Patent Document

This application is a Continuation-In-Part of U.S. patent application Ser. No. 11/713,381 filed Mar. 2, 2007 and still pending, the entire contents of which are incorporated herein by reference. 

   FIELD OF THE INVENTION 
   This invention relates to electrical box assemblies for mounting components for high and low voltage devices and specifically to a flat panel TV box assembly that can be easily installed on an interior wall of a building to provide a recessed housing for electrical services and cable TV connections to a television, computer, or home stereo system. 
   BACKGROUND OF THE INVENTION 
   With the proliferation of high definition televisions and various auxiliary devices, such as digital videodisc players, game stations, and surround sound systems, there is a need to manage the connections between these devices to ensure there is adequate power and also to manage the myriad of cables and cords that accompany such systems. Additionally, many electrical boxes for both high and low voltage components mount the components flush with the wall, which makes the plugs or connectors that mate with the wall-mounted components susceptible to damage, such as when devices, such as vacuum cleaners or other household hazards brush against the plugs or connectors. 
   What is needed therefore is an electrical box assembly that provides connection points for both high and low voltage components, provides isolation of high voltage connections from low voltage connections, provides features for managing the plethora of cables and wiring associated with modern television systems, and recesses the end connector of cords or cables to protect the plug ends of cords or end connectors of cables from undesirable contact with household appliances or household occupants. 
   An electrical box assembly was disclosed by the inventor in U.S. patent application Ser. No. 11/713,381, filed Mar. 2, 2007, and commonly owned with the present invention. The electrical box assembly of U.S. Ser. No. 11/713,381 included a box member and a frame member that formed an electrical box assembly for recessing high and low voltage electrical components within the wall of a structure and providing a mounting area for organizing the various electrical leads that supply a home entertainment center, such as a TV or stereo system. The current invention provides an improved electrical box assembly that accommodates two high voltage components and recesses the high voltage components farther within the wall and also provides an extended flange for more secure mounting of the electrical box assembly to a wall. 
   SUMMARY OF THE INVENTION 
   The invention is an electrical box assembly that provides electrical service including line voltage and signal line hookups for a television or home entertainment center. The electrical box assembly recesses electrical components within the wall to make them unobtrusive and out of the way. The box assembly includes an integral electrical box for housing two line voltage connections and connection points for several low voltage openings. The low voltage connection points are capable of accepting standard jacks for broadband cable, direct TV, surround sound cabling, or phone systems. The electrical box assembly includes a box member, a frame member, and an extended flange on the frame member to enable secure mounting to a pair of studs. The electrical box assembly enables easy consolidation of all the various electrical and signal hookups for TV or home entertainment systems. 
   OBJECTS AND ADVANTAGES 
   The electrical box assembly of the present invention includes several advantages over the prior art, including:
         (1) Connection points are provided for mounting both high and low voltage components. An electrical box, integral with the box member of the assembly, is provided for housing and isolating a plurality of high voltage components, such as a duplex receptacle to provide line voltage to a TV or other electrical device. Connection points are also provided for mounting several low voltage components, such as a coupling plate for a coaxial cable.   (2) The electrical box assembly includes a backward projecting box portion that mounts within a wall, thereby recessing electrical devices within the wall to render them unobtrusive and out of the way. By recessing the electrical devices, the plug ends of cords or end connectors of cables are advantageously protected from undesirable contact with household appliances, household occupants, or other hazards.   (3) The electrical box assembly provides features for managing the plethora of cables and wiring associated with modern television systems, including integral loops for bundling and tying-off wires and cables, thereby providing a clean installation that is unobtrusive and minimizes excessive wires and cables running between the wall and the television, speaker system, or other components of a home entertainment system. The loops are positioned against the back wall of the box member, thereby positioning the wires and cables along the back wall of the assembly and advantageously recessing them behind the wall surface and away from household hazards.   (4) Mounting apertures are provided to coincide with the standard stud spacing to meet local construction codes. As a result, the electrical box assembly can be securely mounted between and supported by two adjacent studs.       

   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 embodiment of a flat panel TV box assembly according to the present invention. 
       FIG. 2  is a perspective view of a box member that forms a portion of the flat panel TV box assembly of  FIG. 1 . 
       FIG. 3  is a front view of the box member of  FIG. 2 . 
       FIG. 4  is a bottom view of the box member of  FIG. 3 . 
       FIG. 4A  is a side view of the box member of  FIG. 3 . 
       FIG. 5  is a perspective view of a frame member that forms a portion of the flat panel TV box assembly of  FIG. 1 . 
       FIG. 6  is a front view of the frame member of  FIG. 5 . 
       FIG. 7  is a sectional view of the frame member taken along line  7 - 7  of  FIG. 6 . 
       FIG. 8  is a front view of the flat panel TV box assembly of  FIG. 1 . 
       FIG. 9  is a sectional view of the flat panel TV box assembly taken along line  9 - 9  of  FIG. 8 . 
       FIG. 10  is a side view of the flat panel TV box assembly of  FIG. 8 . 
       FIG. 11  is an exploded perspective view of the flat panel TV box assembly of the present invention including some high and low voltage components in alignment with the box assembly to be installed therein. 
       FIG. 12  is a side view of the flat panel TV box assembly with a portion of the frame member and box member cut away to show a duplex power receptacle and an electrical cord plugged therein. 
       FIG. 13  is a perspective view of a flat panel TV box assembly according to the present invention installed in a wall and with high and low voltage components installed therein. 
       FIG. 14  is a perspective view of a second and preferred embodiment of a flat panel TV box assembly according to the present invention. 
       FIG. 15  is a front perspective view of the preferred embodiment of a box member that forms a portion of the flat panel TV box assembly of  FIG. 14 . 
       FIG. 16  is a rear perspective view of a box member that forms a portion of the flat panel TV box assembly of  FIG. 14 . 
       FIG. 17  is a front view of the box member of  FIG. 15 . 
       FIG. 18  is a bottom view of the box member of  FIG. 15 . 
       FIG. 19  is a perspective view of a divider wall that forms a portion of the preferred embodiment of the electrical box assembly of the present invention. 
       FIG. 20  is a sectional view of the box member taken along line  20 - 20  of  FIG. 17 . 
       FIG. 21  is a perspective view of the preferred embodiment of a frame member that forms a portion of the flat panel TV box assembly of  FIG. 14 . 
       FIG. 22  is a front view of the frame member of  FIG. 21 . 
       FIG. 23  is a sectional view of the frame member taken along line  23 - 23  of  FIG. 22 . 
       FIG. 24  is a sectional view of the frame member taken along line  24 - 24  of  FIG. 22 . 
       FIG. 25  is an exploded perspective view of a preferred embodiment of the flat panel TV box assembly of the present invention including a box member and a frame member and some high and low voltage components in alignment with the box assembly to be installed therein. 
       FIG. 26  is an exploded perspective view of another preferred embodiment of the flat panel TV box assembly of the present invention including a one-piece box member and some high and low voltage components in alignment with the box assembly to be installed therein. 
       FIG. 27  is a sectional view of the preferred embodiment of the flat panel TV box assembly mounted in a wall and with a duplex power receptacle secured therein and an electrical cord plugged in the duplex receptacle. 
   

   TABLE OF NOMENCLATURE 
   The following is a listing of part numbers used in the drawings along with a brief description: 
   
     
       
             
             
             
           
         
             
                 
                 
             
             
                 
               Part Number 
               Description 
             
             
                 
                 
             
           
           
             
                 
                20 
               electrical box assembly 
             
             
                 
                22 
               box member 
             
             
                 
                24 
               frame member 
             
             
                 
                26 
               electrical box 
             
             
                 
                28 
               open area 
             
             
                 
                30 
               connection point 
             
             
                 
                30A 
               vertically oriented connection point 
             
             
                 
                30B 
               horizontally oriented connection point 
             
             
                 
                32 
               peripheral wall of box member 
             
             
                 
                34 
               back wall of box member 
             
             
                 
                36 
               sidewalls of electrical box 
             
             
                 
                38 
               side of open area 
             
             
                 
                40 
               sidewall portion of peripheral wall 
             
             
                 
                42 
               aperture in sidewall of box member 
             
             
                 
                44 
               inner edge of peripheral wall 
             
             
                 
                46 
               juncture of peripheral wall and back wall 
             
             
                 
                48 
               outer edge of peripheral wall 
             
             
                 
                50 
               bottom wall 
             
             
                 
                52 
               loop member 
             
             
                 
                54 
               boss of electrical box 
             
             
                 
                56 
               threaded bore 
             
             
                 
                58 
               rear wall of electrical box 
             
             
                 
                60 
               high voltage enclosure 
             
             
                 
                62 
               boss on peripheral wall of box member 
             
             
                 
                63 
               flared portion on sidewalls of peripheral wall 
             
             
                 
                64 
               peripheral flange of frame member 
             
             
                 
                66 
               transverse flange of frame member 
             
             
                 
                68 
               guide member 
             
             
                 
                69 
               inner edge of transverse flange 
             
             
                 
                70 
               aperture in transverse flange 
             
             
                 
                72 
               attachment arrangement 
             
             
                 
                74 
               fastener for securing frame to box member 
             
             
                 
                76 
               aperture for low voltage component 
             
             
                 
                78 
               hole 
             
             
                 
                80 
               sheet rock 
             
             
                 
                82 
               wall 
             
             
                 
                84 
               stud 
             
             
                 
                86 
               mounting arrangement 
             
             
                 
                87 
               fastener 
             
             
                 
                88 
               mounting fastener 
             
             
                 
                89 
               apertures in transverse flange 
             
             
                 
                90 
               duplex receptacle 
             
             
                 
                92 
               fastener 
             
             
                 
                94 
               cover plate 
             
             
                 
                96 
               CATV connector plate 
             
             
                 
                98 
               fastener 
             
             
                 
                99 
               outer edge of electrical box assembly 
             
             
                 
               100 
               plug end 
             
             
                 
               102 
               electrical cord 
             
             
                 
               104 
               horizontally oriented CATV connector 
             
             
                 
               106 
               vertically oriented CATV connector 
             
             
                 
               108 
               telephone jack 
             
             
                 
               110 
               depressed area 
             
             
                 
               112 
               removable wall portion or knockout 
             
             
                 
               114 
               push-in electrical connector 
             
             
                 
               200 
               electrical box assembly 
             
             
                 
               202 
               box member 
             
             
                 
               204 
               frame member 
             
             
                 
               206 
               peripheral sidewall 
             
             
                 
               208 
               front edge 
             
             
                 
               209 
               first portion of box member 
             
             
                 
               210 
               second portion of box member 
             
             
                 
               212 
               back wall 
             
             
                 
               214 
               electrical box 
             
             
                 
               216 
               side of electrical box 
             
             
                 
               218 
               rear wall of electrical box 
             
             
                 
               220 
               connection point for high voltage component 
             
             
                 
               222 
               first sidewall portion 
             
             
                 
               224 
               second sidewall portion 
             
             
                 
               226 
               rear edge of second sidewall portion 
             
             
                 
               228 
               short wall 
             
             
                 
               230 
               edge of first sidewall portion 
             
             
                 
               232 
               stiffening rib 
             
             
                 
               234 
               exterior rib 
             
             
                 
               236 
               outer surface of box member 
             
             
                 
               238 
               tab 
             
             
                 
               240 
               first end of tab 
             
             
                 
               242 
               second end of tab 
             
             
                 
               244 
               integral boss 
             
             
                 
               246 
               bore 
             
             
                 
               248 
               low voltage opening in back wall 
             
             
                 
               250 
               connection point for low voltage component 
             
             
                 
               252 
               boss at low voltage opening 
             
             
                 
               254 
               groove 
             
             
                 
               256 
               divider Wall 
             
             
                 
               258 
               knockout 
             
             
                 
               260 
               top wall portion 
             
             
                 
               262 
               bottom wall portion 
             
             
                 
               264 
               loop member 
             
             
                 
               266 
               opening in loop member 
             
             
                 
               268 
               transverse flange 
             
             
                 
               270 
               peripheral flange 
             
             
                 
               272 
               top portion of transverse flange 
             
             
                 
               274 
               bottom portion of transverse flange 
             
             
                 
               276 
               side portion of transverse flange 
             
             
                 
               278 
               mounting aperture 
             
             
                 
               280 
               mounting arrangement 
             
             
                 
               282 
               hole in wall 
             
             
                 
               284 
               wall 
             
             
                 
               286 
               mounting fastener 
             
             
                 
               288 
               stud 
             
             
                 
               290 
               second set of mounting apertures 
             
             
                 
               292 
               duplex receptacle high voltage component 
             
             
                 
               294 
               low voltage component 
             
             
                 
               296 
               attachment arrangement 
             
             
                 
               298 
               boss of attachment arrangement 
             
             
                 
               300 
               aperture of attachment arrangement 
             
             
                 
               302 
               fastener of attachment arrangement 
             
             
                 
               304 
               aperture in wall 
             
             
                 
               306 
               sheetrock 
             
             
                 
               308 
               face of stud 
             
             
                 
               310 
               fastener 
             
             
                 
               312 
               aperture in peripheral wall 
             
             
                 
               314 
               electrical box assembly, one-piece embodiment 
             
             
                 
               316 
               plug end of electrical cord 
             
             
                 
               318 
               electrical cord 
             
             
                 
               D1 
               depth of peripheral wall 
             
             
                 
               D2 
               length of tab 
             
             
                 
               D3 
               stud center to center spacing 
             
             
                 
               D4 
               depth of recessed high voltage component 
             
             
                 
               D5 
               depth of recessed low voltage component 
             
             
                 
                 
             
           
        
       
     
   
   DETAILED DESCRIPTION OF THE INVENTION 
     FIG. 1  depicts a first embodiment of an electrical box assembly  20  according to the present invention. The recessed electrical box assembly  20  includes a box member  22  and a frame member  24 . The box member  22  includes an electrical box  26  for accommodating high voltage components (not shown) and open areas  28  having connection points  30  for accommodating low voltage components (not shown). 
   With reference to  FIG. 2 , a first embodiment of the box member  22  includes a forward extending peripheral wall  32  and a back wall  34 . The electrical box  26  includes sidewalls  36  and is integral with the back wall  34  of the box member  22 . The connection points  30  are provided on the back wall  34  of the box member  22  typically on opposing sides  38  of the open areas  28 . The peripheral wall  32  of the box member  22  includes sidewalls  40  and apertures  42  are provided in the sidewalls  40 . The peripheral wall  32  of the box member  22  includes an inner edge  44  at a juncture  46  with the back wall  34  of the box member  22  and an outer edge  48  with the apertures  42  in the peripheral wall  32  adjacent or very close to the inner edge  44 . The peripheral wall  32  of the box member  22  includes a bottom wall  50  and loop members  52  in linear alignment along the bottom wall  50 . The loop members  52  extend across the juncture  46  of the bottom wall  50  and the back wall  34 . The electrical box  26  includes bosses  54  that are integral with the sidewalls  36  of the electrical box  26 . 
   Referring to  FIGS. 3-4A , threaded bores  56  are provided in the bosses  54  of the electrical box  26 . The electrical box  26  includes a rear wall  58  that closes the rear of the electrical box and provides a high voltage enclosure  60  therein. As shown at the cutaway portion of the peripheral wall  32  in  FIG. 4 , the peripheral wall  32  of the box member  22  includes a depth D 1  as measured from the inner edge  44  to the outer edge  48 . The box member  22  includes a plurality of bosses  62  extending inward from the peripheral wall  32 . The peripheral wall  32  of the box member  22  further includes a flared portion  63  near the outer edge  48  at both the top and bottom ends of the peripheral wall  32 . As shown in  FIG. 3 , the connection points  30  for the low voltage components may include connection points  30 A aligned for vertical connection of the low voltage components and connection points  30 B aligned for horizontal connection of the low voltage components. 
   With reference to  FIGS. 5-7 , a first embodiment of the frame member  24  includes a rearward extending peripheral flange  64  and a transversely extending flange  66 . A plurality of guide members  68  is provided on the peripheral flange  64 , with each guide member  68  positioned along the inner edge  69  of the transverse flange  66  of the frame member  24 . The transverse flange  66  of the frame member  24  includes apertures  70  therein. 
   Referring to  FIGS. 8 and 9 , there is shown an attachment arrangement  72  for securing the frame member  24  to the box member  22  to create the recessed electrical box assembly  20  of the present invention. The attachment arrangement  72  includes fasteners  74  which are secured through each guide member  68  on the peripheral flange  64  of the frame member  24  into a corresponding boss  62  (see  FIG. 2 ) on the peripheral wall  32  of the box member  22 . To secure the frame member  24  to the box member  22 , the peripheral flange  64  of the frame member  24  is aligned with the peripheral wall  32  of the box member  22 . With the frame member  24  thus aligned with the box member  22 , each guide member  68  in the frame  24  is aligned with a corresponding boss  62  in the box member  22 . As shown in  FIG. 8 , the connection points  30  for low voltage components (not shown) include apertures  76  on opposing sides  38  of the open areas  28  in the back wall  34  of the box member  22 . 
   As shown in  FIG. 10 , after the frame member  24  is secured to the box member  22  to form electrical box assembly  20 , the electrical box  26  projects from the back wall  34  of the box member  22  and the sidewalls  36  and rear wall  58  of the electrical box  26 . The sidewalls  36  and rear wall  58  of the electrical box  26  thereby create a high voltage enclosure  60  that isolates any high voltage wiring or components therein (not shown) from nearby low voltage components. 
   For operation of the electrical box assembly  20  of the present invention, reference is made to  FIG. 11 . An installer first cuts a hole  78  in the sheet rock  80  or similar wall covering on a wall  82  thereby exposing a stud  84 . The box member  22  is inserted into the hole  78  until the transverse flange  66  is flush with the surrounding wall  82 . The electrical box assembly  20  includes a mounting arrangement  86  for securing the box member  22  to the stud  84  and thereby positioning the back wall  34  of the box member substantially within the wall  82 . The mounting arrangement  86  for securing the box member  22  to the stud  84  includes mounting fasteners  88  that are secured through the apertures  42  in the peripheral wall  32  and into the stud  84  thereby securing the box member  22  to the stud  84 . After the box member  22  is secured to the stud  84 , the frame member  24  is secured to the box member  22  by tightening the fasteners  74  of the attachment arrangement  72  through the guide members  68  of the frame  24  and into the bosses  62  on the peripheral wall  32  of the box member  22 . As an alternative to fastening the frame  24  to the box member  22  with the attachment arrangement, the frame  24  may be secured directly to the wall  82  by driving fasteners  87  through alternative apertures  89  in the transverse flange  66  into the wall  82 . A high voltage component such as the duplex power receptacle  90  can be secured to the electrical box  26  by fasteners  92  and a cover plate  94  attached thereto. Low voltage components such as the CATV connector plate  96  can then be secured with fasteners  98  to the connection points  30  surrounding the open areas  28 . 
   Referring to  FIG. 12 , after the electrical box assembly  20  is secured to the wall  82  and electrical components installed therein, all electrical components, such as the duplex receptacle  90  shown, are recessed within the wall  82  by at least the depth D 1  of the peripheral wall  32  of the box member  22 . Preferably the electrical components are recessed from the outer edge  99  of the electrical box assembly  20  by between 1 and 2 inches. Most preferably, the electrical components are recessed from the outer edge  99  of the electrical box assembly  20  by at least 1.5 inches. With the electrical box assembly  20  recessed within the wall  82  as shown, the plug ends  100  of cords  102  or connector ends of low voltage cables (not shown) are protected from being dislodged by contact from vacuum cleaners or similar hazards. 
   With reference to  FIG. 13  there is shown a completed installation of an electrical box assembly  20  of the present invention in a wall  82 . The electrical box assembly  20  includes a duplex receptacle  90  and cover plate  94 , a horizontally oriented CATV connector  104 , a vertically oriented CATV connector  106 , and a horizontally oriented telephone jack  108 . 
   As shown in  FIG. 4  or  9 , the electrical box  26  of the present invention may include a depressed area  110  in one of the sidewalls  36  and a knockout or removable wall portion  112  therein in the depressed area  110 . The depressed area  110  in the sidewall  36  enables the use of electrical fittings or connectors such as the Black Button™ push-in connector  114  for connecting non-metallic cable to electrical boxes, which is available from Arlington Industries of Scranton, Pa. The depressed area  110  permits use of the connectors  114  without projecting from the sidewall  36  and interfering with placement of the electrical box assembly  20  in locations where space is tightly restricted. 
   With reference to  FIG. 14  there is shown a second and preferred embodiment of an electrical box assembly  200  according to the present invention. Although the electrical box assembly  200  is depicted with a box member  202  and a frame member  204 , the electrical box assembly could also be constructed and provided in one piece, with the frame member  204  integral with the box member  202 . 
   Referring to  FIG. 15 , the box member  202  includes a rearward extending peripheral sidewall  206  having a front edge  208 . The box member  202  includes a first portion  209  and a second portion  210  with a back wall  212  closing off the box member  202  at the first portion  209 . An electrical box  214  extends rearward from the second portion  210  of the box member  202 . The electrical box  214  includes sides  216  and a rear wall  218 . Connection points  220  are provided in the electrical box  214  for later connecting an electrical component (not shown) thereto. The first portion  209  of the box member  202  includes a first sidewall portion  222  and the second portion  210  of the box member  202  includes a second sidewall portion  224  with the second sidewall portion  224  extending to a greater depth from the front edge  208  than the first sidewall portion  222 . The second sidewall portion  224  includes a rear edge  226  and a short wall  228  extending transversely at the rear edge  226 . The first sidewall portion  224  terminates in an edge  230 . The sides  216  of the electrical box  214  extend rearward from the edge  226  of the short wall  228 . 
   As shown in  FIG. 15 , the interior of the box member  202  includes a plurality of stiffening ribs  232  extending from the back wall  212  and along a substantial portion of the peripheral sidewall  206  toward the front edge  208 . Additionally, as shown in  FIG. 16 , exterior ribs  234  project from the exterior surface of the short wall  228  and along the exterior surface of the sides  216  of the electrical box  214 . 
   With reference to  FIG. 16 , the peripheral sidewall  206  of the box member  202  includes an outer surface  236  and tabs  238  extending from the outer surface  236 . The tabs  238  include a first end  240  flush with the front edge  208  of the box member  202  and a second end  242  at a distance D 2  (see  FIG. 20 ) from the front edge  208 . Preferably, the distance D 2  is between 0.25 and 0.75 inches for later aligning the front edge  208  of the box member  202  at a proper offset from a stud for accommodating sheetrock thereon (see  FIG. 27 ). 
   Referring to  FIG. 17 , the connection points  220  in the electrical box  214  include integral bosses  244  extending from opposing sides  216  of the electrical box  214  and bores  246  in the bosses  244 . As shown in  FIG. 17 , the electrical box  214  is a two-gang box that includes space for two electrical components (not shown) and includes two sets of integral bosses  244 . The box member  202  includes a plurality of openings  248  in the back wall  212  for later accommodating low voltage electrical components (not shown). The openings  248  include connection points  250  in the back wall  212  for securing low voltage components thereto. The connection points  250  for the low voltage components include bosses  252  on opposing sides of the openings  248  in the back wall  212  of the box member  202 . 
   As shown in  FIG. 17 , the preferred embodiment of the electrical box assembly includes a two-gang electrical box  214 . Opposing sides  216  of the electrical box  214  include grooves  254  therein for dividing the two-gang box into single electrical boxes. A divider wall  256 , such as that shown in  FIG. 19 , can be inserted or slid into the grooves  254  to dividing the electrical box into two single electrical boxes. 
   As shown in  FIG. 18 , one or more sides  216  of the electrical box  214  are provided with removable wall portions or knockouts  258 . The knockouts  258  are removed to provide openings for passage of electrical cable (not shown) into the electrical box  214 . Additionally, the knockouts  258  can have electrical fittings or connectors inserted therein for connecting electrical cables to the electrical box. 
   With reference to  FIG. 20 , the peripheral sidewall  206  of the box member  202  further includes a top wall portion  260  and a bottom wall portion  262 . A loop member  264  is provided on the bottom wall portion  262  and on the top wall portion  260 . The loop members  264  extend from the back wall  212  to the top or bottom wall portions  260 ,  262  and include an opening  266  therein. The loop member  264  can be used for bundling and holding cables and wiring (not shown) against the back wall  212  of the box member  202 . 
   Referring to  FIGS. 21-24 , the frame member  204  portion of the electrical box assembly is shown. The frame member  204  includes a transverse flange  268  and a rearward extending peripheral flange  270 . The transverse flange  268  includes a top portion  272 , a bottom portion  274 , and side portions  276 . As shown in  FIG. 22 , mounting apertures  278  are provided in the side portions  276  of the transverse flange  268  and form a portion of a mounting arrangement  280  for mounting the electrical box assembly to a wall. 
   With reference to  FIG. 25 , there is shown the preferred embodiment of the electrical box assembly  200  in alignment with a hole  282  in a wall  284  to be inserted therein and mounted to the wall  284 . The mounting arrangement  280  includes the mounting apertures  278  in the transverse flange  268  and mounting fasteners  286  for tightening through the mounting apertures  278  into a stud  288 . The mounting apertures  278  in side portions  276  of the transverse flange  268  are preferably spaced apart by a distance equivalent to the spacing D 3  between the studs  288 . If, for example, the distance D 3  between the studs  288  was 16 inches, then mounting apertures  278  are preferably spaced apart by a distance of between 15.5 and 16.5 inches, or most preferably by 16 inches. The hole  282  made in the wall  284  would therefore be made to extend between two adjacent studs. For wood studs  288 , wood screws would preferably be used to secure the electrical box assembly  200  to the wall  284 . For metal studs (not shown), sheet metal screws or their equivalents would be used to secure the electrical box assembly  200  to the wall  284 . A second set of apertures  290  are provided on one side of the transverse flange  268  inward of the mounting apertures  278  for walls with studs spaced apart at a distance of 14.5 inches. For longer stud spacing, one end of the transverse flange  268  would be anchored into a stud in the normal manner and the opposite end would be anchored to the drywall with drywall screws. Also, the electrical box assembly  200  could be constructed in a larger length to accommodate a longer stud spacing. 
   As shown in  FIG. 25 , the electrical box  214  extends at a first depth D 4  from the front edge  208  of the box member  202 . The low voltage openings  248  extend at a second depth D 5  from the front edge  208  of the box member  202 . As a result of the electrical box  214  being offset at a greater distance from the front edge  208 , any high voltage component, such as the duplex receptacle  292  will be recessed a greater depth D 4  within the wall  284  than would a low voltage component  294  such as the CATV outlet plate shown in  FIG. 25 . 
   In the preferred embodiment of the electrical box assembly  200  of the present invention, the box member  202  could be provided in one piece, as shown in  FIG. 14 , with the transverse flange  268  as an integral part of the box member  202 . Conversely, as shown in  FIG. 25 , the electrical box assembly  200  could be provided with a separate box member  202  and frame member  204 . An attachment arrangement  296  for securing the frame member  204  to the box member  202  includes a plurality of bosses  298  on the peripheral sidewall  206  of the box member  202  and a plurality of apertures  300  in the frame member  204 . The apertures  300  in the frame member  204  are in axial alignment with the bosses  298  on the box member  202  when the frame member  204  is aligned with the box member  202 . Fasteners  302  are used in the attachment arrangement  296  for securing through the apertures  300  in the frame member  204  into the bosses  298  on the box member  202 . 
   The reader is referred to  FIG. 25  for an understanding of the operation of the preferred embodiment of the electrical box assembly  200  including a separate box member  202  and frame member  204 . An appropriately sized hole  282  to accommodate the outer periphery of the box member  202  and spanning the distance between two studs  288  is cut in the wall  284 .  FIG. 25  illustrates a wall having studs spaced a distance D 3  apart on their centers. The frame member  204  is then secured to the box member  202  using fasteners  302  through apertures  300  of frame member  204  into bosses  298  in box member  202 . Cables are then fed through the appropriate openings including knockouts  258  for high voltage cables or through openings  248  for low voltage cables. The cables (not shown) can be routed through loop members  264  to hold them within the box member  202 . The electrical box assembly  200 , consisting of the frame member  204  secured to the box member  202 , is then secured to the wall using the mounting arrangement  280  including mounting fasteners  286  secured through mounting apertures  278  in the transverse flange  268  and into apertures  304  and the studs  288  in the wall  284 . High voltage components, such as the duplex receptacle  292  shown, are then secured to the high voltage connection points  220  within the electrical box assembly  200  and low voltage components, such as the CATV outlets  294 , are secured to the low voltage connection points  250  within the electrical box assembly  200 . 
   With continued reference to  FIG. 25 , in the case of installing the electrical box assembly  200  on a newly constructed wall in which the sheetrock  306  has not yet been installed, tabs  238  are used to align the box member  202  against the bare studs. In this situation, the second or rear ends  242  of the tabs  238  are placed against the face  308  of the studs  288 , which would position the box member  202  at the correct distance to place the front edge  208  of the box member  202  approximately flush with the eventual face of the installed sheetrock  306 . Fasteners  310  are secured through apertures  312  in the peripheral sidewall  206  of the box member  202  to temporarily secure the box member  202  to the wall until the sheetrock  306  is installed and the frame member  204  is secured to the box member  202  and to the wall  284  by mounting arrangement  280 . 
   The reader is referred to  FIG. 26  for an understanding of the operation of the one-piece preferred embodiment of the electrical box assembly  314  in which the transverse flange  268  is an integral portion of the box member  202 . An appropriately sized hole  282  to accommodate the outer periphery of the peripheral sidewall  206  of the box member  202  and spanning the distance between two studs  288  is cut in the wall  284 . Cables (not shown) are then fed through the appropriate openings including knockouts  258  for high voltage cables or through openings  248  for low voltage cables. The electrical box assembly  314 , consisting of the one-piece box member  202 , is then secured to the wall using the mounting arrangement  280  including mounting fasteners  286  secured through mounting apertures  278  in the transverse flange  268  and into apertures  304  and the studs  288  in the wall  284 . High voltage components, such as the duplex receptacle  292  shown, are then secured to the high voltage connection points  220  within the electrical box assembly  314  and low voltage components, such as the CATV outlets  294 , are secured to the low voltage connection points  250  within the electrical box assembly  314 . 
   As shown in  FIG. 27 , after the electrical box assembly  200  has been secured to the wall  284 , both high voltage components  292  and low voltage components  294  are recessed substantially within the wall  284 , thus protecting the components. High voltage components such as the duplex receptacle  292  shown are offset a distance D 4  and low voltage components  294  are offset a distance D 5 . The greater offset of the duplex receptacle  292  provides ample space for protecting plug ends  316  of electrical cords  318  while they are in use and plugged into the duplex receptacle  292 . 
   As shown and described herein, the current invention provides an improved electrical box assembly  200  or  314  that has the advantage of accommodating two high voltage components and recesses the high voltage components farther within the wall. It also provides the advantage of an extended flange for more secure mounting of the electrical box assembly to a wall. 
   The electrical box assembly of the present invention could be constructed of metal or plastic but, most preferably, is molded of plastic. In a first method of construction, the box member  202  of the present invention is molded in one piece of plastic and the frame member  204  is also molded in one piece of plastic. In a second method of construction, a single piece is molded in one piece of plastic with the single piece being a box member including a transverse flange as an integral molded portion of the box member thereby negating the need for a separated frame member. Suitable plastics include polycarbonate and polyvinylchloride. 
   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 Category: h