AU2017100897B4

AU2017100897B4 - A covering for use with a floor box

Info

Publication number: AU2017100897B4
Application number: AU2017100897A
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: 2017-06-30
Publication date: 2018-02-01
Anticipated expiration: 2023-07-16
Also published as: NZ710135A; AU2015204344A1; AU2019268210B2; AU2019268210A1; AU2015204344B2; AU2017100897A4

Abstract

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.

Description

(21) Application No: 2017100897 (22) Date of Filing: 2017.06.30 (45) Publication Date: 2017.08.03 (45) Publication Journal Date: 2017.08.03 (45) Granted Journal Date: 2017.08.03 (45) Certified Journal Date: 2018.02.01 (62) Divisional of:

2015204344 (71) Applicant(s)

Electric Cable Duct Systems Pty. Ltd.

(72) Inventor(s)

Booth, Bradley Noel;Cesarin, Daniele (74) Agent / Attorney

Phillips Ormonde Fitzpatrick, PO Box 323, Collins Street West, VIC, 8007, AU (56) Related Art

LEGRAND, ‘Workstation Solutions Power and Data Distribution for the Office Environment’, April 2014.

SCHNEIDER ELECTRIC, ‘Power, Data & Audiovisual Anywhere, Anytime Moduline Floor Boxes Clipsal by Scheider Electric’, 2012.

SCHNEIDER ELECTRIC, OptiLine 45 The 45 direct Click-in installation system’, 2013.

US 2005/0050820 A1 WO 2013/063640 A1 WO 2009/004301 A2

2017100897 30 Jun2017

ABSTRACT

2017100897 30 Jun2017

A Covering for use with a Floor Box [0001] The present application is a divisional application from Australian Patent Application No. 2015204344, the entire disclosure of which is incorporated herein by reference.

[0002] 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.

[0003] 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.

[0004] 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.

2017100897 30 Jun2017 [0005] 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.

[0006] It would be desirable to provide a solution to these safety issues.

[0007] 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.

[0008] 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 connected 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 pivots 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, the lid including a main portion and an exit flap which pivots relative to the main portion, and a protector means formed from a polymer material which is shaped so as to protect the electrical cable when in use the cable is positioned between the lid and the frame inhibiting the lid from adopting the closed position.

[0009] The lid and frame may be made from any suitable metal, however it is preferred from an aesthetics perspective that they are made from stainless steel. It is further preferred that the lid and frame each have an upper surface which is substantially co-planar when the lid is in the closed position as this facilitates providing a relatively safe trafficable surface.

[0010] 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 when the lid moves between the open position and the closed position, and it is preferred that the exit flap be located at the free side, and the protector means extends

2017100897 30 Jun 2017 from at least the free side to the fixed side of the lid. The protector means may also extend further along the free side incorporating the flap.

[0011] The covering may include a gap between the lid and frame to facilitate free movement of the lid relative to the frame and in one preferred embodiment the gap is no more than 10mm between the lid and the frame when the lid is in the closed position. It is further preferred that the protector means including a lid portion associated with the lid occupying at least a portion of said gap.

[0012] 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 connected to when in use, the floor box including a base for housing said at least one socket when in use the base having at least one knock-out for creating a hole in the base, and a covering as herein before defined attached to the base.

[0013] 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.

[0014] Figure 1 is an isometric view of a floor box according to a preferred embodiment of the invention.

[0015] Figure 2 is an exploded view of the floor box from Figure 1.

[0016] Figure 3 is the floor box from Figure 1 with the lid in a partially closed position.

[0017] 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.

[0018] Figure 5 is a partial sectional view of the lid in the closed position from Figure 4.

2017100897 30 Jun 2017 [0019] Figure 6 is the box from Figure 3 with one of the cables moved away from the exit.

[0020] Figure 7 is an exploded view of a preferred embodiment of a covering according to another aspect of this invention.

[0021] 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.

[0022] Figure 9 is the sectional view from Figure 8 with the lid and frame engaging the cable.

[0023] 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 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.

[0024] 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.

[0025] 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

2017100897 30 Jun 2017 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.

[0026] 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.

[0027] 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.

[0028] 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.

[0029] 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

2017100897 30 Jun2017 exit flap 17 pivots relative to the main portion 21. This pivoting arrangement will be described in greater detail with reference to latter illustrations.

[0030] 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.

[0031] 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.

[0032] 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.

[0033] 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

2017100897 30 Jun2017 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.

[0034] 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.

[0035] 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 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.

[0036] 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.

[0037] 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.

[0038] 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.

2017100897 30 Jun2017 [0039] 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.

[0040] 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 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.

[0041] 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.

[0042] 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

2017100897 30 Jun 2017 provisional claims at a later date so as to further define or re-define the invention.

2017100897 30 Jun2017

Claims

THE CLAIMS DEFINING THE INVENTION ARE AS FOLLOWS:

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 connected 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 pivots 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, the lid including a main portion and an exit flap which pivots relative to the main portion, and a protector means formed from a polymer material which is shaped so as to protect the electrical cable when in use the cable is positioned between the lid and the frame inhibiting the lid from adopting the closed position.
2. A covering according to claim 1 wherein both the lid and frame are made from stainless steel, and each have an upper surface which is substantially coplanar when the lid is in the closed position.
3. A covering according to any one of the preceding claims 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 when the lid moves between the open position and the closed position, the exit flap being located at the free side, and the protector means extends from at least the free side to the fixed side of the lid.
4. A covering according to any one of the preceding claims including a gap of no more than 10mm between the lid and the frame when the lid is in the closed position, with the protector means including a lid portion associated with the lid occupying at least a portion of said gap.

2017100897 30 Jun2017
5. A floor box for accommodating at least one socket outlet to which an electrical cable with a plug can be connected to when in use, the floor box including a base for housing said at least one socket when in use the base having at least one knock-out for creating a hole in the base, and a covering according to any one of the preceding claims attached to the base.

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FIGURE 1

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FIGURE 2

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FIGURE 5

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FIGURE 6

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FIGURE 7

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FIGURE 8

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