CA2507586C - Wall recessed outlet box assembly - Google Patents
Wall recessed outlet box assembly Download PDFInfo
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- CA2507586C CA2507586C CA 2507586 CA2507586A CA2507586C CA 2507586 C CA2507586 C CA 2507586C CA 2507586 CA2507586 CA 2507586 CA 2507586 A CA2507586 A CA 2507586A CA 2507586 C CA2507586 C CA 2507586C
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- faceplate
- outlet box
- support housing
- box assembly
- inner faceplate
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Abstract
An outlet box assembly includes an outer faceplate having an interior opening. An inner faceplate is connected to the outer faceplate such that the inner faceplate is recessed from the outer faceplate and access to the inner faceplate is provided through the interior opening. The inner faceplate has an outlet port and a communication port. The outlet box assembly further includes a support housing having an inner surface and an interior region bounded by the inner surface. The support housing is connected to a rear surface of the inner faceplate such that the outlet port provides access to the interior region. The support housing is configured to allow insertion of an electrical receptacle into the interior region and to provide an enclosure for the electrical receptacle.
Description
WALL RECESSED OUTLET BOX ASSEMBLY
BACKGROUND OF THE INVENTION
[00011 The present invention relates generally to outlet boxes for mounting electrical outlets and connectors on wall structures, and more particularly, to such an outlet box in which the electrical outlet and connector is recessed from the wall structure.
[00021 Electrical outlet boxes which support an electrical receptacle and a connector are known. Such outlet boxes may support the electrical receptacle in the plane of the outer surface of the wall structure. As a result, when a plug is inserted into the electrical receptacle which is so supported, the plug extends outward of the wall surface. The electrical plug is thereby exposed to being struck by a transverse force such as from a person, piece of furniture or other object which may move along the side of the wall structure in close proximity thereto. If such a transverse force is sufficient, it may dislodge the plug from the electrical receptacle, either partially or completely, or cause damage to the plug or receptacle, as well as a combination PATENT
Attorney Docket No.: 577-658 thereof. Additionally, extension of the electrical plug beyond the outer surface of the wall structure normally prevents the positioning of a piece of furniture, wall hanging or similar object in close proximity to the outer surface of the wall in the vicinity of the electrical receptacle.
Such an object may, for example, be a television which would desirably be positioned close to the outer surface of the wall structure in front of and adjacent to the electrical receptacle. This would enable the power cable from the television to extend to the electrical receptacle for connection thereto and for the power cable and electrical receptacle to be obstructed from view by the television.
[00031 To reduce the extension of the electrical plug beyond the outer surface of the wall structure, electrical boxes may be configured to support the electrical receptacle in a recessed position relative to the outer surface of the wall structure. This recessed position of the electrical receptacle reduces or, if sufficient, eliminates entirely the exposure of the electrical plug to the aforementioned undesirable forcible contact.
[00041 Additionally, electronic devices frequently require connection to an electrical power source and a separate connection to a communication network, such as a telephone or television network, or a local area network (LAN) or the internet for computers. Examples of such electrical devices include telephones, televisions, answering machines and personal computers. Such requirements typically result in separate electrical cables extending from the electronic devices where the power cable is connected to an electrical receptacle and the communication cable is connected to a separate connector, such as a telephone jack, or a connector for digital data transmission or for a coaxial cable.
BACKGROUND OF THE INVENTION
[00011 The present invention relates generally to outlet boxes for mounting electrical outlets and connectors on wall structures, and more particularly, to such an outlet box in which the electrical outlet and connector is recessed from the wall structure.
[00021 Electrical outlet boxes which support an electrical receptacle and a connector are known. Such outlet boxes may support the electrical receptacle in the plane of the outer surface of the wall structure. As a result, when a plug is inserted into the electrical receptacle which is so supported, the plug extends outward of the wall surface. The electrical plug is thereby exposed to being struck by a transverse force such as from a person, piece of furniture or other object which may move along the side of the wall structure in close proximity thereto. If such a transverse force is sufficient, it may dislodge the plug from the electrical receptacle, either partially or completely, or cause damage to the plug or receptacle, as well as a combination PATENT
Attorney Docket No.: 577-658 thereof. Additionally, extension of the electrical plug beyond the outer surface of the wall structure normally prevents the positioning of a piece of furniture, wall hanging or similar object in close proximity to the outer surface of the wall in the vicinity of the electrical receptacle.
Such an object may, for example, be a television which would desirably be positioned close to the outer surface of the wall structure in front of and adjacent to the electrical receptacle. This would enable the power cable from the television to extend to the electrical receptacle for connection thereto and for the power cable and electrical receptacle to be obstructed from view by the television.
[00031 To reduce the extension of the electrical plug beyond the outer surface of the wall structure, electrical boxes may be configured to support the electrical receptacle in a recessed position relative to the outer surface of the wall structure. This recessed position of the electrical receptacle reduces or, if sufficient, eliminates entirely the exposure of the electrical plug to the aforementioned undesirable forcible contact.
[00041 Additionally, electronic devices frequently require connection to an electrical power source and a separate connection to a communication network, such as a telephone or television network, or a local area network (LAN) or the internet for computers. Examples of such electrical devices include telephones, televisions, answering machines and personal computers. Such requirements typically result in separate electrical cables extending from the electronic devices where the power cable is connected to an electrical receptacle and the communication cable is connected to a separate connector, such as a telephone jack, or a connector for digital data transmission or for a coaxial cable.
PATENT
Attorney Docket No.: 577-658 [0005] To provide the required connection for such cables, the electrical outlet box may have an additional connector for such a cable. Such a cable typically has a cable plug which is coupled to the additional connector. The additional connector may be recessed from the outer surface of the wall structure to reduce the extension of the cable plug which is coupled thereto.
This reduction of the extension of the cable plug may limit or eliminate entirely the exposure thereof to undesirable forcible contact, and the unfavorable consequences, similar to those which may befall an electrical plug which extends beyond the outer surface of the wall structure, as described herein above.
[0006] The electrical receptacle may be supported within the outlet box by securing the front surface of the electrical receptacle to a vertical flange or similar structure within the outlet box. This may be the only support provided to the electrical receptacle within the outlet box.
This limited support may result from clearances being provided between the outer surfaces of the electrical receptacle which do not contact the vertical flange or other support structure within the outlet box. This limited support may necessitate a high strength connection between the limited surface of the electrical receptacle which is directly attached to the outlet box. In the absence of such a high strength connection, the electrical receptacle may undesirably translate or pivot relative to the outlet box, such as when the electrical plug is inserted into the electrical receptacle or if the electrical plug, after insertion thereof into the electrical receptacle, is contacted by an external force.
Attorney Docket No.: 577-658 [0005] To provide the required connection for such cables, the electrical outlet box may have an additional connector for such a cable. Such a cable typically has a cable plug which is coupled to the additional connector. The additional connector may be recessed from the outer surface of the wall structure to reduce the extension of the cable plug which is coupled thereto.
This reduction of the extension of the cable plug may limit or eliminate entirely the exposure thereof to undesirable forcible contact, and the unfavorable consequences, similar to those which may befall an electrical plug which extends beyond the outer surface of the wall structure, as described herein above.
[0006] The electrical receptacle may be supported within the outlet box by securing the front surface of the electrical receptacle to a vertical flange or similar structure within the outlet box. This may be the only support provided to the electrical receptacle within the outlet box.
This limited support may result from clearances being provided between the outer surfaces of the electrical receptacle which do not contact the vertical flange or other support structure within the outlet box. This limited support may necessitate a high strength connection between the limited surface of the electrical receptacle which is directly attached to the outlet box. In the absence of such a high strength connection, the electrical receptacle may undesirably translate or pivot relative to the outlet box, such as when the electrical plug is inserted into the electrical receptacle or if the electrical plug, after insertion thereof into the electrical receptacle, is contacted by an external force.
PATENT
Attorney Docket No.: 577-658 SUMMARY OF THE INVENTION
[0007] The outlet box assembly of the present invention includes an outer faceplate having an interior opening. An inner faceplate is connected to the outer faceplate such that the inner faceplate is recessed from the outer faceplate and access to the inner faceplate is provided through the interior opening. The inner faceplate has an outlet port and a communication port.
[0008] The outlet box assembly further includes a support housing having an inner surface and an interior region bounded by the inner surface. The support housing is connected to a rear surface of the inner faceplate such that the outlet port provides access to the interior region. The support housing is configured to allow insertion of an electrical receptacle into the interior region and to provide an enclosure for the electrical receptacle.
[0009] The enclosure of the electrical receptacle by the support housing provides protection to the electrical receptacle and limits access thereto which is normally desirable. The connection of the support housing to the rear surface of the inner faceplate, and the recess of the inner faceplate from the outer faceplate provides for the recess of the electrical receptacle from the outer faceplate. Consequently, an electrical plug, which may be inserted into the electrical receptacle, is recessed from the outer faceplate thereby reducing the the likelihood of the electrical plug being contacted by an external force. Also, the recess of the inner faceplate from the outer faceplate results in the communication port being recessed from the outer faceplate. A
receptacle may be supported in the communication port and a cable plug may be inserted into the receptacle. The recess of the communication port results in the cable plug being recessed which reduces the likelihood of the cable plug being contacted by an external force.
[0009.1 ] According to one aspect of the present invention there is provided an outlet box assembly comprising an outer faceplate having an interior opening, the interior opening having an outer periphery; an inner faceplate connected to the outer faceplate such that the inner faceplate is recessed from the outer faceplate and access to the inner faceplate is provided through the interior opening, the inner faceplate having a planar front surface which is separated from the outer periphery by a distance which is orthogonal relative to the front surface of the outer faceplate, the distance being constant along the outer periphery, the inner faceplate having an outlet port and a communication port; and a support housing having an inner surface and an interior region bounded by the inner surface, the support housing being connected to a rear surface of the inner faceplate such that the outlet port provides access to the interior region, the support housing being configured to allow insertion of an electrical receptacle into the interior region and to provide an enclosure for the electrical receptacle; the inner faceplate having at least a first portion extending beyond the support housing, the first portion including the communication port, the first portion being disposed outside of the support housing and having a rear surface that is unenclosed wherein access to the communication port via the rear surface is unrestricted by a housing.
[0009.2] According to a further aspect of the present invention there is provided an outlet box assembly comprising a support housing having an interior for receiving an electrical receptacle; an inner faceplate extending outwardly from the support housing and defining an opening to the support housing interior, the inner faceplate having a first portion including a communication port adapted to receive a receptacle, the communication port being disposed outside the support housing, the inner face plate first portion and the opening to the support housing interior lying in a common plane; a flange extending from the inner faceplate, the flange and inner faceplate forming a chamber adapted to contain an electrical plug, the inner faceplate first portion having an upper surface bounding the chamber and an opposed lower surface, the lower surface being unenclosed and wherein access to the receptacle received in the communication port is permitted from the exterior of the outlet box assembly; an outer faceplate disposed on the flange, wherein the inner faceplate is recessed from the outer faceplate.
[0009.3] According to another aspect of the present invention there is provided an outlet box assembly comprising a support housing having an opening for receiving an electrical receptacle and the opening lying in a first plane, the support housing including an exterior; an inner faceplate extending outwardly from the support housing, the inner faceplate having a first portion lying in a second plane, the first portion including a communication port adapted to receive a receptacle, the first plane and the second planes being substantially parallel to each other, the communication port being disposed outside the support housing, the inner face plate having an exterior surface; a flange extending 5a from the inner faceplate, the flange and inner faceplate forming a chamber adapted to contain an electrical plug, the flange having an exterior surface; the inner faceplate first portion having an upper surface bounding the chamber and an opposed lower surface, the lower surface being unenclosed and wherein access to the receptacle received in the communication port is permitted from the exterior of the outlet box assembly;
an outer faceplate disposed on the flange, wherein the inner faceplate is recessed from the outer faceplate.
[0010] These and other features of the invention will be more fully understood from the following description of specific embodiments of the invention taken together with the accompanying drawings.
5b PATENT
Attorney Docket No.: 577-658 BRIEF DESCRIPTION OF THE DRAWINGS
[0011] In the drawings:
[0012] Fig. 1 is a front perspective view of the wall recessed outlet box assembly of the present invention before assembly of the electrical receptacle and interior faceplate thereto and removal of the knockouts from the outer faceplate;
[0013] Fig. 2 is a front elevation view of the outlet box assembly of Fig. 1;
[0014] Fig. 3 is a rear elevation view of the outlet box assembly of Fig. 1 showing the arms in the retracted and clamped positions;
[0015] Fig. 4 is a right side elevation view of the outlet box assembly of Fig. 1 showing the arms in the clamped positions;
[0016] Fig. 5 is a left side elevation view of the outlet box assembly of Fig.
1 showing the arms in the clamped positions;
[0017] Fig. 6 is a top plan view of the outlet box assembly of Fig. 1;
[0018] Fig. 7 is a bottom plan view of the outlet box assembly of Fig. 1;
[0019] Fig. 8 is a front elevation view of the outlet box assembly of Fig. 1 after assembly of the electrical receptacle and interior faceplate thereto and removal of the knockouts from the outer faceplate;
PATENT
Attorney Docket No.: 577-658 [0020] Fig. 9 is a rear elevation view of the outlet box assembly of Fig. 8 showing the arms in the retracted and clamped positions;
[0021] Fig. 10 is a front elevation view of an alternative second embodiment of the outlet box assembly of Fig. 1 after assembly of the electrical receptacle and interior faceplate thereto and removal of the knockouts from the outer faceplate, the outlet box assembly having an alternative configuration of the communication ports;
[0022] Fig. 11 is a rear elevation view of the outlet box assembly of Fig. 10 showing the arms in the retracted and clamped positions;
[0023] Fig. 12 is a front elevation view of an alternative third embodiment of the outlet box assembly of Fig. 1 after assembly of the electrical receptacle and interior faceplate thereto and removal of the knockouts from the outer faceplate, the outlet box assembly having an alternative configuration of the communication ports;
[0024] Fig. 13 is a rear elevation view of the outlet box assembly of Fig. 12 showing the arms in the retracted and clamped positions;
[0025] Fig. 14 is a front elevation view of an alternative fourth embodiment of the outlet box assembly of Fig. 1 after assembly of the electrical receptacle and interior faceplate thereto and removal of the knockouts from the outer faceplate, the outlet box assembly having an alternative configuration of the communication ports;
PATENT
Attorney Docket No.: 577-658 [0026] Fig. 15 is a rear elevation view of the outlet box assembly of Fig. 14 showing the arms in the retracted and clamped positions;
[0027] Fig. 16 is a front elevation view of an alternative fifth embodiment of the outlet box assembly of Fig. 1 after assembly of the electrical receptacle and interior faceplate thereto and removal of the knockouts from the outer faceplate, the outlet box assembly having an alternative configuration of the communication ports;
[0028] Fig. 17 is a rear elevation view of the outlet box assembly of Fig. 16 showing the arms in the retracted and clamped positions;
[0029] Fig. 18 is a front elevation view of an alternative sixth embodiment of the outlet box assembly of Fig. 1 after assembly of the electrical receptacle and interior faceplate thereto and removal of the knockouts from the outer faceplate, the outlet box assembly having an alternative configuration of the communication ports; and [0030] Fig. 19 is a rear elevation view of the outlet box assembly of Fig. 18 showing the arms in the retracted and clamped positions.
[0031] Corresponding reference characters indicate corresponding parts throughout the several views of the drawings.
PATENT
Attorney Docket No.: 577-658 DETAILED DESCRIPTION OF THE INVENTION
[0032] Referring to the drawings and more particularly to Figs. I to 7, a wall recessed outlet box assembly 10 is shown for mounting to a wall structure 12, such as the vertical wall board of an interior wall of a building structure.
[0033] The outlet box assembly 10 includes an outer faceplate 14 which has an interior opening 16 and a rear surface 18. The outer faceplate 14 is planar and has an outer edge which may be beveled.
[0034] A flange structure 20 is fixed to the rear surface 18 and has a top flange 22, a pair of side flanges 24, and a bottom flange 26 which are fixed to one another such that each of the side flanges is between the top and bottom flanges in perpendicular relation thereto. This results in the flange structure 20 having a vertical cross-section which is rectangular.
[0035] The outlet box assembly 10 includes an inner faceplate 28 having a front surface 30 which is fixed to the rear edges of the flange structure 20 such that the inner faceplate is recessed from the outer faceplate 14. The inner faceplate 28 is planar and parallel to the outer faceplate. Access to the inner faceplate 28 is provided through the interior opening 16.
[0036] The inner faceplate 28 has an outlet port 31 and knockouts 33. The outer peripheries of the knockouts 33 are indented in the rearward direction to form grooves 34 as shown in Fig. 2. The grooves 34 may be indented by a dimension, such as 50 mils. The rear PATENT
Attorney Docket No.: 577-658 ends of the knockouts 33 do not extend to the rear surface 35 of the inner faceplate 28 resulting in the knockouts being indented in the forward direction. These indentations of the knockouts 33 may be by a dimension, such as 50 mils. The knockouts 33 are removed to provide communication ports 36 in the inner faceplate 28. The communication ports 36 provide openings in which receptacles, such as telephone jacks, co-axial cable connectors or plugs for electrical cables, may be supported. Such cables may be for telephone, cable television, personal computers, data transmissions or digital communications. The communication ports 36 may be referred to as data ports.
[00371 The cross-sections of the communication ports 36 may vary in shape to be compatible with the connectors to be supported therein. For example, as shown Fig. 8, the communication ports 36 may include rectangular communication ports 37 each of which has a rectangular cross-section. The communication ports 36 may further include circular/hexagonal communication ports 38 each of which has a forward end 40 which intersects the front surface 30 of the inner faceplate 28, as shown in Fig. 9. Each forward end 40 has a circular cross-section.
The circular/hexagonal communication ports 38 each have a rear end 42 which intersects the rear surface 35 of the inner faceplate 28, as shown in Fig. 9. Each rear end 42 has a hexagonal cross-section.
[00381 Additionally, the communication ports 36 may vary in number and in configuration relative to the outlet port 31. For example, as shown in Figs. 2 and 3, the communication ports 36 are arranged such that two of the rectangular communication ports 37 PATENT
Attorney Docket No.: 577-658 are arranged above two of the circular/hexagonal communication ports 38 in respective columns on either side of the outlet port 31.
[0039] Other configurations for the communication ports 36 are possible as shown in the alternative embodiments of Figs. 10 to 19. Parts illustrated in Figs. 10 to 19 which correspond to parts illustrated in Figs. 1 to 9 have the same reference numeral as in Figs.
1 to 9 with the addition of the suffix "a" in Figs. 10 and 11, suffix "b" in Figs. 12 and 13, suffix "c" in Figs. 14 and 15, suffix "d" in Figs. 16 and 17, and suffix "e" in Figs. 18 and 19.
[0040] Referring now to Figs. 1, 4 and 5, the outlet box assembly 10 includes a support housing 46 having an outlet box 48 including a top wall 50, a pair of side walls 52, and a bottom wall 54 each of which has a front edge which is fixed to the rear surface 35 of the inner faceplate 28 such that the top, side and bottom walls are perpendicular to the inner faceplate 28. The top wall 50, side walls 52 and bottom wall 54 are fixed to one another such that each of the side walls is between the top and bottom walls in perpendicular relation thereto.
This results in the outlet box 48 having a vertical cross-section which is rectangular.
[0041] The outlet box 48 includes a rear wall 56 fixed to the rear edges of the top wall 50, side walls 52 and bottom wall 54 such that the top, side and bottom walls are between the rear wall and inner faceplate 28 and the rear wall 56 is parallel to the inner faceplate 28. The rear wall 56 has a dome-shaped protrusion 58 extending inwardly from the front surface thereof and a corresponding indentation on the rear surface of the rear wall. Elongate support ribs 60 are secured to the front surface of the rear wall 56. The support ribs 60 bisect the front surface both PATENT
Attorney Docket No.: 577-658 horizontally and vertically and intersect the dome-shaped protrusion 58. The dome-shaped protrusion 58 and support ribs 60 provide structural support to the rear wall 56.
[00421 The top wall 50, side walls 52, bottom wall 54, and rear wall 56 each have an inner surface each of which defines a portion of the inner surface 62 of the support housing 46.
The inner surface 62 bounds an interior region 64 of the support housing 46.
Access to the interior region 64 is provided by the outlet port 31.
[00431 The support housing 46 includes an upper shoulder 66 which extends downwardly from the lower surface of the top wall 50, and a lower shoulder 68 which extends upwardly from the upper surface of the bottom wall 54. The upper and lower shoulders 66, 68 are formed by elongate recesses in the upper surface of the top wall 50 and lower surface of the bottom wall 54, as shown in Fig. 3. The upper and lower shoulders 66, 68 are perpendicular to the plane of the inner faceplate 28 and are equidistant from the side walls 52.
[00441 The inner faceplate 28 has upper and lower tab portions 70, 72 which extend downwardly and upwardly, respectively, to cover the forward ends of the upper and lower shoulders 66, 68. Each of the tab portions 70, 72 has an opening through which an elongate fastener may be inserted.
[0045] The top and bottom walls 50, 54 each have a pair of notches 74 at the corners formed by the intersection of the rear wall 56 with the top wall 50, side walls 52 and bottom wall 54. The forward ends of the notches 74 terminate at wire ports 76.
PATENT
Attorney Docket No.: 577-658 [0046] The outlet box assembly 10 includes a pair of clips 78 each of which has a post 80 and an arm 82 pivotally connected to the post in perpendicular relation thereto. Each post 80 is connected to the front surface 30 of the inner faceplate 28 adjacent to opposing corners thereof, as shown in Figs. 1 and 2. Each of the arms 82 is coupled to an elongate member, such as a pin 84, which extends through an elongate cavity in the post 80, as shown in Figs.
2 and 3. The forward end of the pin 84 has a head 86 to which may be coupled a tool for rotating the pin.
Such coupling may be provided, for example, by forming in the front surface of the head 86 a recess which may be engaged by a screw driver. Rotation of the pin 84, such as by a screw driver, causes pivoting of the arm 82 about the associated post 80. Each of the arms 82 may be thereby be swung between a retracted position 88 in which the arm is within the outer periphery 90 of the inner faceplate 28 and a clamped position 92 in which the arm extends beyond the outer periphery 90.
[0047] The outlet box assembly 10 is prepared for mounting to the wall structure 12 by removing the knockouts 33, such as by applying a force thereto which is sufficient to fracture the knockouts from the inner faceplate 28. Such fracturing will occur along the grooves 34 resulting in the cross-sections of the communication ports 36 having the specific shapes shown in Figs. 2, 3, and 10 to 19. Alternatively, the knockouts 33 may be removed by cutting the outer peripheries thereof at the grooves 34. Knockouts 33 which are removed by such cutting may be referred to as cutouts.
PATENT
Attorney Docket No.: 577-658 [0048] The preparation of the outlet box assembly 10 for mounting to the wall structure 12 further includes assembling an electrical receptacle 94 to the outlet box assembly. Such assembly may be either before or after the removal of the knockouts 33 from the inner faceplate 28.
[0049] The electrical receptacle 94 is assembled to the outlet box assembly 10 by insertion of the electrical receptacle 94 through the interior opening 16 and outlet port 31 into the interior region 64 of the support housing 46. The electrical receptacle 94 has an outer surface 96 and elongate slots 98 to receive the prongs of an electrical plug. When the electrical plug is inserted into the electrical receptacle 94, at least a portion of the plug or possibly the entire plug is contained within the flange structure 20.
[0050] The wire ports 76 provide a pathway for wires to extend from the electrical receptacle 94 within the interior region 64 to a location outside of the support housing 46.
Provision of the wire ports 76 at the top and bottom walls 50, 54 accommodates wires which are connected to the top or bottom of the electrical receptacle 94, typically to the rear thereof. Such wires typically extend to the power source for the provision of electrical power to the electrical receptacle 94. This results in electrical power being supplied to an electrical plug inserted in the electrical receptacle 94.
[0051] The insertion of the electrical receptacle 94 into the interior region 64 is facilitated by the configuration of the support housing 46. For example, the configuration of the
Attorney Docket No.: 577-658 SUMMARY OF THE INVENTION
[0007] The outlet box assembly of the present invention includes an outer faceplate having an interior opening. An inner faceplate is connected to the outer faceplate such that the inner faceplate is recessed from the outer faceplate and access to the inner faceplate is provided through the interior opening. The inner faceplate has an outlet port and a communication port.
[0008] The outlet box assembly further includes a support housing having an inner surface and an interior region bounded by the inner surface. The support housing is connected to a rear surface of the inner faceplate such that the outlet port provides access to the interior region. The support housing is configured to allow insertion of an electrical receptacle into the interior region and to provide an enclosure for the electrical receptacle.
[0009] The enclosure of the electrical receptacle by the support housing provides protection to the electrical receptacle and limits access thereto which is normally desirable. The connection of the support housing to the rear surface of the inner faceplate, and the recess of the inner faceplate from the outer faceplate provides for the recess of the electrical receptacle from the outer faceplate. Consequently, an electrical plug, which may be inserted into the electrical receptacle, is recessed from the outer faceplate thereby reducing the the likelihood of the electrical plug being contacted by an external force. Also, the recess of the inner faceplate from the outer faceplate results in the communication port being recessed from the outer faceplate. A
receptacle may be supported in the communication port and a cable plug may be inserted into the receptacle. The recess of the communication port results in the cable plug being recessed which reduces the likelihood of the cable plug being contacted by an external force.
[0009.1 ] According to one aspect of the present invention there is provided an outlet box assembly comprising an outer faceplate having an interior opening, the interior opening having an outer periphery; an inner faceplate connected to the outer faceplate such that the inner faceplate is recessed from the outer faceplate and access to the inner faceplate is provided through the interior opening, the inner faceplate having a planar front surface which is separated from the outer periphery by a distance which is orthogonal relative to the front surface of the outer faceplate, the distance being constant along the outer periphery, the inner faceplate having an outlet port and a communication port; and a support housing having an inner surface and an interior region bounded by the inner surface, the support housing being connected to a rear surface of the inner faceplate such that the outlet port provides access to the interior region, the support housing being configured to allow insertion of an electrical receptacle into the interior region and to provide an enclosure for the electrical receptacle; the inner faceplate having at least a first portion extending beyond the support housing, the first portion including the communication port, the first portion being disposed outside of the support housing and having a rear surface that is unenclosed wherein access to the communication port via the rear surface is unrestricted by a housing.
[0009.2] According to a further aspect of the present invention there is provided an outlet box assembly comprising a support housing having an interior for receiving an electrical receptacle; an inner faceplate extending outwardly from the support housing and defining an opening to the support housing interior, the inner faceplate having a first portion including a communication port adapted to receive a receptacle, the communication port being disposed outside the support housing, the inner face plate first portion and the opening to the support housing interior lying in a common plane; a flange extending from the inner faceplate, the flange and inner faceplate forming a chamber adapted to contain an electrical plug, the inner faceplate first portion having an upper surface bounding the chamber and an opposed lower surface, the lower surface being unenclosed and wherein access to the receptacle received in the communication port is permitted from the exterior of the outlet box assembly; an outer faceplate disposed on the flange, wherein the inner faceplate is recessed from the outer faceplate.
[0009.3] According to another aspect of the present invention there is provided an outlet box assembly comprising a support housing having an opening for receiving an electrical receptacle and the opening lying in a first plane, the support housing including an exterior; an inner faceplate extending outwardly from the support housing, the inner faceplate having a first portion lying in a second plane, the first portion including a communication port adapted to receive a receptacle, the first plane and the second planes being substantially parallel to each other, the communication port being disposed outside the support housing, the inner face plate having an exterior surface; a flange extending 5a from the inner faceplate, the flange and inner faceplate forming a chamber adapted to contain an electrical plug, the flange having an exterior surface; the inner faceplate first portion having an upper surface bounding the chamber and an opposed lower surface, the lower surface being unenclosed and wherein access to the receptacle received in the communication port is permitted from the exterior of the outlet box assembly;
an outer faceplate disposed on the flange, wherein the inner faceplate is recessed from the outer faceplate.
[0010] These and other features of the invention will be more fully understood from the following description of specific embodiments of the invention taken together with the accompanying drawings.
5b PATENT
Attorney Docket No.: 577-658 BRIEF DESCRIPTION OF THE DRAWINGS
[0011] In the drawings:
[0012] Fig. 1 is a front perspective view of the wall recessed outlet box assembly of the present invention before assembly of the electrical receptacle and interior faceplate thereto and removal of the knockouts from the outer faceplate;
[0013] Fig. 2 is a front elevation view of the outlet box assembly of Fig. 1;
[0014] Fig. 3 is a rear elevation view of the outlet box assembly of Fig. 1 showing the arms in the retracted and clamped positions;
[0015] Fig. 4 is a right side elevation view of the outlet box assembly of Fig. 1 showing the arms in the clamped positions;
[0016] Fig. 5 is a left side elevation view of the outlet box assembly of Fig.
1 showing the arms in the clamped positions;
[0017] Fig. 6 is a top plan view of the outlet box assembly of Fig. 1;
[0018] Fig. 7 is a bottom plan view of the outlet box assembly of Fig. 1;
[0019] Fig. 8 is a front elevation view of the outlet box assembly of Fig. 1 after assembly of the electrical receptacle and interior faceplate thereto and removal of the knockouts from the outer faceplate;
PATENT
Attorney Docket No.: 577-658 [0020] Fig. 9 is a rear elevation view of the outlet box assembly of Fig. 8 showing the arms in the retracted and clamped positions;
[0021] Fig. 10 is a front elevation view of an alternative second embodiment of the outlet box assembly of Fig. 1 after assembly of the electrical receptacle and interior faceplate thereto and removal of the knockouts from the outer faceplate, the outlet box assembly having an alternative configuration of the communication ports;
[0022] Fig. 11 is a rear elevation view of the outlet box assembly of Fig. 10 showing the arms in the retracted and clamped positions;
[0023] Fig. 12 is a front elevation view of an alternative third embodiment of the outlet box assembly of Fig. 1 after assembly of the electrical receptacle and interior faceplate thereto and removal of the knockouts from the outer faceplate, the outlet box assembly having an alternative configuration of the communication ports;
[0024] Fig. 13 is a rear elevation view of the outlet box assembly of Fig. 12 showing the arms in the retracted and clamped positions;
[0025] Fig. 14 is a front elevation view of an alternative fourth embodiment of the outlet box assembly of Fig. 1 after assembly of the electrical receptacle and interior faceplate thereto and removal of the knockouts from the outer faceplate, the outlet box assembly having an alternative configuration of the communication ports;
PATENT
Attorney Docket No.: 577-658 [0026] Fig. 15 is a rear elevation view of the outlet box assembly of Fig. 14 showing the arms in the retracted and clamped positions;
[0027] Fig. 16 is a front elevation view of an alternative fifth embodiment of the outlet box assembly of Fig. 1 after assembly of the electrical receptacle and interior faceplate thereto and removal of the knockouts from the outer faceplate, the outlet box assembly having an alternative configuration of the communication ports;
[0028] Fig. 17 is a rear elevation view of the outlet box assembly of Fig. 16 showing the arms in the retracted and clamped positions;
[0029] Fig. 18 is a front elevation view of an alternative sixth embodiment of the outlet box assembly of Fig. 1 after assembly of the electrical receptacle and interior faceplate thereto and removal of the knockouts from the outer faceplate, the outlet box assembly having an alternative configuration of the communication ports; and [0030] Fig. 19 is a rear elevation view of the outlet box assembly of Fig. 18 showing the arms in the retracted and clamped positions.
[0031] Corresponding reference characters indicate corresponding parts throughout the several views of the drawings.
PATENT
Attorney Docket No.: 577-658 DETAILED DESCRIPTION OF THE INVENTION
[0032] Referring to the drawings and more particularly to Figs. I to 7, a wall recessed outlet box assembly 10 is shown for mounting to a wall structure 12, such as the vertical wall board of an interior wall of a building structure.
[0033] The outlet box assembly 10 includes an outer faceplate 14 which has an interior opening 16 and a rear surface 18. The outer faceplate 14 is planar and has an outer edge which may be beveled.
[0034] A flange structure 20 is fixed to the rear surface 18 and has a top flange 22, a pair of side flanges 24, and a bottom flange 26 which are fixed to one another such that each of the side flanges is between the top and bottom flanges in perpendicular relation thereto. This results in the flange structure 20 having a vertical cross-section which is rectangular.
[0035] The outlet box assembly 10 includes an inner faceplate 28 having a front surface 30 which is fixed to the rear edges of the flange structure 20 such that the inner faceplate is recessed from the outer faceplate 14. The inner faceplate 28 is planar and parallel to the outer faceplate. Access to the inner faceplate 28 is provided through the interior opening 16.
[0036] The inner faceplate 28 has an outlet port 31 and knockouts 33. The outer peripheries of the knockouts 33 are indented in the rearward direction to form grooves 34 as shown in Fig. 2. The grooves 34 may be indented by a dimension, such as 50 mils. The rear PATENT
Attorney Docket No.: 577-658 ends of the knockouts 33 do not extend to the rear surface 35 of the inner faceplate 28 resulting in the knockouts being indented in the forward direction. These indentations of the knockouts 33 may be by a dimension, such as 50 mils. The knockouts 33 are removed to provide communication ports 36 in the inner faceplate 28. The communication ports 36 provide openings in which receptacles, such as telephone jacks, co-axial cable connectors or plugs for electrical cables, may be supported. Such cables may be for telephone, cable television, personal computers, data transmissions or digital communications. The communication ports 36 may be referred to as data ports.
[00371 The cross-sections of the communication ports 36 may vary in shape to be compatible with the connectors to be supported therein. For example, as shown Fig. 8, the communication ports 36 may include rectangular communication ports 37 each of which has a rectangular cross-section. The communication ports 36 may further include circular/hexagonal communication ports 38 each of which has a forward end 40 which intersects the front surface 30 of the inner faceplate 28, as shown in Fig. 9. Each forward end 40 has a circular cross-section.
The circular/hexagonal communication ports 38 each have a rear end 42 which intersects the rear surface 35 of the inner faceplate 28, as shown in Fig. 9. Each rear end 42 has a hexagonal cross-section.
[00381 Additionally, the communication ports 36 may vary in number and in configuration relative to the outlet port 31. For example, as shown in Figs. 2 and 3, the communication ports 36 are arranged such that two of the rectangular communication ports 37 PATENT
Attorney Docket No.: 577-658 are arranged above two of the circular/hexagonal communication ports 38 in respective columns on either side of the outlet port 31.
[0039] Other configurations for the communication ports 36 are possible as shown in the alternative embodiments of Figs. 10 to 19. Parts illustrated in Figs. 10 to 19 which correspond to parts illustrated in Figs. 1 to 9 have the same reference numeral as in Figs.
1 to 9 with the addition of the suffix "a" in Figs. 10 and 11, suffix "b" in Figs. 12 and 13, suffix "c" in Figs. 14 and 15, suffix "d" in Figs. 16 and 17, and suffix "e" in Figs. 18 and 19.
[0040] Referring now to Figs. 1, 4 and 5, the outlet box assembly 10 includes a support housing 46 having an outlet box 48 including a top wall 50, a pair of side walls 52, and a bottom wall 54 each of which has a front edge which is fixed to the rear surface 35 of the inner faceplate 28 such that the top, side and bottom walls are perpendicular to the inner faceplate 28. The top wall 50, side walls 52 and bottom wall 54 are fixed to one another such that each of the side walls is between the top and bottom walls in perpendicular relation thereto.
This results in the outlet box 48 having a vertical cross-section which is rectangular.
[0041] The outlet box 48 includes a rear wall 56 fixed to the rear edges of the top wall 50, side walls 52 and bottom wall 54 such that the top, side and bottom walls are between the rear wall and inner faceplate 28 and the rear wall 56 is parallel to the inner faceplate 28. The rear wall 56 has a dome-shaped protrusion 58 extending inwardly from the front surface thereof and a corresponding indentation on the rear surface of the rear wall. Elongate support ribs 60 are secured to the front surface of the rear wall 56. The support ribs 60 bisect the front surface both PATENT
Attorney Docket No.: 577-658 horizontally and vertically and intersect the dome-shaped protrusion 58. The dome-shaped protrusion 58 and support ribs 60 provide structural support to the rear wall 56.
[00421 The top wall 50, side walls 52, bottom wall 54, and rear wall 56 each have an inner surface each of which defines a portion of the inner surface 62 of the support housing 46.
The inner surface 62 bounds an interior region 64 of the support housing 46.
Access to the interior region 64 is provided by the outlet port 31.
[00431 The support housing 46 includes an upper shoulder 66 which extends downwardly from the lower surface of the top wall 50, and a lower shoulder 68 which extends upwardly from the upper surface of the bottom wall 54. The upper and lower shoulders 66, 68 are formed by elongate recesses in the upper surface of the top wall 50 and lower surface of the bottom wall 54, as shown in Fig. 3. The upper and lower shoulders 66, 68 are perpendicular to the plane of the inner faceplate 28 and are equidistant from the side walls 52.
[00441 The inner faceplate 28 has upper and lower tab portions 70, 72 which extend downwardly and upwardly, respectively, to cover the forward ends of the upper and lower shoulders 66, 68. Each of the tab portions 70, 72 has an opening through which an elongate fastener may be inserted.
[0045] The top and bottom walls 50, 54 each have a pair of notches 74 at the corners formed by the intersection of the rear wall 56 with the top wall 50, side walls 52 and bottom wall 54. The forward ends of the notches 74 terminate at wire ports 76.
PATENT
Attorney Docket No.: 577-658 [0046] The outlet box assembly 10 includes a pair of clips 78 each of which has a post 80 and an arm 82 pivotally connected to the post in perpendicular relation thereto. Each post 80 is connected to the front surface 30 of the inner faceplate 28 adjacent to opposing corners thereof, as shown in Figs. 1 and 2. Each of the arms 82 is coupled to an elongate member, such as a pin 84, which extends through an elongate cavity in the post 80, as shown in Figs.
2 and 3. The forward end of the pin 84 has a head 86 to which may be coupled a tool for rotating the pin.
Such coupling may be provided, for example, by forming in the front surface of the head 86 a recess which may be engaged by a screw driver. Rotation of the pin 84, such as by a screw driver, causes pivoting of the arm 82 about the associated post 80. Each of the arms 82 may be thereby be swung between a retracted position 88 in which the arm is within the outer periphery 90 of the inner faceplate 28 and a clamped position 92 in which the arm extends beyond the outer periphery 90.
[0047] The outlet box assembly 10 is prepared for mounting to the wall structure 12 by removing the knockouts 33, such as by applying a force thereto which is sufficient to fracture the knockouts from the inner faceplate 28. Such fracturing will occur along the grooves 34 resulting in the cross-sections of the communication ports 36 having the specific shapes shown in Figs. 2, 3, and 10 to 19. Alternatively, the knockouts 33 may be removed by cutting the outer peripheries thereof at the grooves 34. Knockouts 33 which are removed by such cutting may be referred to as cutouts.
PATENT
Attorney Docket No.: 577-658 [0048] The preparation of the outlet box assembly 10 for mounting to the wall structure 12 further includes assembling an electrical receptacle 94 to the outlet box assembly. Such assembly may be either before or after the removal of the knockouts 33 from the inner faceplate 28.
[0049] The electrical receptacle 94 is assembled to the outlet box assembly 10 by insertion of the electrical receptacle 94 through the interior opening 16 and outlet port 31 into the interior region 64 of the support housing 46. The electrical receptacle 94 has an outer surface 96 and elongate slots 98 to receive the prongs of an electrical plug. When the electrical plug is inserted into the electrical receptacle 94, at least a portion of the plug or possibly the entire plug is contained within the flange structure 20.
[0050] The wire ports 76 provide a pathway for wires to extend from the electrical receptacle 94 within the interior region 64 to a location outside of the support housing 46.
Provision of the wire ports 76 at the top and bottom walls 50, 54 accommodates wires which are connected to the top or bottom of the electrical receptacle 94, typically to the rear thereof. Such wires typically extend to the power source for the provision of electrical power to the electrical receptacle 94. This results in electrical power being supplied to an electrical plug inserted in the electrical receptacle 94.
[0051] The insertion of the electrical receptacle 94 into the interior region 64 is facilitated by the configuration of the support housing 46. For example, the configuration of the
Claims (9)
1. An outlet box assembly comprising:
an outer faceplate having an interior opening, said interior opening having an outer periphery;
an inner faceplate connected to said outer faceplate such that said inner faceplate is recessed from said outer faceplate and access to said inner faceplate is provided through said interior opening, said inner faceplate having a planar front surface which is separated from said outer periphery by a distance which is orthogonal relative to said front surface of said outer faceplate, said distance being constant along said outer periphery, said inner faceplate having an outlet port and a communication port; and a support housing having an inner surface and an interior region bounded by said inner surface, said support housing being connected to a rear surface of said inner faceplate such that said outlet port provides access to said interior region, said support housing being configured to allow insertion of an electrical receptacle into said interior region and to provide an enclosure for the electrical receptacle;
said inner faceplate having at least a first portion extending beyond said support housing, said first portion including said communication port, said first portion being disposed outside of said support housing and having a rear surface that is unenclosed wherein access to said communication port via said rear surface is unrestricted by a housing.
an outer faceplate having an interior opening, said interior opening having an outer periphery;
an inner faceplate connected to said outer faceplate such that said inner faceplate is recessed from said outer faceplate and access to said inner faceplate is provided through said interior opening, said inner faceplate having a planar front surface which is separated from said outer periphery by a distance which is orthogonal relative to said front surface of said outer faceplate, said distance being constant along said outer periphery, said inner faceplate having an outlet port and a communication port; and a support housing having an inner surface and an interior region bounded by said inner surface, said support housing being connected to a rear surface of said inner faceplate such that said outlet port provides access to said interior region, said support housing being configured to allow insertion of an electrical receptacle into said interior region and to provide an enclosure for the electrical receptacle;
said inner faceplate having at least a first portion extending beyond said support housing, said first portion including said communication port, said first portion being disposed outside of said support housing and having a rear surface that is unenclosed wherein access to said communication port via said rear surface is unrestricted by a housing.
2. The outlet box assembly according to claim 1, wherein said support housing comprises:
an outlet box comprising a top wall, a pair of side walls, and a bottom wall each of which is fixed to said inner faceplate in perpendicular relation thereto, said top, side, and bottom walls being fixed to one another such that each of said side walls is between said top and bottom walls in perpendicular relation thereto resulting in said outlet box having a vertical cross-section which is rectangular, said outlet box further comprising a rear wall fixed to said top, side and bottom walls such that said top, side and bottom walls are between said rear wall and inner faceplate, and said rear wall is parallel to said inner faceplate, said top, side, bottom and rear walls each having an inner surface each of which defines a portion of said inner surface of said support housing.
an outlet box comprising a top wall, a pair of side walls, and a bottom wall each of which is fixed to said inner faceplate in perpendicular relation thereto, said top, side, and bottom walls being fixed to one another such that each of said side walls is between said top and bottom walls in perpendicular relation thereto resulting in said outlet box having a vertical cross-section which is rectangular, said outlet box further comprising a rear wall fixed to said top, side and bottom walls such that said top, side and bottom walls are between said rear wall and inner faceplate, and said rear wall is parallel to said inner faceplate, said top, side, bottom and rear walls each having an inner surface each of which defines a portion of said inner surface of said support housing.
3. The outlet box assembly according to claim 1, wherein said communication port is rectangular.
4. The outlet box assembly according to claim 1, wherein said communication port has a forward end which intersects with a forward surface of said inner faceplate, said forward end having a circular cross-section, said communication port having a rear end which intersects with a rear surface of said inner faceplate, said rear end having a hexagonal cross-section.
5. The outlet box assembly according to claim 1, wherein said inner faceplate is parallel to said outer faceplate.
6. The outlet box assembly according to claim 1, and further comprising a flange structure fixed to a rear surface of said outer faceplate and to a front surface of said inner faceplate, said flange structure comprising a top flange, a pair of side flanges, and a bottom flange which are fixed to one another such that each of said side flanges is between said top and bottom flanges in perpendicular relation thereto resulting in said flange structure having a vertical cross-section which is rectangular.
7. The outlet box assembly according to claim 1, wherein said support housing is within an outer periphery of said inner faceplate, said outlet box assembly further comprising a pair of clips connected to a rear surface of said inner faceplate for clamping said outlet box assembly to a wall structure, said inner faceplate having opposing corners each of which has a respective one of said clips connected thereto, each of said clips having an arm which may be swung between a retracted position in which said arm is within said outer periphery and a clamped position in which said arm extends beyond said outer periphery such that said arm does not obstruct insertion and retraction of said inner faceplate through an opening in the wall structure when said arm is in said retracted position, said arm obstructing retraction of said inner faceplate through the opening in the wall structure when said arm is in said clamped position and the wall structure is clamped between said arms and outer faceplate.
8. An outlet box assembly comprising:
a support housing having an interior for receiving an electrical receptacle;
an inner faceplate extending outwardly from said support housing and defining an opening to said support housing interior, said inner faceplate having a first portion including a communication port adapted to receive a receptacle, said communication port being disposed outside said support housing, said inner face plate first portion and said opening to said support housing interior lying in a common plane;
a flange extending from said inner faceplate, said flange and inner faceplate forming a chamber adapted to contain an electrical plug, said inner faceplate first portion having an upper surface bounding said chamber and an opposed lower surface, said lower surface being unenclosed and wherein access to the receptacle received in the communication port is permitted from said exterior of said outlet box assembly;
an outer faceplate disposed on said flange, wherein said inner faceplate is recessed from said outer faceplate.
a support housing having an interior for receiving an electrical receptacle;
an inner faceplate extending outwardly from said support housing and defining an opening to said support housing interior, said inner faceplate having a first portion including a communication port adapted to receive a receptacle, said communication port being disposed outside said support housing, said inner face plate first portion and said opening to said support housing interior lying in a common plane;
a flange extending from said inner faceplate, said flange and inner faceplate forming a chamber adapted to contain an electrical plug, said inner faceplate first portion having an upper surface bounding said chamber and an opposed lower surface, said lower surface being unenclosed and wherein access to the receptacle received in the communication port is permitted from said exterior of said outlet box assembly;
an outer faceplate disposed on said flange, wherein said inner faceplate is recessed from said outer faceplate.
9. An outlet box assembly comprising:
a support housing having an opening for receiving an electrical receptacle and said opening lying in a first plane, said support housing including an exterior;
an inner faceplate extending outwardly from said support housing, said inner faceplate having a first portion lying in a second plane, said first portion including a communication port adapted to receive a receptacle, said first plane and said second planes being substantially parallel to each other, said communication port being disposed outside said support housing, said inner face plate having an exterior surface;
a flange extending from said inner faceplate, said flange and inner faceplate forming a chamber adapted to contain an electrical plug, said flange having an exterior surface;
the inner faceplate first portion having an upper surface bounding said chamber and an opposed lower surface, said lower surface being unenclosed and wherein access to the receptacle received in the communication port is permitted from said exterior of said outlet box assembly;
an outer faceplate disposed on said flange, wherein said inner faceplate is recessed from said outer faceplate.
a support housing having an opening for receiving an electrical receptacle and said opening lying in a first plane, said support housing including an exterior;
an inner faceplate extending outwardly from said support housing, said inner faceplate having a first portion lying in a second plane, said first portion including a communication port adapted to receive a receptacle, said first plane and said second planes being substantially parallel to each other, said communication port being disposed outside said support housing, said inner face plate having an exterior surface;
a flange extending from said inner faceplate, said flange and inner faceplate forming a chamber adapted to contain an electrical plug, said flange having an exterior surface;
the inner faceplate first portion having an upper surface bounding said chamber and an opposed lower surface, said lower surface being unenclosed and wherein access to the receptacle received in the communication port is permitted from said exterior of said outlet box assembly;
an outer faceplate disposed on said flange, wherein said inner faceplate is recessed from said outer faceplate.
Applications Claiming Priority (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US57227604P | 2004-05-18 | 2004-05-18 | |
| US60/572,276 | 2004-05-18 | ||
| US29/205,607 USD545276S1 (en) | 2004-05-18 | 2004-05-18 | Wall recessed outlet box assembly |
| US29/205,607 | 2004-05-18 |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2507586A1 CA2507586A1 (en) | 2005-11-18 |
| CA2507586C true CA2507586C (en) | 2010-09-21 |
Family
ID=35452206
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2507586 Expired - Fee Related CA2507586C (en) | 2004-05-18 | 2005-05-17 | Wall recessed outlet box assembly |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2507586C (en) |
-
2005
- 2005-05-17 CA CA 2507586 patent/CA2507586C/en not_active Expired - Fee Related
Also Published As
| Publication number | Publication date |
|---|---|
| CA2507586A1 (en) | 2005-11-18 |
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| Date | Code | Title | Description |
|---|---|---|---|
| EEER | Examination request | ||
| MKLA | Lapsed |
Effective date: 20190517 |