box to mount electrical components at a shallow depth with respect to the mounting surface. The device and method includes a spacer for adjusting the depth at which an electrical component is mounted within a recessed electrical box. The spacer includes a frame member with side members and end members that define an opening therein. A front face on the spacer is adapted to accept the mounting of two electrical components thereto. A rear face on the spacer is adapted to fit flush against the peripheral wall of a recessed electrical box assembly. Two arms extending from each end member of the spacer include apertures therein for acceptance of fasteners for mounting the electrical components. The spacer enables an installer to mount an electrical component at a shallow depth within a recessed electrical box. 
    
    
     
       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 a preferred embodiment of an electrical box and spacer assembly in accordance with embodiments of the invention. 
         FIG. 2  is a front view of a preferred embodiment of an electrical box which forms a portion of the electrical box and spacer assembly of  FIG. 1 . 
         FIG. 3  is a top view of the electrical box of  FIG. 2 . 
         FIG. 4  is a sectional view of the electrical box taken along line  4 - 4  of  FIG. 2 . 
         FIG. 5  is a sectional view of the electrical box taken along line  5 - 5  of  FIG. 2 . 
         FIG. 6  is a front perspective view of the electrical box with a cover member attached. 
         FIG. 7  is a front perspective view of the electrical box without the cover. 
         FIG. 8  is a front view of the preferred embodiment of a cover member which forms a portion of the electrical box and spacer assembly of  FIG. 1 . 
         FIG. 9  is a side view of the cover. 
         FIG. 10  is a sectional view of the cover taken along line  10 - 10  of  FIG. 8 . 
         FIG. 11  is a front perspective view of the cover. 
         FIG. 12  is a rear elevation view of the preferred embodiment of a spacer which forms a portion of the electrical box and spacer assembly of  FIG. 1 . 
         FIG. 13  is a sectional view of the spacer taken along line  13 - 13  of  FIG. 12 . 
         FIG. 14  is a sectional view of the spacer taken along line  14 - 14  of  FIG. 12 . 
         FIG. 15  is a front isometric view of the spacer. 
         FIG. 16  is a rear isometric view of the spacer. 
         FIG. 17  is a sectional view depicting a spacer installed in an electrical box according to the present invention. 
         FIG. 18  is a sectional view depicting a spacer in alignment with an electrical box to be inserted therein. 
         FIG. 19  is an isometric view of an alternative embodiment of an electrical box according to the present invention. 
         FIG. 20  is an isometric view of another alternative embodiment of an electrical box according to the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     With reference to  FIG. 1 , the present invention comprises an electrical box and spacer assembly  20  for mounting electrical components. The electrical box and spacer assembly  20  includes an electrical box  22  with a hinged cover  24  and an optional spacer  26  that may be used at the installer&#39;s discretion to reduce the depth of the electrical box inner cavity  28 . 
     Referring to  FIGS. 2-3 , the electrical box  22  includes four inner sidewalls  30 , four outer sidewalls  32 , and a back wall  34  that define the inner enclosure or cavity  28 . Outer sidewalls  32  are of a larger dimension D1 than the inner sidewalls  30  of dimension D2. Four bosses  36  extend from the inner surface  37  of the inner sidewalls  30 . A peripheral wall  40  extends between the inner sidewalls  30  and outer sidewalls  32 . Outer sidewalls  32  and peripheral wall  40  define the inner cavity  28 . Bosses  36  include component mounting bores  42  therein and a groove  44  adjacent the bores  42  and extending fully across each boss  36 . The electrical box  22  includes an inner flange  46  including a plurality of ears  48  and a slot  50  in each of the ears. Knockout wall portions  52  are included in the back wall  34  and the inner sidewalls  30 . One outer sidewall  32  includes a front edge  54  and four cord openings  56  therein. Two grooves  58  in the outer sidewall  32  extend inward from the front edge  54 . The grooves  58  define a deflectable latch  60 . Two axially aligned apertures or bores  62  are included therein on opposing sides of the peripheral wall  40 , the axially aligned apertures  62  located substantially centered between the two bosses  36 . Electrical box  20  may further include an outer flange  64  and two axially aligned posts  66  extending from the outer sidewall  32 . Inner sidewalls  30  further include a plurality of recesses  68  formed therein and corner ribs  70  and interior ribs  72  extending outward therefrom. 
     With reference to  FIGS. 6 and 7 , electrical box  22  can be used with cover member  24  engaged on posts  66  to form an electrical box assembly  74  in which peripheral wall  40  is recessed deep within the box enclosure  38 . The four outer sidewalls  32  and the peripheral wall  40  define the box enclosure  38 . As shown in  FIG. 7 , an electrical component (not shown) may be mounted to bosses  36 , which would recess the electrical component well behind the wall surface. 
     Referring to  FIGS. 8-11 , cover member  24  includes a faceplate  76  with a top  78 , a bottom  80 , and two sides  82 . A peripheral wall  84  extends around the entire rear periphery of the cover  24 . As shown in  FIG. 8 , the rear surface  86  of the cover  24  includes two corner filets  88  along the bottom  80  that add strength at the bottom edge of the cover. Two offset tabs  90  extend from opposing sides of the rear surface  86  near the top  78  of the cover  24 . Opposing sides of the peripheral wall  84  include ears  91  with apertures  92  therein. A tab  94  extends from the cover bottom  80  and includes an opening  96  therein. As shown in  FIG. 9 , tab  94  includes a rearward-extending leg  98 . The peripheral wall  84  includes a plurality of cord openings  100  therein along the bottom of the cover member. 
     With reference to  FIGS. 12-14 , the optional spacer  26  of the present invention includes a frame member  101  having a central opening  102 , two side members  103 , two end members  105 , a front face  107 , a rear face  109 , and a peripheral wall  111  extending orthogonally from the front face  107  of the frame member  101 . The end members  105  include an outer wall  113  and an inner wall  115  with an opening  127  there between and a bridge  117  extending between the outer wall  113  and inner wall  115 . Bridge  117  includes an aperture  119  therein. Two arms  120  extend inward from the two end members  105  of the frame. Arms  120  include a through bore  121  that extends completely through the arm  120 , an alignment tab  123  extending from the arm  120  at the rear face  109  of the frame  101 , and an aperture  125  extending into the arm  120  from the front face  107 . The alignment tabs  123  extend outward from the planar rear face  109 . The frame  101  includes openings  127  therein between the outer wall  113  and inner wall  115  on either side of the bridge  117 . A plurality of integral ribs  129  extend inward from the side members  103 . 
     Referring to  FIGS. 15 and 16 , front face  107  and rear face  109  of spacer  26  are each planar. Through bores  121  and apertures  125  are available for insertion of fasteners (not shown) thereto for the connection of electrical components to the spacer  26 . As shown in  FIG. 16 , alignment tabs  123  extend from the bosses  120  of the spacer. 
       FIG. 17  illustrates the connection of the spacer  26  to the electrical box  22  in order to reduce the distance an electrical component is recessed within the wall. To reduce the recessed distance, spacer  26  is inserted within the box enclosure  38  until rear face  109  of spacer  26  seats against the planar face  132  (see  FIG. 18 ) of the peripheral wall  40  of electrical box  22 . With spacer  26  seated against peripheral wall  40 , apertures  62  in peripheral wall  40  of electrical box  22  are in alignment with apertures  119  in bridge  117  portion of spacer  26 . A fastener  131  is then driven through peripheral wall  40  of electrical box  22  into aperture  119  to secure the spacer within the electrical box. A channel  133  is provided on the exterior of electrical box  22  between inner flange  46  and outer flange  64  for accommodating siding. 
     With reference to  FIG. 17 , to operate the invention a hole, large enough to accommodate inner sidewalls  30  is cut in the substrate of a building. Electrical box  22  is then inserted in the hole (not shown) until inner flange  46  is flush against the wall of the building. Fasteners (not shown) may then be inserted through slots  50  (see  FIG. 2 ) in flange  46  to secure the electrical box to the substrate. As exterior siding is installed around the secured box, it is inserted into channel  133 . As outer sidewalls  32  are integral with flanges  46  and  64 , any rain or water running down the siding will be channeled to the bottom side of the electrical box and then away from the electrical box. Electrical box  22  provides a substantially deep enclosure  38  for recessing an electrical component. As an example, without the spacer  26 , distance D3 in  FIG. 17  depicts the depth at which a component will be mounted in the electrical box  22 . Distance D3 is preferably 2.875 inches. The width of spacer  26 , denoted by distance D4 in  FIG. 17 , is preferably 0.875 inch. Thus use of spacer  26  within electrical box  22  reduces the mounting depth of the electrical component to 2.0 inches, which is preferable for many low voltage components. 
     Referring to  FIG. 18 , for those situations in which it is desired that an electrical component need not be recessed as far as peripheral wall  40 , spacer  26  is inserted into electrical box  22  to reduce the depth of the component within the box. Alignment tabs  123  enable rapid alignment of spacer  26  with the electrical box. When spacer  26  is inserted within the box  22 , alignment tabs  123  engage grooves  44  in peripheral wall  40  and nest therein. 
     With reference to  FIGS. 19 and 20 , there are shown two alternative embodiments of the electrical box, including in  FIG. 19  an electrical box  135  for retrofit on an existing building. For this electrical box  135 , the inner flange is eliminated and outer flange  64  is retained. A plurality of apertures  137  are included in outer flange  64 . To operate the retrofit electrical box, a hole is cut in the outer wall of the building large enough to accommodate outer walls  32  of electrical box. Electrical box  135  is then inserted into the hole (not shown) until outer flange  64  is flush with the exterior wall. Fasteners (not shown) are then driven through apertures  137  to secure electrical box  135  to the wall. Caulking may be applied around the perimeter of the box where it contacts the wall in order to seal against rain and moisture. 
       FIG. 20  depicts an electrical box  139  for new construction on which stucco will be applied. For this electrical box  139 , the outer flange is eliminated and inner flange  46  is retained. A plurality of apertures  141  are included in inner flange  46 . To operate the electrical box for stucco construction, a hole is cut in the outer wall of the building large enough to accommodate outer walls  32  of electrical box. Electrical box  139  is then inserted into the hole (not shown) until inner flange  46  is flush with the exterior wall. Fasteners (not shown) are then driven through slots  50  to secure electrical box  139  to the wall. Stucco is then applied over inner flange  46  to the desired depth. Apertures  141  in inner flange  46  promote better adhesion of stucco to the flange and to the surrounding wall (not shown). 
     The electrical box  22 , cover member  24  and spacer  26  of the present invention may be manufactured of metal or plastic. Preferably the electrical box  22 , cover member  24  and spacer  26  of the present invention are each molded in one piece of plastic. 
     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.