Patent ID: 12224568

DETAILED DESCRIPTION

The present disclosure may be understood more readily by reference to the following detailed description of the disclosure taken in connection with the accompanying drawing figures, which form a part of this disclosure. It is to be understood that this disclosure is not limited to the specific devices, methods, conditions, or parameters described and/or shown herein, and that the terminology used herein is for the purpose of describing particular embodiments by way of example only and is not intended to be limiting of the claimed disclosure.

Also, as used in the specification and including the appended claims, the singular forms “a,” “an,” and “the” include the plural, and reference to a particular numerical value includes at least that particular value, unless the context clearly dictates otherwise. Ranges may be expressed herein as from “about” or “approximately” one particular value and/or to “about” or “approximately” another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another embodiment. It is also understood that all spatial references, such as, for example, horizontal, vertical, top, upper, lower, bottom, left and right, are for illustrative purposes only and can be varied within the scope of the disclosure.

FIG.1shows an electrical box100according to an exemplary embodiment of the present disclosure mounted to a two-gang box50.FIGS.2and3illustrate top and front views of the electrical box100shown inFIG.1. The electrical box100has a rear side adjacent to the box50, an opposite front side, and top and bottom sides. In this exemplary embodiment, the two-gang box50may be, for example, a Hubbell HBL985 or any other suitable multi-gang (e.g., two-gang) box. A further described below, the electrical box100may alternatively be mounted to a single-gang box (seeFIGS.13-16). The box50may be secured at least partially within a wall or pedestal.

The electrical box100may further include an exterior skin or cover110, a first end with first door120, and second end opposite the first end with a second door130. The cover110extends over the front, top, and sides of the electrical box100. The cover110, and/or the doors120,130and other components of the electrical box100, may be manufactured from a corrosion resistant metal such as aluminum (e.g., cast aluminum), stainless steel or other material suitable for outdoor use, or plastic or metal for indoor use. In some embodiments, the cover110can be different colors.

As shown inFIGS.3and4, the first and second doors120,130may be hingedly attached to the electrical box100and/or cover110with hinges including springs122,132to bias the doors120,130closed. Preferably the doors120,130are hinged at an outside edge at the front of the electrical box100. Therefore, the doors120,130open from the wall outward when the electrical box100is vertically mounted, or upward from the ground when horizontally mounted, to protect the switch or outlets and the mating plugs or connector devices while in use from the elements.

As shown inFIG.4, the electrical box100includes a first extension compartment140or recessed frame with an interior cavity exposed when the door120is opened. The first extension compartment140may include cable cutouts142,144on two or more of its sidewalls to route a cord152(having a plug154) when the door120is fully closed. The electrical box100may include plugs145that snap into the cutouts142,144when not in use. A second extension compartment160(shown inFIGS.8A-10) has the same features. The exterior cover110may also have corresponding tabs112that are removable (e.g., break off) to reveal the cutouts142,144.

FIG.5Ais a side view of the first end of the electrical box100with the first door120in an open position. In the exemplary embodiment, the cavity of the first extension compartment140surrounds and encloses a high voltage electrical power outlet150.FIG.5Bis a side view of the second end of the electrical box100with the second door130in an open position. In the exemplary embodiment, the cavity of the second extension compartment160surrounds and encloses a low voltage data or audio/visual (AV) outlet. The outlets shown herein are only exemplary. A variety of electrical and data interface devices may be installed in the electrical box100. Examples include, without limitation, high voltage electrical power outlets, electrical switches, data, or audio/visual outlets (e.g., ethernet, coaxial, telephone, HDMI), and combined power and data outlets (e.g., USB, USB-C, etc.).

The electrical box100according to an exemplary embodiment of the present disclosure may be mounted in vertical and horizontal configurations.FIG.6is an isometric view of the electrical box100mounted in a vertical configuration on a wall200. The vertical configuration can, for example, be used indoors for receptacles which are located behind beds to comply with NEC requirements, such as in health care facilities.FIG.7is an isometric view of the electrical box100mounted in a horizontal configuration on top of a pedestal220.

FIG.8Ais an isometric view of the electrical box100mounted to a two-gang box50with the exterior cover110removed to illustrate the internal components. The electrical box100includes a central back-to-back housing180with a first end and opening and a second opposite end and opening. The central housing180is secured to the box50with a gasket in between. Extension compartments140,160are secured over the outlets150,170and to respective ends of the central housing180with gaskets in between.

The central housing180may have top and bottom cutouts181to reduce material and form a partial backstop on each side for outlets or switches. As shown inFIGS.8A and8B, the central housing180may also include a removable (e.g., snap in) cover182to allow access to a recess189with fasteners (e.g., four fasteners183) for securing the central housing180to the box50.FIG.8Bshows the electrical box100with the cover182removed. Removal of the cover182also reveals a vertical slot185in the recess189for the insertion and inspection of a barrier between the two outlets150,170. The slot185extends into the central housing180allowing a barrier to be placed between the first and second side openings of the central housing180and out through the rear opening. As one skilled in the art will understand, a barrier is used particularly when the voltages are different between the two outlets150,170, such as when one outlet150is high voltage electrical power and the other outlet170is low voltage data or audio/visual (AV).

FIG.9is an isometric view of the electrical box100shown inFIG.8Awith the first extension compartment140removed and a first side opening184of the central housing180exposed. The outlet150is secured into the first side opening184of the central housing180. The central housing180includes connection mechanisms, such as threaded holes188(seeFIG.11), to receive fasteners151(e.g., screws) to attach the outlets150,170. A gasket186is positioned around the first side opening184of the central housing180.

FIG.10is an isometric view of the electrical box100shown inFIG.9with a central housing180removed. The gasket52between the central housing180and the box50is shown. A gasket186positioned around a second side opening (opposite the first side opening184) of the central housing180is also shown. A barrier54extends between the first and second outlets150,170and into the box50. The barrier54may be inserted and inspected via the slot185behind the removable cover182.

FIG.11is a rear isometric view of the central housing180of the electrical box100mounted to a two-gang box50, with sidewalls of the box50removed for clarity.FIG.12is an exploded view of the central housing180and the two-gang box50shown inFIG.11. The central housing180includes a rear opening engaging with the box50. The gasket52surrounds the rear opening of the central housing180. Each side of the central housing180has two or more holes188for receiving fasteners151to attach the outlet150(or other electrical or data interface device). The central housing180also includes holes190for receiving fasteners to attach the extension compartment140to the central housing180. There may also be a hole192for receiving a grounding fastener.

As discussed above, the electrical box100may be mounted to a single or multi-gang boxes.FIG.13is a top view of an electrical box100according to an exemplary embodiment of the present disclosure mounted to a single-gang box60.FIG.14is a rear isometric view of the electrical box100shown inFIG.13.

FIGS.15and16are isometric views of the electrical box100shown inFIG.13with portions removed to illustrate the internal components. The same central housing180may be used for a single-gang box60and secured together with fasteners under a removable cover182. A gasket62is positioned between the box60and the central housing180. Further, when a single-gang box60is used, an optional mud ring66may be provided to close the opening, at least partially, between the box60and the rear opening of the central housing180.

As shown throughout the drawings, like reference numerals designate like or corresponding parts. While illustrative embodiments of the present disclosure have been described and illustrated above, it should be understood that these are exemplary of the disclosure and are not to be considered as limiting. Additions, deletions, substitutions, and other modifications can be made without departing from the spirit or scope of the present disclosure. Accordingly, the present disclosure is not to be considered as limited by the foregoing description.