AU2015204344A1

AU2015204344A1 - A covering for use with a floor box

Info

Publication number: AU2015204344A1
Application number: AU2015204344A
Authority: AU
Inventors: Bradley Noel Booth; Daniele Cesarin
Original assignee: Electric Cable Duct Systems Pty Ltd
Current assignee: Electric Cable Duct Systems Pty Ltd
Priority date: 2014-07-18
Filing date: 2015-07-16
Publication date: 2016-02-04
Anticipated expiration: 2035-07-16
Also published as: AU2017100897B4; NZ710135A; AU2017100897A4; AU2019268210A1; AU2015204344B2; AU2019268210B2

Abstract

According to one embodiment of this invention there is provided a covering for forming part of a floor box accommodating at least one socket outlet to which an electrical cable with a plug can be connect to when in use, the floor box including a base which in use houses the at least one socket, the covering including a frame made of metal positioned in use adjacent the base, a lid made of metal which is movable relative to the frame between an open position and a closed position whereby in the closed position the lid is substantially aligned with the frame, and a protector means which is shaped so as to protect the electrical cable when in use positioned between the lid and the frame inhibiting the lid from adopting the closed position. -- FI-URE 9

Description

1 A Covering for use with a Floor Box [0001] This invention relates to a covering for use with a floor box, and a floor box including such a covering. The covering was developed for a particular application forming part of a floor box which is installed in a floor, however the covering may have applications installed in other horizontal surfaces such as bench tops. Whilst it will be convenient to hereinafter describe the invention with reference to the particular application, it is to be appreciated that the invention is not limited to this application only. [0002] A floor box can be installed in a floor and provide a recessed outlet point for services such as power, data and communications that may be ducted through the floor. The floor box will generally include a base which is recessed into the floor and provided with fit off brackets for the service outlets to be attached thereto. A covering will be provided to cover the base and provide a trafficable surface at the floor level. The covering will generally include a lid which can be opened to provide cable access to the service outlets. The cables will naturally need to exit the floor box however it will be generally preferred for the lid to be in a closed position. For the avoidance of doubt a reference to electrical cable in this specification is not to be limited to power cable only, but is intended to include power, data, and communications cables at least. [0003] The covering may be made of metal particularly if durability is required. The applicant has appreciated a problem with metal lids in that they can damage or even cut the cables exiting the floor box if sufficient force is applied to the lid as it moves towards the closed position. This is particularly the case if the lid is formed by a process leaving a sharp edge. Where the cable is a power cable, this can cause a safety problem as it can convert the entire floor box to a live terminal presenting an electrocution hazard. [0004] One solution has been to leave a significant gap around the lid which is larger than the diameter of the cables. This addressed the issue of the cables being cut, however it presents a tripping hazard particularly for those people wearing high heel shoes that can get caught in the gap. Brad - Floor Box diclation specification 1 July 2014 2 [0005] It would be desirable to provide a solution to these safety issues. [0006] A reference herein to a patent document or other matter which is given as prior art is not to be taken as an admission that that document or matter was, in Australia, known or that the information it contains was part of the common general knowledge as at the priority date of any of the claims. [0007] According to one aspect of this invention there is provided a covering for forming part of a floor box accommodating at least one socket outlet to which an electrical cable with a plug can be connect to when in use, the floor box including a base which in use houses the at least one socket, the covering including a frame made of metal positioned in use adjacent the base, a lid made of metal which is movable relative to the frame between an open position and a closed position whereby in the closed position the lid is substantially aligned with the frame, and a protector means which is shaped so as to protect the electrical cable when in use positioned between the lid and the frame inhibiting the lid from adopting the closed position. [0008] It is preferred that the floor box include a gap of no more than 10mm between the lid and the frame when the lid is in the closed position. One advantage of this is that when in use it reduces the likelihood of a person tripping on or having their shoe caught in the gap. Clearly the gap dimension may vary and it may be more than 10mm, however it is preferred to be less than 10mm. It is preferred that the protector means occupies at least a portion of said gap. It is further preferred that the protector means occupies a significant majority of the gap so to increase the likelihood that a person won't trip or get their shoe caught in the gap. The protector means may be formed from a plastics material, as this will render the protector means trafficable. This material selection will also render the protector means non-conductive to electricity. [0009] The protector means may be formed from as a single unit however in a preferred embodiment the protector means includes a lid portion associated with the lid and or a frame portion associated with the frame. Regardless of whether the protector means is associated with the lid or the frame, it is preferred that it have an edge shaped to protect the cable. In a particularly Brad - Floor Box diclation specification 1 July 2014 3 preferred embodiment the protector means includes both the lid portion and the frame portion and each of which have an edge complementary shaped to protect the cable. The manner in which the complementary shape protects the cable may take any suitable form however in one form the complementary shape defines a path there between for the cable when the lid approaches the closed position. The path may include at least one bend, and the bend may have a radius of no less than 3mm, however this dimension may vary. The path includes a pair of return bends with a relatively straight section between each bend, as this provides the advantage of sandwiching the cable between the lid and the frame. It is preferred that the straight section is substantially parallel to an upper surface of the lid as this reduces the likelihood of the lid and frame creating a cutting action when it approaches the closed position. In one preferred embodiment the path includes an exit section that extends in a direction to make an acute angle with the frame. This allows the cable to exit the box in a direction substantially parallel to the floor, reducing the likelihood that the cable will produce a tripping hazard as it exits the floor box. [0010] The manner by which the lid moves relative to the frame may take any suitable form and in one preferred form the lid pivots relative to the frame when moving between the open position and the closed position. [0011] The lid and or the frame may be formed as a single unit however it is preferred that one or each of them is formed as an assembly of components. Where they are formed as an assembly it is preferred that the lid and the frame each include a top plate. Where the lid and frame include a top plate it is preferred that they have an upper surface which are substantially co-planar when the lid is in the closed position. [0012] It is preferred that the lid includes at least one exit through which the cable can exit when the lid is in the closed position. This exit provides the preferred manner by which the cable exits the floor box, and may take any suitable form. In one preferred embodiment the lid includes a main portion and an exit flap which pivots relative to the main portion to adopt an open condition to allow the cable to exit. The location of the exit flap may be on any where on the lid, and in one preferred embodiment the lid includes a fixed side at which Brad - Floor Box dictation specificaion 1 July 2014 4 the lid pivots relative to the frame and a free side which raises and lowers relative to the frame a, the exit flap being located at the free side. [0013] The extent of the protector means may take any suitable form, however it is preferred that it at least extends from the free side to the fixed side of the lid. It is further preferred that the protector means extends along the free side to the exit flap. The protector means may also extend in other areas if it is desirable from a manufacturing perspective. The protector means may extend along the fixed side, however it should be appreciated that protection of the cable in this area is not required as the cable is unable to exit the floor box in this area. The protector means may extend across the exit flap, however given the exit flap pivots relative to the main portion of the lid, protection is generally not required. [0014] The lid and the frame may be made from any suitable metal and one suitable metal is stainless steel. The entire lid and frame need not be formed from stainless steel however when the lid and frame are formed as an assembly, it is preferred that at least the top plate of each is formed from stainless steel, or a stainless steel laminate or a stainless steel coloured finish. [0015] The protector means maybe formed from any suitable material and one suitable material a polymer material. The polymer material may be relatively hard and may be selected from any one of the following polyamide, PVC, ABS or polystyrene. Alternatively the polymer material may be selected from a relatively soft material including neoprene, foamed synthetic material, polyurethane or polyethylene. [0016] According to another aspect of this invention there is provided a floor box for accommodating at least one socket outlet to which an electrical cable with a plug can be connect to when in use, the floor box including a base for housing said at least one socket when in use, and a covering substantially as herein before defined attached to the base. [0017] It is preferred that the at least one socket includes any one or more of the following a power outlet, a data outlet or a communications outlet. These outlets may be provided pre-installed, or installed on site. It is further preferred Brad - Floor Box dictation specificaion 1 July 2014 5 that the base includes a cable retainer for retaining the cables exiting the base adjacent one wall of the base. The base is also preferably configured relative to the covering so that can lid adopt the closed position while the plug is connected to the socket. [0018] It will be convenient to hereinafter describe the two aspects of the invention with reference to the attached illustrations which are of preferred embodiments. The illustrations and following description is merely for assisting an understanding of the invention and how it might work, however the invention is not limited to these preferred embodiments. [0019] Figure 1 is an isometric view of a floor box according to a preferred embodiment of the invention. [0020] Figure 2 is an exploded view of the floor box from Figure 1. [0021] Figure 3 is the floor box from Figure 1 with the lid in a partially closed position. [0022] Figure 4 is the floor box from Figure 3 with the lid in a closed position and the cables exiting the box out through an exit in the lid. [0023] Figure 5 is a partial sectional view of the lid in the closed position from Figure 4. [0024] Figure 6 is the box from Figure 3 with one of the cables moved away from the exit. [0025] Figure 7 is an exploded view of a preferred embodiment of a covering according to another aspect of this invention. [0026] Figure 8 is a partial sectional view showing the cable in the position from Figure 6 and the lid being moved towards the closed position. [0027] Figure 9 is the sectional view from Figure 8 with the lid and frame engaging the cable. [0028] Figure 1 illustrates a preferred embodiment of a floor box 1 according to one aspect of the invention, including a preferred embodiment of a covering 2 Brad - Floor Box diclation specification 1 July 2014 6 according to another aspect of this invention. The covering 2 in summary includes a frame 3, a lid 4 movable relative to the frame 3, and a protector means 5. The floor box 1 includes in summary the covering 2, and a base 6 to which the covering 2 is attached, for housing at least one socket 7a, 7b. When the floor box 1 is in use the base 6 may have more than one socket installed therein, and Figure 1 illustrates four sockets 7 including a pair of twin electrical socket outlets (GPO's), to which a pair of electrical plugs 8 are connected with cables 9a, 9b extending therefrom. [0029] Figure 1 illustrates the lid 4 in an open position to enable plugs 8 to be connected to the sockets 7a,7b. The manner in which the lid 4 moves relative to the frame 3 may take any suitable form however in the embodiment illustrated the lid 4 pivots relative to the frame 3. The pivot mechanism will be explained in greater detail with reference to latter illustrations. However, it should be appreciated from Figure 1 that the pivot mechanism may include a rod 10 which locates in pivot recesses formed in the frame 3. [0030] Referring now to Figure 2 which illustrates the floor box 1 from Figure 1 exploded view, and in particular the covering 2 detached from the base 6. The covering 2 may be attached to the base 6 in any suitable manner and in the embodiment illustrated the attachment includes a plurality of screw fasteners 11 which attach the frame 3 to a pair of opposed flanges 12 extending out from opposed side walls 13 of the base 6. The floor box 1 as illustrated in Figure 2 also includes a pair of mounting brackets 14a, 14b which are to be positioned adjacent the opposed side walls 13. The illustration shows a power mounting bracket 14a for accommodating the pair of twin power sockets 7a, and a data/communications bracket 14b for accommodating a pair of data/communication sockets 7b. Figure 2 also illustrates a pair of cable retainers 15 located on the front wall 16 of the base, which are provided for capturing the cables 9a, 9b (see figure 1) exiting the base 6 adjacent the front wall 16. It should be noted that these cable retainers 15 are positioned to align with an exit flap 17 forming part of the lid 4, and this exit flap 17 will be described in greater detail by reference to latter illustrations. Brad - Floor Box dictation specificaion 1 July 2014 7 [0031] Figure 2 also illustrates a recess 18 which may be typically formed in the floor (not shown), in this case is a concrete floor, into which the floor box 1 may be located. One option for locating the floor box 1 is for the base 6 to be located within the floor before forming, or another option is for a disposable insert (not shown) to located in the floor which is removed before the base 6 is installed. [0032] Figure 2 also illustrates a series of knock-out holes 19 on the front wall 16 and side walls 13 of the base 6. These knock-out holes 19 are provided to allow main cable (not shown) access through the floor into the floor box 1 for termination at the sockets 7. [0033] Referring now to Figure 3 which illustrates the floor box 1 from Figure 1 with the lid 4 moved towards the closed position. It should be noted from Figure 3 that when the cables 9a, 9b are captured by the cable retainers 15, they exit the base 6 in the correct position adjacent the exit flap 17. [0034] Figure 4 illustrates the floor box 1 from Figure 3 with the lid 4 now in the closed position with the exit flap 17 raised to accommodate the cables 9a, 9b. It is preferred that the exit flap 17 be provided with a soft pad 20 attached to the underside of the exit flap 17 to protect the cables 9a, 9b exiting the base 6. It should be noted from Figure 4 that the lid 4 includes a main portion and the exit flap 17 pivots relative to the main portion 21. This pivoting arrangement will be described in greater detail with reference to latter illustrations. [0035] Referring now to Figure 5 which illustrates a partial cross section of the floor box 1 around the side wall 13 associated with the power mounting bracket 14a. The power socket 7a is illustrated with a plug 8 inserted into the socket 7a. The lid 4 is in the closed position relative to the frame 3, and it can be noted that an upper surface of the lid 4 is planar with an upper surface of the frame 3. When the lid 4 is in this position it is preferred in use that the cable 9a exit the floor box 1 adjacent the exit flap 17. Figure 5 also illustrates a gap x-x between the lid 4 and the frame 3. In a preferred embodiment this gap is no more than 10mm, and particularly in the preferred embodiment the gap x-x is occupied by the substantially by protector means 5. Brad - Floor Box dictation specificaion 1 July 2014 8 [0036] The protector means 5 may take a suitable form for protecting the cable 9. One form is illustrated in Figure 5 as including a lid portion 22 and a frame portion 23. In the arrangement illustrated the lid portion 22 seats on the frame portion 23 when the lid 4 is in the closed position. [0037] Figure 6 illustrates the arrangement whereby the cable 9a has come lose from the cable retainer 15 or may have been inadvertently incorrectly inserted into the floor box 1 whereby extends out adjacent a side wall 13 of the floor box 1 rather than adjacent a front wall 16. It will be appreciated from Figure 6 that as the lid 4 is moved towards the closed position it will engage the cable 9 so that the cable 9a is squeezed between the lid 4 and the frame 3. Whilst this arrangement is not ideal, the protector means 5 is designed to protect the cable 9a if it is inadvertently found to be located in this position. [0038] Figure 7 illustrates a preferred embodiment of the covering 2 according to another aspect of this invention. More specifically it is preferred that the elements of the covering 2 be each formed as an assembly. The elements of the covering 2 in summary include the lid 4, the lid portion 22 of the protector means, the frame portion 23 of the protector means 5 and the frame 3. The lid 4 is preferably an assembly of elements including a metal backing plate 24, a top plate 25, an exit flap body 26 and an exit flap cap 27. These elements may be formed from any suitable metal however it is preferred that at least top plate 25 and the exit flap cap 27 are formed from stainless steel. The backing plate and the exit flap body may be formed from mild steel. [0039] Figure 7 illustrates the lid portion 22 of the protector means 5 is positioned between the backing plate 24 and the top plate 25. The lid portion 22 illustrated includes a rebate to receive the top plate 25. The top plate 25 and lid portion 22 illustrated each includes a central cut-out to receive a portion of carpet (not shown) which corresponds to the carpet used on the floor. Naturally, if a carpeted lid is not required, the top plate could be a continuous stainless steel plate. [0040] Figure 7 also illustrates the exit flap body 26 being formed with a retaining groove 28 for retaining a pivoting rod 29. The lid portion 22 includes a Brad - Floor Box dictation specificaion 1 July 2014 9 pair of recesses 30 to accommodate ends of the rod 29 so as to allow the flap body 26 to pivot relative to the lid portion 22. [0041] It should also be noted from Figure 7 that the lid portion 22 also includes a pivoting rod 31 for pivoting the lid 4 relative to the frame 3. It is preferred that the rod 31 be formed integrally with the lid portion 22. [0042] Figure 7 also illustrates the preferred elements of the frame 3 including in summary a top plate 32, a backing plate 33, and a packer 34. A further packer may be included in the frame 3 for spacing the frame 3 relative to the base 6, particularly if there is thick carpet on the floor. [0043] Figure 7 also illustrates a preferred embodiment of the frame portion 23 of the protector means 5. The frame portion 23 illustrated includes an edge 35 shape to protect the cable 9 (see fig 8) which extends around the majority of the inner surface of frame portion 23. Figure 7 illustrates a break in the shaped edge 35 adjacent the exit flap, however this shaped edge 35 could be continuous across. It is at least preferred that the shaped edge extend along the sides of the frame portion that are adjacent the side walls 13 of the base when assembled. [0044] The protector means 5 may be formed from any suitable material, however in the preferred embodiment it is formed from a polymer selected from any one of the following: polyamide, polyvinylchloride, ABS or polystyrene. Clearly other materials for the protector means may also be found suitable. [0045] Figure 8 illustrates a partial sectional view similar to figure 5 with the cable 9a exiting adjacent the side wall 13 of the floor box 1. When the lid approaches the closed position, the cable 9a is caught between the lid 4 and the frame 3. Figure 9 illustrates the cable 9a lying over the frame portion 23, with the lid portion 22 lying on top of the cable 9a. The complimentary shape of the lid portion 22 and frame portion 23 define a path 36 there between for accommodating the cable 9a. The preferred path as illustrated includes a pair of return bends with a straight section between each bend so as to reduce the likelihood of the lid 4 applying a cutting force to the cables. It is preferred that lid portion 22 and the frame portion 23 be shaped that that the bends in the path Brad - Floor Box dictation specificaion 1 July 2014 10 have a radius of no less than 3mm however this is merely preferred. Furthermore, the straight section between each bend encourages the cable 9a to cushion the lid 4 rather than be cut by the lid 4. The length of the straight section is preferably at least 3mm. Figure 9 also illustrates the path 36 having an exit section which makes an acute angle with the frame 3 which again reduces the likelihood of the cable sticking up from the floor box causing a tripping hazard. [0046] It ought to be appreciated from the forgoing that the invention provides a relatively simple and unique solution to the issue of floor boxes 1 cutting electrical cables 9. Various alterations and/or additions may be introduced to the covering and floor box as hereinbefore described without departing from the spirit or ambit of the invention. [0047] Future patent applications may be filed in Australia or overseas on the basis of or claiming priority from the present application. It is to be understood that the following provisional claims are provided by way of example only, and are not intended to limit the scope of what may be claimed in any such future application. Features may be added to or omitted from the provisional claims at a later date so as to further define or re-define the invention. Brad - Floor Box dictation specificaion 1 July 2014

Claims

1. A covering for forming part of a floor box accommodating at least one socket outlet to which an electrical cable with a plug can be connect to when in use, the floor box including a base which in use houses the at least one socket, the covering including a frame made of metal positioned in use adjacent the base, a lid made of metal which is movable relative to the frame between an open position and a closed position whereby in the closed position the lid is substantially aligned with the frame, and a protector means which is shaped so as to protect the electrical cable when in use positioned between the lid and the frame inhibiting the lid from adopting the closed position.

2. A covering according to claim I including a gap of no more than 10mm between the lid and the frame when the lid is in the closed position.

3. A covering according to claim 2 wherein the protector means occupies at least a portion of said gap.

4. A covering according to any one of claims 1 to 3 wherein the protector means is formed from a plastics material.

5. A covering according to any one of the preceding claims wherein the protector means includes a lid portion associated with the lid and or a frame portion associated with the frame, the lid portion and or frame portion have an edge shaped to protect the cable.

6. A covering according to claim 5 wherein the protector means includes both the lid portion and the frame portion each of which have an edge complementary shaped to protect the cable.

7. A covering according to claim 6 wherein the complementary shape defines a path there between for the cable when the lid approaches the closed position.

8. A covering according to claim 7 wherein the path includes at least one bend with a radius of no less than 3mm.

9. A covering according to 8 wherein the path includes a pair of return bends with a relatively straight section between each bend.

10.A covering according to claim 9 wherein the straight section is substantially parallel to an upper surface of the lid. 12

11.A covering according to claim 10 wherein the path includes an exit section that extends in a direction to make an acute angle with the frame.

12.A covering according to any one of the preceding claims wherein the lid pivots relative to the frame when moving between the open position and the closed position.

13.A covering according to any one of the preceding claims wherein both the lid and frame each have an upper surface which is substantially co planar when the lid is in the closed position.

14.A covering according to any one of the preceding claims wherein the lid includes at least one exit through which the cable can exit when the lid is in the closed position.

15.A covering according to claim 14 wherein the lid includes a main portion and an exit flap which pivots relative to the main portion to adopt an open condition to allow the cable to exit.

16.A covering according to claim 15 wherein the lid includes a fixed side at which the lid pivots relative to the frame and a free side which raises and lowers relative to the frame, the exit flap being located at the free side.

17.A covering according to claim 16 wherein the protector means extends from at least the free side to the fixed side of the lid.

18.A covering according to claim 17 wherein the protector means extends along the free side to the exit flap.

19.A covering according to any one of the preceding claims wherein the lid and the frame are made from stainless steel.

20.A covering according to any one of the preceding claims wherein the protector means is formed from a polymer material.

21.A covering according to claim 20 wherein the polymer is selected from any one of the following polyamide, PVC, ABS or polystyrene.

22.A covering according to claim 20 or 21 wherein the polymer is relatively hard.

23.A covering according to claim 20 or 21 wherein the polymer is relatively soft.

24.A covering according ot claim 23 wherein the polymer is formed from neoprene, foamed synthetic material, polyurethane or polyethylene. 13

25.A floor box for accommodating at least one socket outlet to which an electrical cable with a plug can be connect to when in use, the floor box including a base for housing said at least one socket when in use, and a covering according to any one of the preceding claims attached to the base.

26.A floor box according to claim 25 wherein the at least one socket includes any one or more of the following a power outlet, a data outlet or a communications outlet.

27.A floor box according to claim 25 or 26 wherein the base includes a cable retainer for retaining the cables exiting the base adjacent one wall of the base.

28.A floor box according to any one of claims 25 to 27 wherein the base is configured relative to the covering so that can lid adopt the closed position while the plug is connected to the socket.