GB2542005A

GB2542005A - A sunken backbox

Info

Publication number: GB2542005A
Application number: GB1614784.5A
Authority: GB
Inventors: michael jones Christopher
Original assignee: Individual
Current assignee: Individual
Priority date: 2015-09-01
Filing date: 2016-09-01
Publication date: 2017-03-08
Anticipated expiration: 2036-09-01
Also published as: GB2542005B; GB2541889A; GB201515448D0; GB201614784D0

Abstract

An electrical back box assembly for a sunken backbox for fitting in a structural element such as a wall. The electrical backbox assembly comprises: a sunken back box 100 with a back wall 9 and side walls 2 extending outwards from the back wall to define an opening; connectors 60 for connecting to clips 6; an aperture 11 corresponding to a front region 22 of a pattress 8; the back wall is adapted to receive the pattress which abuts and connects to a rearward side of the back wall; and a displaceable lid 1 is arranged to cover the opening of the backbox; wherein the clip is adapted to engage with the at least one connector and a structural element (see figure 15B) so as to locate and fix the back-box assembly to the structural element, such as a plasterboard (20, figure 16B). Preferably the clip has resiliently deformable fingers (6A) to grip the structural element.

Description

A SUNKEN BACKBOX

Field of the Invention

The present invention relates to an electrical backbox assembly for a sunken backbox for fitting in a structural element such as a wall; more particularly but not exclusively for use with a stud wall.

Background

Increasing reliance on electrical goods ensures that electrical outlets are a fundamental object in the fabric of building or renovating domestic and commercial properties.

However electrical outlets or sockets can be unsightly, dangerous, space consuming and inconvenient; standing proud of walls and preventing use of the relevant wall space.

Prior Art US 8 739 997 (PLOOF) discloses an electrical box comprising: an enclosure having sidewalls forming a front opening, said sidewalls being configured to mount at least one electrical outlet; a front frame extending perpendicularly outward from a perimeter edge of said sidewalls; a plurality of frame clamps mechanically connected to said front frame and configured to secure said enclosure to a wall surface; and, a door slidably connected to said enclosure behind said front frame. US 7 645 937 (BHOSALE) discloses an electrical wiring box assembly comprising: an inner wall box including a peripheral inner wall bounded and enclosed by a rear wall and open at a front end of the inner wall box to form an inner volume. US 6 956 169 (KINNARD et al) discloses a recessed electrical outlet box and cover system mountable substantially flush with a mounting surface for receiving at least one plug having an electrical cord extending therefrom. US 6 737 576 (DINH) discloses an electrical backbox assembly including a box with a base wall perimetrically bounded by a sidewall forming a housing adapted to receive an electrical component. US 7 319 192 (GRETZ) discloses an electrical box assembly with a frame member and an outlet box and a hinged cover. US 7 820 912 (SHOTEY et. al.) discloses an electrical outlet cover assembly with an electrical outlet mounting box. US 8 445 780 (ROBINS) discloses an apparatus with a mount plate secured to a wall or ceiling panel that leads to an electrical device. US2004/0238197 (GATES) discloses an electrical box with recessed faceplate having a one-piece recesses faceplate that is adapted to accommodate a two-piece recessed faceplate. WO2013/046111 (BRUNO) discloses a box assembly for a flush mounting containing concealable sockets.

Summary of the Invention

According to a first aspect of the present invention there is provided an electrical backbox assembly comprising: a sunken backbox having a back wall and a plurality of side walls extending outwards from the back wall to define an opening; at least one connector is provided on at least one of the side walls for connecting to a clip; an aperture is provided in the back wall and corresponds to a front region of a pattress; the back wall is adapted to receive the pattress that in use abuts a rearward side of the back wall and connects thereto; and a displaceable lid is arranged to cover the opening of the backbox, wherein the or each clip is adapted to engage with the at least one connector and a structural element so as to locate and fix the backbox assembly to the structural element.

In this way the sunken backbox assembly can be easily located and fitted in a structural element such as a wall.

The upper and lower side walls preferably have two connectors for receiving at least two clips or inserts. The clips are configured to interfit with or grip the structural element such as plasterboard and to also engage with an outer side of the backbox.

In some embodiments the sunken backbox may additionally or alternatively be glued in position. For example glue may be applied to the clips before the backbox is located in an opening in the structural element.

Preferably the connectors are cut out portions, such as a channel in the side wall in which the clips sit in use. In some embodiments the connector may be a recessed portion of the side wall.

The connector is dimensioned to hold the clips so that they are held in a fixed position in use.

Typically, the clips are loose until the sunken backbox is fitted to the structural element such as the plasterboard, or other similar structure or material. In this way the clip is located in the connector and becomes fixed in the connector when fitted in or on the structural element. Furthermore this enables different types of clips to be engaged with the connector depending upon the structural element and shape and size of the connector.

Preferably the clips are also partially supported and held in position by the lid when fitted to a front face of the sunken backbox. Typically the clips are arranged to fit flush with the rim of the backbox so the lid engages with the rim and overlaps part of the clips when in place.

In some other embodiments the clip may be connected to the connector by an engagement means. For example, the clips may be fitted by a magnet, snap fit, friction fit, detent mechanism or interlocking means.

Preferably each clip has two fingers, one arranged each side of part of the structural element. For example one finger may extend either side of a plasterboard or similar structure in use so as to fix the clips and thereby the sunken backbox in place. Ideally the fingers are resiliently deformable so that they can flex to accommodate the plasterboard during fitting and to ensure the clips are fixed firmly to the plasterboard.

In some embodiments the fingers may include a resiliently deformable portion such as rubber nodule or layer so as to aid with gripping to the structure.

Typically the fingers have a smooth outer face so as to pass smoothly over the structural element during fitting.

The sunken backbox has a lid that covers a cavity defined by the back wall and side walls of the backbox. The cavity is an access route to any sockets arranged in the pattress that abuts the back wall. Advantageously the lid limits access to the sockets and any plugs. In this way unauthorised access is prevented, for example by children or vulnerable adults.

Preferably the lid is held against the backbox by means of at least one catch. Typically the catch is intentionally stiff so that it is harder to release the lid, therefore preventing vulnerable adults or children from erroneously removing the lid and gaining access to the plugs and/or sockets. For example in some embodiments a tool or coin may be used to release the catch.

In some embodiments the lid may be locked to the sunken backbox by a lock.

In some embodiments the lid or cover is slidably engaged on the backbox, for example being mounted on the rim of the backbox. In this way the lid may be slid open and closed.

In another embodiment the cover is alternatively or additionally hingeably engaged on the backbox, such that the cover may be swung open or closed.

In some embodiment the sunken backbox may include a runner for the lid. For example, the rim may have an indented moulding standing forward of the wall structure in use, and a vertically arranged runner for the lid.

The lid may slide up and down in the runner and may be able to exit the runner and/or stopped therefrom at a top or bottom terminus. In some embodiments the top or bottom terminus may comprise a hinge for the cover, such that the cover may pivot away from the frame at the terminus.

In some embodiments engagement of the backbox and lid is accomplished by an engagement mechanism. Said engagement mechanism may comprise plural steps, for example wherein the cover may be slid into a frame provided on the backbox and a lock or catch mechanism operated to hold the cover in place.

Preferably the lid and in some cases also part of the side wall is shaped to define a passage that allows passage for a wire or cable. In this way the lid is fitted whilst plugs are fitted in the sockets.

For example, the lid may be slid in place to cover the cavity whilst the sockets on a fascia of the pattress are also in use and, wherein the lead from a plug may be able to pass through the lid and/or side wall of the backbox by means of the passage.

Preferably the passage may be situated towards the lowermost point of the sunken backbox in use, advantageously running from the plug bottom.

In some embodiments the fascia of the pattress into which plugs are accepted may be angled. The aperture may consequently provide an opening configured for abutting the angled fascia. Advantageously this enables the fascia of the pattress to be maintained at an angle relative to the lid and orientation of the structural element. In this way it may be easier for plugs to be inserted into the sockets for some user’s.

In some embodiments a portion of the side wall may be inclined, in particular the lowermost side wall, such that leads may be fed out along the incline surface so as to prevent damage.

In some embodiments the fascia of the pattress may be integrated with the sunken backbox. For example, the backbox and fascia may be continuous. In this way the sunken backbox comprises a backbox and fascia, wherein the fascia for example may be indented into the backbox.

In some other embodiments the sunken backbox may also be integrated with the pattress.

Preferably the pattress fascia is a separate, and/or independently available part, for example advantageously utilising standard dimensions and format for a socket fascia.

In use the pattress is installed deeper into the structural element, such as a wall or plasterboard structure, than a standard pattress, with a user having to pass the plug through the cavity of sunken backbox in order to engage with the sockets on the pattress.

Preferably the sunken backbox may be arranged to be flush with the structural elements.

In some embodiments the sunken backbox may be configured to stand forward of the wall structure.

In some embodiments the side walls and/or rim may comprise means to attach to the wall structure. For example, screw holes may be provided.

The sunken backbox is formed from a material suitable for electrical use, such as a synthetic electrically rated plastic, metal or metal alloy.

Ideally a front face of the sunken backbox is suitable for being painted.

In some embodiments the sunken backbox includes a lip against which plaster can be applied up to so as to aid with securing the sunken backbox in a wall and providing a neat finish when fitted.

Preferred embodiments will now be described with reference to the Figures in which: Brief Description of Figures

Figures 1 show a first embodiment of the sunken backbox according to the present invention in isometric and reverse isometric views;

Figures 2 show the first embodiment of the sunken backbox as shown in Figures 1, in section and reverse exploded isometric views respectively;

Figure 3 shows the first embodiment of the sunken backbox as shown in Figures 1, in exploded isometric view;

Figures 4 show a second embodiment of the sunken backbox according to the present invention in isometric and reverse isometric views;

Figures 5 show the second embodiment of the sunken backbox as shown in Figures 4, in section and reverse exploded isometric views respectively;

Figure 6 shows the second embodiment of the sunken backbox as shown in Figures 4, in exploded isometric view;

Figures 7 show a third embodiment of the sunken backbox according to the present invention in isometric and reverse isometric views;

Figures 8 show the third embodiment of the sunken backbox as shown in Figures 7 in isometric and reverse isometric views with the cover open;

Figures 9 show the third embodiment of the sunken backbox as shown in Figures 7, in section and reverse exploded isometric views respectively;

Figure 10 shows the third embodiment of the sunken backbox as shown in Figures 7, in exploded isometric view;

Figures 11 to 13 show sketch views of a fourth embodiment of the sunken backbox;

Figures 14 show a fifth embodiment of a sunken backbox; in which Figure 14A shows a side view of the backbox with two clips fitted in the connectors;

Figure 14B shows a front view of the backbox;

Figure 14C shows a side view of the backbox;

Figure 14D shows a top view of the backbox;

Figure 14E shows an overview of the backbox;

Figure 14F shows the backboxwith the lid displaced;

Figure 14G shows the lid;

Figures 14H show different views of a clip;

Figures 15 show various of the connectors and clip; and Figure 16 shows the clip in use.

Detailed Description of Figures

With reference to figures 1 to 3 there is shown an embodiment of the sunken backbox 100 having side walls 2 a rear wall 9 that abuts to the fascia 22 of a pattress 8.

The sunken backbox 100 has a rim 10 and a lid 1 that is an integrally moulded thermoplastics plate such as acrylonitrile butadiene styrene (ABS) or polyethylene. The lid 1 has a pair of wings 1A that extend from opposed sides and are adapted to slot within the sunken backbox. The lid 1 includes a passage 5 defining an inlet in the bottom edge of the lid 1 through which a cable can lie in use.

The lid 1 is fixed to the backbox by a catch 7 comprised by a resiliently deformable tab arranged centrally to the top edge. In some embodiments multiple catches/tabs 7 may be provided.

The side walls 2 extend from a back wall 9. The back wall 9 has an aperture 11 that corresponds to the fascia 22 of the pattress 8.

The lid 1 is slid onto a front face of the sunken backbox, wherein the backbox has a rim 10 parallel to the structural element and the slid when in place.

The rim 10 is larger than the opening made in the structural element to prevent the sunken backbox 100 entering the structural element and so as to conceal edges of the opening created to receive the sunken backbox.

The sunken backbox 100 includes four side walls 2 with radiused corners, a front rim 10, a back wall 9 wherein the back wall is adapted to receive the fascia 22 of the pattress 8.

The side walls 2 of the sunken backbox 100 extend orthogonally backwards from the rim 10 to the back wall 9, which back wall 9 has an aperture 11 (see Figures 2 and 3) that corresponds to the pattress 8. The aperture 11 is typically set higher on the back wall to allow space for the cables or leads (not shown) from the plugs in the space below.

The back wall 9 has a chamfered aperture 11, which aperture permits the fascia 22 to sit snugly.

The fascia 22 is a standard electrical outlet fascia, and is shown in use with a standard electrical fascia pattress 8. Both the pattress 8 and the fascia 22 may be part of the sunken backbox, part of a kit of parts, or available separately, for example comprising standardised parts.

The top and bottom side walls 2 of the frame have connectors 60 for receiving structure attachment clips 6, which are configured to grip to either side of a piece of plasterboard, wherein the clips include resiliently deformable tongues 6B which deform to accept the plasterboard.

In some embodiments the clips 6 may be put in place after the sunken backbox 100 has been inserted into the structural element, wherein the clips 6 are engaged by an interference fit into the sunken backbox.

With reference to the second embodiment 200 of the sunken backbox shown in Figures 4 to 6 the sunken backbox has a bottom side wall 14 angled obliquely away from the back wall 9 to the rim 10. In this way the bottom side wall 14 advantageously slopes away from where the plug will be in use and the lead will start.

The fascia 222 in the second embodiment is integrated into and forms a part of the back wall 9, and the pattress 8 may be supplied as a whole with the embodiment or may comprise a separately available part.

The lid 1 in the second embodiment is arranged to clip into the rim 10 of the sunken backbox, displacing horizontally out of the sunken backbox to permit access to the fascia 222.

The lid 1 has a wire inlet passage 5 centrally in the lowermost edge of the lid 1, which passage 5 is stepped upwards centrally to guide wires out of the sunken backbox 200.

The lowermost side wall 14 of the sunken backbox 200 is inclined obliquely away from the fascia 8 to further guide the wires, and prevent strain on the wires or plug or fascia through sudden directional changes.

With respect to the third embodiment 300 there is shown in Figures 7 to 10 the sunken backbox has a sliding cover 110, has a runner 110A for sliding vertically on the rim 10, upwards so as to allow access to the fascia 223. The passage 5 is central and situated on the lowermost edge of the lid 110.

The side edges of the rim 10 include a stopper 111 to the lowermost corners, which stopper 111 interacts with a stopper in the topmost perimetric corners of the rim 10 to prevent the lid 110 sliding too far.

The fascia 223 in the third embodiment is inclined and incorporated in the sunken backbox to provide a seamless, hygienic and simple form.

The fascia 223 continues an incline in the bottom side wall 114 of the frame away from the rim 10. The backbox lower side wall 114 acts as a continuous form leading from the fascia to the rim 10 to allow easy and guided movement of the cables/wires.

The fascia of the pattress may be single or double or more.

Figure 11 shows various views of a fourth embodiment of a lid 1 and clips 6. Like parts have been referred to with like references.

Figure 12 shows an overview of the fourth embodiment of the sunken backbox 400.

Figure 13 shows the fourth embodiment 400 with the lid removed and no clips located in the connectors 60.

Figures 14 show various view of the backbox 500. The sunken backbox is substantially rectangular, having a sunken backbox 500 with a flange or rim 10 surrounding the opening the backbox 500. The back wall 9 of the backbox 500 has an opening 911 that corresponds to a second backbox or pattress 8 in which the sockets are located in use. In this way the first backbox defines a cavity or void that is enclosed when the lid 1 is shut.

The side walls 2 have 4 connectors 60 which are dimensioned to receive the clips 6 (Figure 141). The connectors 60 are cutaway portions that traverse the side walls 2. The clips 6 sit in the connector 60 so that the clips 6 serve to locate the backbox.

The clip 6 has two fingers 6A and 6B. The figures are located either side of a sheet of plasterboard so that the clip 6 is fixed in position. The clip 6 is located in the connector 60 and thereby the backbox is fixed in position by means of the clips 6 being secured to the plasterboard 20.

The fingers 6A, 6B are arranged to be spaced apart so as to correspond with the thickness of plasterboard or any other wall material.

The lid 1 has a plurality of catches 7 for fitting the lid to the backbox. The lid 1 has two cutaway regions 5 from which cables can extend from in use, whilst keeping the cavity enclosed by having the lid 1 shut.

The cutaway regions 5 are typically sizes so as to only accommodate a cable and not to allow a user to insert their fingers under the lid 1. In addition, the lid shown in Figure 14G has three lower catches 7B in the form of pins that slot into corresponding holes on the sunken backbox to secure the lid and to further prevent lifting of the lid when closed.

The catch 7A arranged on an upper section of the lid is provided to open the lid. Typically the catch 7 A is deformed in order to be released.

Figures 15 show the connectors 60 on the backbox 500 and clips 6 that engage with the connectors 60.

Figure 15E shows the edges 60A of the connectors 60 have stepped edges 60A. The clip 6 is shown engaged with the connector 60 in Figure 15E.15B and 15C.

The opening in the structural element, typically a wall, is dimensioned to correspond to the sunken backbox.

Typically, the clips are located in the connectors 60 and the backbox and clips 6 are then pushed into the wall opening. The finger 6B has a sloped surface that aids with guiding the clip over and onto the plasterboard.

In some embodiments the clip 6 and the connector 60 may have an engagement mechanism so that the parts engage with one and other. For example, the clip 6 and connector 60 may have corresponding portions, interlocking parts, male and female connectors or a snap fitting.

Figures 16 show close up views of the clips 6. Figure 6A has a lip 6C which serves to overlap part of the backbox. This aids with securing the clip to the sunken backbox and provides a flush finish.

An outer face of the clip 6 has a groove 6D that is adapted to receive an edge of the lid in use. This enables the lid to fit over the cavity of the sunken backbox to provide a flush outer surface.

The clips 6 are mounted over plasterboard 20.

Figures 16B and 16C show the clips 6 adapted to receive two different thickness of plasterboard 20. The clip shown in A6B accepts 9.5mm plasterboard 20 and the clip in 16C accepts 12.5mm plasterboard 20.

Each clip 6 has a leg 6E that corresponds to the depth of the sunken backbox 500 so that the toe 6F hooks over the back wall 9 of the sunken backbox.

The invention has been described by way of examples only and it will be appreciated that variation may be made to the above-mentioned embodiments without departing from the scope of invention as defined by the claims.

Claims

1. An electrical backbox assembly comprising: a sunken backbox having a back wall and a plurality of side walls extending outwards from the back wall to define an opening; at least one connector is provided on at least one of the side walls for connecting to a clip; an aperture is provided in the back wall and corresponds to a front region of a pattress; the back wall is adapted to receive the pattress that in use abuts a rearward side of the back wall and connects thereto; and a displaceable lid is arranged to cover the opening of the backbox, wherein the or each clip is adapted to engage with the at least one connector and a structural element so as to locate and fix the backbox assembly to the structural element.

2. An electrical backbox assembly according to claim 1 wherein the connector is a channel.

3. An electrical backbox assembly according to claim 1 wherein the connector is a recess.

4. An electrical backbox assembly according to any preceding claim including an engagement mechanism for fixing the lid to the sunken backbox.

5. An electrical backbox assembly according to any of the preceding claims wherein the lid is slidably fitted to the backbox.

6. An electrical backbox assembly according to any of the preceding claims wherein the lid is hingeably attached to the backbox.

7. An electrical backbox assembly according to any of the preceding claims wherein the lid has a passage for exit of wiring from the backbox.

8. An electrical backbox assembly according to any of the preceding claims wherein the clips have resiliently deformable fingers to grip the structural element.

9. An electrical back box assembly according to any preceding claim including engagement means for fitting the clips to the connectors.

10. An electrical backbox assembly according to any of the preceding claims wherein a lower side wall is inclined obliquely away from the fascia of the pattress such that leads/cables/wires may be fed out along the inclined side wall.

11. An electrical backbox assembly according to any of the preceding claims wherein the back wall is adapted to receive an inclined fascia.

12. An electrical backbox assembly as substantially herein described with reference to the Figures.