CA2695110C - An electrical box assembly - Google Patents
An electrical box assembly Download PDFInfo
- Publication number
- CA2695110C CA2695110C CA2695110A CA2695110A CA2695110C CA 2695110 C CA2695110 C CA 2695110C CA 2695110 A CA2695110 A CA 2695110A CA 2695110 A CA2695110 A CA 2695110A CA 2695110 C CA2695110 C CA 2695110C
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- CA
- Canada
- Prior art keywords
- cover plate
- electrical box
- base portion
- receiving
- box assembly
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Active
Links
- 238000007373 indentation Methods 0.000 claims description 5
- 229910000831 Steel Inorganic materials 0.000 claims description 3
- 239000010959 steel Substances 0.000 claims description 3
- 238000010276 construction Methods 0.000 description 3
- 238000010079 rubber tapping Methods 0.000 description 2
- 238000009429 electrical wiring Methods 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
Classifications
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02G—INSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES
- H02G3/00—Installations of electric cables or lines or protective tubing therefor in or on buildings, equivalent structures or vehicles
- H02G3/02—Details
- H02G3/08—Distribution boxes; Connection or junction boxes
- H02G3/12—Distribution boxes; Connection or junction boxes for flush mounting
- H02G3/123—Distribution boxes; Connection or junction boxes for flush mounting in thin walls
- H02G3/126—Distribution boxes; Connection or junction boxes for flush mounting in thin walls with supporting means for mounting on a single wall stud
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02G—INSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES
- H02G3/00—Installations of electric cables or lines or protective tubing therefor in or on buildings, equivalent structures or vehicles
- H02G3/02—Details
- H02G3/08—Distribution boxes; Connection or junction boxes
- H02G3/14—Fastening of cover or lid to box
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- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Casings For Electric Apparatus (AREA)
Abstract
An electrical box assembly is provided that comprises a box portion having a 4 inch trade size height and a cover plate. The box portion has a back wall, a first side wall, a second side wall opposite to the first side wall, a top wall, a bottom wall opposite to the top wall and an open front face. The cover plate is suitable for covering the open front face of the box portion and comprises a base portion, an opening in the base portion for receiving an electrical device and first and second tabs spaced from the base portion. The first and second tabs have first and second apertures respectively for receiving fasteners for mounting the electrical device to the cover plate. The first and second apertures are spaced from one another by a distance of about 3.5 inches. Furthermore, a distance between an outer surface of the top wall and a center of an adjacent one of the first and second apertures is less than about 0.29 inches when the cover plate is secured to the box portion.
Description
TITLE: AN ELECTRICAL BOX ASSEMBLY
FIELD OF THE INVENTION
The present invention relates generally to the field of electrical boxes, and more particularly to a cover plate and electrical box portion that are suitable for receiving electrical devices that are rated for high voltage (347V AC) applications.
BACKGROUND
Electrical boxes for 110V/120V voltage applications are known in the art, and come in a variety of shapes and sizes. When working on a construction job, many electricians favor working with 4 inch square trade-size electrical boxes, which they often use for the majority of the construction jobs. Depending on the wall finish and on the electrical device that will be installed in the electrical box, (duplex receptacles, toggle switches, etc...), the electrician may then mount the appropriate cover to the 4 inch square box.
However, while 4 inch square electrical boxes may be used for 110V/120V
voltage applications, they are not presently used in high voltage (347V) applications.
This is due, at least in part, to the fact that electrical devices rated for 347V
have mounting screws that are positioned at 3.5 inches apart (nominally 3.531 inches), instead of 3.3 inches (nominally 3.281 inches) apart, as in the case of voltage electrical devices. This increased distance between mounting screws makes a traditional raised cover plate unsuitable for a standard 4 inch square electrical box. Therefore, for high voltage (347V) applications, a special electrical box having an increased size needs to be used together with a special mounting plate that also has an increased size. Obviously, this prevents electricians from using the same 4 inch square trade size electrical box for a construction job that includes both 110V/120V voltage and high voltage applications.
Against this background, it may be seen that there is a need in the industry to provide an electrical box assembly that comprises a high voltage raised cover plate that is able to work with a 4 inch square trade size electrical box that can receive electrical devices rated for 347V.
Note that for the purpose of this document, 110V/120V will be referred to as low voltage, while 347 V will be referred to as high voltage.
SUMMARY OF THE INVENTION
In accordance with a first broad aspect, the present invention provides an electrical box assembly, comprising a box portion having a 4 inch trade size height and a cover plate. The box portion has a back wall, a first side wall, a second side wall opposite to the first side wall, a top wall, a bottom wall opposite to the top wall and an open front face. The cover plate is suitable for covering the open front face of the box portion and comprises a base portion, an opening in the base portion for receiving an electrical device and first and second tabs spaced from the base portion. The first and second tabs have first and second apertures respectively for receiving fasteners for mounting the electrical device to the cover plate. The first and second apertures are spaced from one another by a distance of about 3.5 inches.
Furthermore, a distance between an outer surface of the top wall and a center of an adjacent one of the first and second apertures is less than about 0.29 inches when the cover plate is secured to the box portion. The first and second apertures the first and second apertures are threaded for receiving threaded fasteners to mount the electrical device to the cover plate. The base portion includes a first fastener-receiving opening and a second fastener-receiving opening registering with the first and the second apertures, respectively, the first and second fastener-receiving openings receiving the respective threaded fasteners when the threaded fasteners are engaged in the first and second apertures.
In accordance with a second broad aspect, the present invention provides an electrical box assembly, comprising a cover plate having a base portion, first and second tabs in a spaced apart relationship with the base portion, first and second threaded apertures on the first and second tabs, respectively for receiving threaded fasteners for mounting an electrical device to the cover plate and first and second fastener-receiving openings on said base portion registering with the first and second apertures respectively, the first and second fastener-receiving openings receiving the respective threaded fasteners when the threaded fasteners are engaged in the first and second threaded apertures.
In accordance with a third broad aspect, the present invention provides a cover plate for an electrical box comprising a base portion for mounting the cover plate to the electrical box, an opening for receiving an electrical device, the opening having a periphery, a rim portion that projects from the base portion, arim portion extending along at least a portion of the periphery, a first tab that extends from the rim portion in a direction away from the opening, the first tab comprising a first aperture for receiving a first electrical device fastening screw and a second tab that extends from the rim portion in a direction away from the opening, the second tab comprising a second aperture for receiving a second electrical device fastening screw, a first fastener-receiving opening on the base portion registering with the first aperture to receive the first screw when the first screw is threadedly engaged in the first aperture, a second fastener-receiving opening on the base portion registering with the second aperture to receive the second screw when the second screw is threadedly engaged in the second aperture.
In accordance with a fourth broad aspect, the present invention provides a cover plate for an electrical box, comprising a base portion for mounting the cover plate to the electrical box, an opening for receiving an electrical device, the opening having a periphery, a rim portion that projects from the base portion, the rim portion extending along at least a portion of the periphery, a first tab that extends from the rim portion in a direction away from the opening, the first tab comprising a first aperture for receiving a first electrical device fastening screw, a second tab that extends from the rim portion in a direction away from the opening, the second tab comprising a second aperture for receiving a second electrical device fastening 2a screw, a first fastener-receiving indentation on the base portion registering with the first aperture to receive the first screw when the first screw is threadedly engaged in the first aperture and a second fastener-receiving indentation on the base portion registering with the second aperture to receive the second screw when the second screw is threadedly engaged in the second aperture.
These and other aspects and features of the present invention will now become apparent to those of ordinary skill in the art upon review of the following description of specific embodiments of the invention in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings:
Figure 1 shows a front perspective view of an electrical box assembly according to a non-limiting example of implementation of the present invention;
Figure 2 shows a front plan view of the electrical box assembly of Figure 1;
Figure 3 shows a side elevational view of the electrical box assembly of Figure 1;
Figure 4 shows a top plan view of the electrical box assembly of Figure 1;
Figure 5 shows a front perspective view of an electrical box portion according to a non-limiting example of implementation of the present invention without the cover plate mounted thereto;
I
, Figure 6 shows a front plan view of the electrical box portion of Figure 5;
Figure 7 shows a front perspective view of a cover plate according to a non-limiting example of implementation of the present invention;
Figure 8 shows a front plan view of the cover plate of Figure 7;
Figure 9 shows a side elevational view of the cover plate of Figure 7;
Figure 10 shows a top plan view of the cover plate of Figure 7; and Figure 11 shows a back plan view of the cover plate of Figure 7.
It is to be expressly understood that the description and drawings are only for the purpose of illustration of certain embodiments of the invention and are an aid for understanding. They are not intended to be a definition of the limits of the invention DETAILED DESCRIPTION
Shown in Figures 1-4 is a non-limiting example of an electrical box assembly according to the present invention that comprises an electrical box portion 12 and a cover plate 14 for covering an open face of the electrical box portion 12.
The electrical box portion 12 is suitable for being positioned within a wall for housing an electrical device, such as a duplex receptacle or a toggle switch, among other possibilities.
As best shown in Figure 5, the electrical box portion 12 comprises walls that define an internal volume for receiving electrical wiring associated with an electrical device. In the non-limiting embodiment shown, the electrical box portion 12 comprises a back wall 16, a first side wall 18, a second side wall 20 opposite to the first side wall 18, a top wall 22, a bottom wall 24 opposite to the top wall 22 and an open front face 25. The open front face 25 provides access to the internal volume for allowing an electrician to position one or more electrical devices and all the necessary wiring within the electrical box portion 12.
In accordance with the non-limiting example shown, the electrical box portion 12 is a generally square box, and may be a 4 inch square trade size box. As used herein, the term "trade size" refers to dimensions that are within a trade-accepted tolerance of the specified dimension. As such, a 4 inch square trade size box will have a width from the first side wall 18 to the second side wall 20 of about 4 inches, and a height from the bottom wall 24 to the top wall 22 of about 4 inches.
In a further non-limiting embodiment, the electrical box portion 12 may have a height of about 4 inches, and a width that is greater than 4 inches or less than 4 inches. Other dimensions for the box portion are also possible, and are included within the scope of the present invention.
The electrical box portion 12 comprises at least one knockout on at least one of the top wall 22 and the bottom wall 24. In the non-limiting embodiment shown in Figure 5, the electrical box portion 12 comprises three knockouts 26 on each of the top wall 22 and the bottom wall 24. The term "knockout" is well known in the industry, and refers generally to covered openings that may be relatively easily opened by "knocking-out" a loosely attached covering. Once opened, wires from the electrical device are able to enter and/or exit the electrical box portion through the opened knockout. The box portion 12 of the present invention is intended to be suitable for use with both low as well as for high voltage applications. In order to be able to accommodate high voltage applications, the first and second side walls 18 and 20 of the electrical box portion 12 are free of knockouts. This prevents wires for the electrical device that is housed within the box portion 12 to either enter or exit through any opening in either the first side wall 18 or the second side wall 20. This also prevents side access to live parts.
As shown in Figures 5 and 6 positioned adjacent to the open face 25 of the electrical box portion 12 are flanges 28 for enabling the cover plate 14 to be mounted to the box portion 12. The flanges 28 include apertures 30 for receiving fastening devices, such as screws 32 that mount the cover plate 14 to the electrical box portion 12. The apertures 30 may be unthreaded apertures or threaded apertures depending on type of screws used. Unthreaded apertures 32 would work with self tapping screws while treaded apertures 32 would work to accept screws that are not self tapping.
Shown in Figures 7-10 is a cover plate 14 according to a non-limiting embodiment of the invention. The cover plate 14 comprises a base portion 40 and an opening 42 for receiving an electrical device (not shown). The opening 42 may be of any shape and size that is suitable for the desired application and/or the electrical device being used.
The base portion 40 is generally flat and has a first side edge 54, a second side edge 56 opposite to the first side edge 54, a top edge 58 and a bottom edge 60 opposite to the top edge 58. The cover plate 14 may be a 4 inch square trade size cover plate, having a width of about 4 inches from the first side edge 54 to the second side edge 56 and a height of about 4 inches from the bottom edge 60 to the top edge 58. In this manner, the cover plate 14 is suitable for being mounted to a 4 inch square trade size electrical box portion 12, as described above.
It should, however, be appreciated that the cover plate may also have a height of about 4 inches, and a width that is greater than 4 inches or less than 4 inches.
Cover plates having other dimensions are also included within the scope of the present invention.
The cover plate 14 comprises mounting holes 52 positioned on the base portion 40 to enable the cover plate 14 to be mounted to the electrical box portion 12. In the non-limiting embodiment shown, the mounting holes 52 include a circular portion that is slightly larger than the head of a mounting screw 32 and a narrower passage that extends from the circular portion. In order to mount the cover plate 14 to the electrical box 12, the mounting screws 32 are inserted into the apertures 30 of the flanges 28. The cover plate 14 is then mounted to the electrical box portion 12 by passing the heads of the mounting screws 32 through the circular portions of the mounting holes 52. The cover plate 14 is then rotated counterclockwise (as viewed from the front) to locate the shanks of the mounting screws 32 into the narrow passages. The geometry of the mounting holes 52 is such that when the shanks of the mounting screws 32 abut the ends of the narrow passages, the cover plate is in alignment with the electrical box portion 12.
The mounting screws 32 are then tightened to secure the assembly.
The cover plate 14 further comprises a raised rim portion 62 that projects from the base portion 40 and extends around at least a portion of the periphery of the opening 42. In the non-limiting embodiment shown, the raised rim portion 62 extends around the entire periphery of the opening 42 and comprises four walls that border the four edges of the opening 42. The raised rim portion 62 may have a variety of different heights depending on the wall thickness/finish. In accordance with some non-limiting examples, the raised rim portion 62 may have a height of 1/8", 1/4", 1/2", 5/8", 3/4", 7/8", 1", 1 1/1", 1 1/2", 1 3/4" and 2 inches, among other possible heights.
A first tab 46 and a second tab 48 extend from opposing sides of the raised rim portion 62. Both the first tab 46 and the second tab 48 extend in a direction away from the opening 42. In the non-limiting embodiment shown, the first tab 46 extends from the raised rim portion 62 towards the top edge 58 of the cover plate 14 and the second tab 48 extends from the raised rim portion 62 towards the bottom edge 60 of the cover plate 14. Both the first and second tabs 46, 48 extend generally parallel to the base portion 40. A first channel is formed between the base portion 40 and the first tab 46, such that the first tab 46 and the base portion 40 are separated by a distance that is equivalent to about the height of the rim portion 62. Likewise a second channel is formed between the base portion 40 and the second tab 48, such that the second tab 48 and the base portion 40 are separated by a distance that is equivalent to about the height of the rim portion 62.
In the example shown in the drawings, the tabs 46, 48 are separated from the base portion 40 along an imaginary line that is normal to the plane of the base portion 40, to form the first and the second channels.
The first tab 46 comprises a first aperture 50a and the second tab 48 comprises a second aperture 50b. The apertures 50a and 50b may be threaded to receive threaded fasteners, such as screws, for mounting an electrical device (not shown) to the cover plate 14.
In accordance with a non-limiting embodiment, the cover plate 14 is suitable for accommodating high voltage electrical devices and for mounting to an electrical box having a 4 inch trade size height. In general, high voltage electrical devices include fastening arrangements that are separated by about 3.5 inches (and particularly 3.531 inches). As such, in order to be able to accommodate high voltage electrical devices, the first and second apertures 50a and 50b are spaced apart from one another by a distance of about 3.5 inches.
Traditional raised cover plates that include a stamped-out raised ridge are unable to accommodate electrical device fasteners that are separated by about 3.5 inches on a cover plate that is only about 4 inches high. The raised rim portion 62 and the first and second tabs 46 and 48 that extend from the rim away from the opening 42, allow the cover plate 14 to include first and second apertures 50a and 50b that are spaced apart at a distance to accommodate high voltage electrical devices while still fitting on a cover plate 12 that has a height of about 4 inches. As such, the cover plate 14 may accommodate high voltage electrical devices within an electrical box 12 having a trade size height of about 4 inches.
When the cover plate 14 is mounted to an electrical box portion 12 that has a trade size height of about 4 inches, the distance between the outer surface of the top wall 22 of the electrical box portion 12 and a center of the first aperture 50a is less than about 0.29 inches and preferably less than 0.25 inches (and nominally 0.235 inches). Likewise, the distance between the outer surface of the bottom wall 24 and a center of the second aperture 50b is also less than about 0.29 inches and preferably less than 0.25 inches (and nominally 0.235 inches).
As best shown in Figures 7 and 11, the base portion 40 comprises a first fastener-receiving relief 64a and a second fastener-receiving relief 64b. The first fastener-receiving relief 64a registers with the first aperture 50a, such that a fastener that is engaged within the first aperture 50a and that is longer than the distance separating the first tab 46 and the base portion 40 will be received within the first fastener-receiving relief 64a. The second fastener-receiving relief 64b registers with the second aperture 50b, such that a fastener that is engaged within the second aperture 50b and that is longer than the distance separating the second tab 48 and the base portion 40 will be received within the second fastener-receiving relief 64b.
The first and second fastener-receiving reliefs 64a and 64b may comprise openings within the base portion 42, such that fasteners that are engaged within the apertures 50a, 50b, may extend slightly through the first and second fastener-receiving reliefs into the internal volume of the electric box portion 12. The openings of the first and second fastener-receiving reliefs 64a and 64b are intended to enable fasteners of different lengths to be engaged within the apertures 50a, 50b without having to worry about whether these fasteners will abut against the base portion 40. In a specific and non-limiting example of implementation, the fastener-receiving reliefs 64a and 64b are non-threaded.
In an alternative embodiment, the first and second fastener-receiving reliefs 64a and 64b may not comprise openings within the base portion 40, and instead may comprise indentations into the base portion 40. In such a case, the first and second fastener-receiving reliefs 64a and 64b are able to receive fasteners that are only slightly longer than the distance separating the tabs 46, 48 and the base portion 40.
The electrical box portion 12 and the cover plate 14 may be made of steel or plastic, among other possible materials.
As shown in Figures 1-3, the first and second side walls 18 and 20 of the electrical box portion 12 are suitable for supporting one or more mounting brackets 70.
The mounting brackets 70 may be welded or riveted to the side walls 18 and 20 of the electrical box portion 12, or may be attached in any other manner known in the art.
The mounting brackets 70 may be of any suitable shape and or size depending on the required application, in order to enable the electrical box portion 12 to be positioned and secured within a wall. The present invention is not limited by the shape, size and type of mounting brackets 70 that are attached to the electrical box portion 12.
While specific embodiments of the present invention have been described and illustrated, it will be apparent to those skilled in the art that numerous modifications and variations may be made without departing from the scope of the invention as defined in the appended claims.
FIELD OF THE INVENTION
The present invention relates generally to the field of electrical boxes, and more particularly to a cover plate and electrical box portion that are suitable for receiving electrical devices that are rated for high voltage (347V AC) applications.
BACKGROUND
Electrical boxes for 110V/120V voltage applications are known in the art, and come in a variety of shapes and sizes. When working on a construction job, many electricians favor working with 4 inch square trade-size electrical boxes, which they often use for the majority of the construction jobs. Depending on the wall finish and on the electrical device that will be installed in the electrical box, (duplex receptacles, toggle switches, etc...), the electrician may then mount the appropriate cover to the 4 inch square box.
However, while 4 inch square electrical boxes may be used for 110V/120V
voltage applications, they are not presently used in high voltage (347V) applications.
This is due, at least in part, to the fact that electrical devices rated for 347V
have mounting screws that are positioned at 3.5 inches apart (nominally 3.531 inches), instead of 3.3 inches (nominally 3.281 inches) apart, as in the case of voltage electrical devices. This increased distance between mounting screws makes a traditional raised cover plate unsuitable for a standard 4 inch square electrical box. Therefore, for high voltage (347V) applications, a special electrical box having an increased size needs to be used together with a special mounting plate that also has an increased size. Obviously, this prevents electricians from using the same 4 inch square trade size electrical box for a construction job that includes both 110V/120V voltage and high voltage applications.
Against this background, it may be seen that there is a need in the industry to provide an electrical box assembly that comprises a high voltage raised cover plate that is able to work with a 4 inch square trade size electrical box that can receive electrical devices rated for 347V.
Note that for the purpose of this document, 110V/120V will be referred to as low voltage, while 347 V will be referred to as high voltage.
SUMMARY OF THE INVENTION
In accordance with a first broad aspect, the present invention provides an electrical box assembly, comprising a box portion having a 4 inch trade size height and a cover plate. The box portion has a back wall, a first side wall, a second side wall opposite to the first side wall, a top wall, a bottom wall opposite to the top wall and an open front face. The cover plate is suitable for covering the open front face of the box portion and comprises a base portion, an opening in the base portion for receiving an electrical device and first and second tabs spaced from the base portion. The first and second tabs have first and second apertures respectively for receiving fasteners for mounting the electrical device to the cover plate. The first and second apertures are spaced from one another by a distance of about 3.5 inches.
Furthermore, a distance between an outer surface of the top wall and a center of an adjacent one of the first and second apertures is less than about 0.29 inches when the cover plate is secured to the box portion. The first and second apertures the first and second apertures are threaded for receiving threaded fasteners to mount the electrical device to the cover plate. The base portion includes a first fastener-receiving opening and a second fastener-receiving opening registering with the first and the second apertures, respectively, the first and second fastener-receiving openings receiving the respective threaded fasteners when the threaded fasteners are engaged in the first and second apertures.
In accordance with a second broad aspect, the present invention provides an electrical box assembly, comprising a cover plate having a base portion, first and second tabs in a spaced apart relationship with the base portion, first and second threaded apertures on the first and second tabs, respectively for receiving threaded fasteners for mounting an electrical device to the cover plate and first and second fastener-receiving openings on said base portion registering with the first and second apertures respectively, the first and second fastener-receiving openings receiving the respective threaded fasteners when the threaded fasteners are engaged in the first and second threaded apertures.
In accordance with a third broad aspect, the present invention provides a cover plate for an electrical box comprising a base portion for mounting the cover plate to the electrical box, an opening for receiving an electrical device, the opening having a periphery, a rim portion that projects from the base portion, arim portion extending along at least a portion of the periphery, a first tab that extends from the rim portion in a direction away from the opening, the first tab comprising a first aperture for receiving a first electrical device fastening screw and a second tab that extends from the rim portion in a direction away from the opening, the second tab comprising a second aperture for receiving a second electrical device fastening screw, a first fastener-receiving opening on the base portion registering with the first aperture to receive the first screw when the first screw is threadedly engaged in the first aperture, a second fastener-receiving opening on the base portion registering with the second aperture to receive the second screw when the second screw is threadedly engaged in the second aperture.
In accordance with a fourth broad aspect, the present invention provides a cover plate for an electrical box, comprising a base portion for mounting the cover plate to the electrical box, an opening for receiving an electrical device, the opening having a periphery, a rim portion that projects from the base portion, the rim portion extending along at least a portion of the periphery, a first tab that extends from the rim portion in a direction away from the opening, the first tab comprising a first aperture for receiving a first electrical device fastening screw, a second tab that extends from the rim portion in a direction away from the opening, the second tab comprising a second aperture for receiving a second electrical device fastening 2a screw, a first fastener-receiving indentation on the base portion registering with the first aperture to receive the first screw when the first screw is threadedly engaged in the first aperture and a second fastener-receiving indentation on the base portion registering with the second aperture to receive the second screw when the second screw is threadedly engaged in the second aperture.
These and other aspects and features of the present invention will now become apparent to those of ordinary skill in the art upon review of the following description of specific embodiments of the invention in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings:
Figure 1 shows a front perspective view of an electrical box assembly according to a non-limiting example of implementation of the present invention;
Figure 2 shows a front plan view of the electrical box assembly of Figure 1;
Figure 3 shows a side elevational view of the electrical box assembly of Figure 1;
Figure 4 shows a top plan view of the electrical box assembly of Figure 1;
Figure 5 shows a front perspective view of an electrical box portion according to a non-limiting example of implementation of the present invention without the cover plate mounted thereto;
I
, Figure 6 shows a front plan view of the electrical box portion of Figure 5;
Figure 7 shows a front perspective view of a cover plate according to a non-limiting example of implementation of the present invention;
Figure 8 shows a front plan view of the cover plate of Figure 7;
Figure 9 shows a side elevational view of the cover plate of Figure 7;
Figure 10 shows a top plan view of the cover plate of Figure 7; and Figure 11 shows a back plan view of the cover plate of Figure 7.
It is to be expressly understood that the description and drawings are only for the purpose of illustration of certain embodiments of the invention and are an aid for understanding. They are not intended to be a definition of the limits of the invention DETAILED DESCRIPTION
Shown in Figures 1-4 is a non-limiting example of an electrical box assembly according to the present invention that comprises an electrical box portion 12 and a cover plate 14 for covering an open face of the electrical box portion 12.
The electrical box portion 12 is suitable for being positioned within a wall for housing an electrical device, such as a duplex receptacle or a toggle switch, among other possibilities.
As best shown in Figure 5, the electrical box portion 12 comprises walls that define an internal volume for receiving electrical wiring associated with an electrical device. In the non-limiting embodiment shown, the electrical box portion 12 comprises a back wall 16, a first side wall 18, a second side wall 20 opposite to the first side wall 18, a top wall 22, a bottom wall 24 opposite to the top wall 22 and an open front face 25. The open front face 25 provides access to the internal volume for allowing an electrician to position one or more electrical devices and all the necessary wiring within the electrical box portion 12.
In accordance with the non-limiting example shown, the electrical box portion 12 is a generally square box, and may be a 4 inch square trade size box. As used herein, the term "trade size" refers to dimensions that are within a trade-accepted tolerance of the specified dimension. As such, a 4 inch square trade size box will have a width from the first side wall 18 to the second side wall 20 of about 4 inches, and a height from the bottom wall 24 to the top wall 22 of about 4 inches.
In a further non-limiting embodiment, the electrical box portion 12 may have a height of about 4 inches, and a width that is greater than 4 inches or less than 4 inches. Other dimensions for the box portion are also possible, and are included within the scope of the present invention.
The electrical box portion 12 comprises at least one knockout on at least one of the top wall 22 and the bottom wall 24. In the non-limiting embodiment shown in Figure 5, the electrical box portion 12 comprises three knockouts 26 on each of the top wall 22 and the bottom wall 24. The term "knockout" is well known in the industry, and refers generally to covered openings that may be relatively easily opened by "knocking-out" a loosely attached covering. Once opened, wires from the electrical device are able to enter and/or exit the electrical box portion through the opened knockout. The box portion 12 of the present invention is intended to be suitable for use with both low as well as for high voltage applications. In order to be able to accommodate high voltage applications, the first and second side walls 18 and 20 of the electrical box portion 12 are free of knockouts. This prevents wires for the electrical device that is housed within the box portion 12 to either enter or exit through any opening in either the first side wall 18 or the second side wall 20. This also prevents side access to live parts.
As shown in Figures 5 and 6 positioned adjacent to the open face 25 of the electrical box portion 12 are flanges 28 for enabling the cover plate 14 to be mounted to the box portion 12. The flanges 28 include apertures 30 for receiving fastening devices, such as screws 32 that mount the cover plate 14 to the electrical box portion 12. The apertures 30 may be unthreaded apertures or threaded apertures depending on type of screws used. Unthreaded apertures 32 would work with self tapping screws while treaded apertures 32 would work to accept screws that are not self tapping.
Shown in Figures 7-10 is a cover plate 14 according to a non-limiting embodiment of the invention. The cover plate 14 comprises a base portion 40 and an opening 42 for receiving an electrical device (not shown). The opening 42 may be of any shape and size that is suitable for the desired application and/or the electrical device being used.
The base portion 40 is generally flat and has a first side edge 54, a second side edge 56 opposite to the first side edge 54, a top edge 58 and a bottom edge 60 opposite to the top edge 58. The cover plate 14 may be a 4 inch square trade size cover plate, having a width of about 4 inches from the first side edge 54 to the second side edge 56 and a height of about 4 inches from the bottom edge 60 to the top edge 58. In this manner, the cover plate 14 is suitable for being mounted to a 4 inch square trade size electrical box portion 12, as described above.
It should, however, be appreciated that the cover plate may also have a height of about 4 inches, and a width that is greater than 4 inches or less than 4 inches.
Cover plates having other dimensions are also included within the scope of the present invention.
The cover plate 14 comprises mounting holes 52 positioned on the base portion 40 to enable the cover plate 14 to be mounted to the electrical box portion 12. In the non-limiting embodiment shown, the mounting holes 52 include a circular portion that is slightly larger than the head of a mounting screw 32 and a narrower passage that extends from the circular portion. In order to mount the cover plate 14 to the electrical box 12, the mounting screws 32 are inserted into the apertures 30 of the flanges 28. The cover plate 14 is then mounted to the electrical box portion 12 by passing the heads of the mounting screws 32 through the circular portions of the mounting holes 52. The cover plate 14 is then rotated counterclockwise (as viewed from the front) to locate the shanks of the mounting screws 32 into the narrow passages. The geometry of the mounting holes 52 is such that when the shanks of the mounting screws 32 abut the ends of the narrow passages, the cover plate is in alignment with the electrical box portion 12.
The mounting screws 32 are then tightened to secure the assembly.
The cover plate 14 further comprises a raised rim portion 62 that projects from the base portion 40 and extends around at least a portion of the periphery of the opening 42. In the non-limiting embodiment shown, the raised rim portion 62 extends around the entire periphery of the opening 42 and comprises four walls that border the four edges of the opening 42. The raised rim portion 62 may have a variety of different heights depending on the wall thickness/finish. In accordance with some non-limiting examples, the raised rim portion 62 may have a height of 1/8", 1/4", 1/2", 5/8", 3/4", 7/8", 1", 1 1/1", 1 1/2", 1 3/4" and 2 inches, among other possible heights.
A first tab 46 and a second tab 48 extend from opposing sides of the raised rim portion 62. Both the first tab 46 and the second tab 48 extend in a direction away from the opening 42. In the non-limiting embodiment shown, the first tab 46 extends from the raised rim portion 62 towards the top edge 58 of the cover plate 14 and the second tab 48 extends from the raised rim portion 62 towards the bottom edge 60 of the cover plate 14. Both the first and second tabs 46, 48 extend generally parallel to the base portion 40. A first channel is formed between the base portion 40 and the first tab 46, such that the first tab 46 and the base portion 40 are separated by a distance that is equivalent to about the height of the rim portion 62. Likewise a second channel is formed between the base portion 40 and the second tab 48, such that the second tab 48 and the base portion 40 are separated by a distance that is equivalent to about the height of the rim portion 62.
In the example shown in the drawings, the tabs 46, 48 are separated from the base portion 40 along an imaginary line that is normal to the plane of the base portion 40, to form the first and the second channels.
The first tab 46 comprises a first aperture 50a and the second tab 48 comprises a second aperture 50b. The apertures 50a and 50b may be threaded to receive threaded fasteners, such as screws, for mounting an electrical device (not shown) to the cover plate 14.
In accordance with a non-limiting embodiment, the cover plate 14 is suitable for accommodating high voltage electrical devices and for mounting to an electrical box having a 4 inch trade size height. In general, high voltage electrical devices include fastening arrangements that are separated by about 3.5 inches (and particularly 3.531 inches). As such, in order to be able to accommodate high voltage electrical devices, the first and second apertures 50a and 50b are spaced apart from one another by a distance of about 3.5 inches.
Traditional raised cover plates that include a stamped-out raised ridge are unable to accommodate electrical device fasteners that are separated by about 3.5 inches on a cover plate that is only about 4 inches high. The raised rim portion 62 and the first and second tabs 46 and 48 that extend from the rim away from the opening 42, allow the cover plate 14 to include first and second apertures 50a and 50b that are spaced apart at a distance to accommodate high voltage electrical devices while still fitting on a cover plate 12 that has a height of about 4 inches. As such, the cover plate 14 may accommodate high voltage electrical devices within an electrical box 12 having a trade size height of about 4 inches.
When the cover plate 14 is mounted to an electrical box portion 12 that has a trade size height of about 4 inches, the distance between the outer surface of the top wall 22 of the electrical box portion 12 and a center of the first aperture 50a is less than about 0.29 inches and preferably less than 0.25 inches (and nominally 0.235 inches). Likewise, the distance between the outer surface of the bottom wall 24 and a center of the second aperture 50b is also less than about 0.29 inches and preferably less than 0.25 inches (and nominally 0.235 inches).
As best shown in Figures 7 and 11, the base portion 40 comprises a first fastener-receiving relief 64a and a second fastener-receiving relief 64b. The first fastener-receiving relief 64a registers with the first aperture 50a, such that a fastener that is engaged within the first aperture 50a and that is longer than the distance separating the first tab 46 and the base portion 40 will be received within the first fastener-receiving relief 64a. The second fastener-receiving relief 64b registers with the second aperture 50b, such that a fastener that is engaged within the second aperture 50b and that is longer than the distance separating the second tab 48 and the base portion 40 will be received within the second fastener-receiving relief 64b.
The first and second fastener-receiving reliefs 64a and 64b may comprise openings within the base portion 42, such that fasteners that are engaged within the apertures 50a, 50b, may extend slightly through the first and second fastener-receiving reliefs into the internal volume of the electric box portion 12. The openings of the first and second fastener-receiving reliefs 64a and 64b are intended to enable fasteners of different lengths to be engaged within the apertures 50a, 50b without having to worry about whether these fasteners will abut against the base portion 40. In a specific and non-limiting example of implementation, the fastener-receiving reliefs 64a and 64b are non-threaded.
In an alternative embodiment, the first and second fastener-receiving reliefs 64a and 64b may not comprise openings within the base portion 40, and instead may comprise indentations into the base portion 40. In such a case, the first and second fastener-receiving reliefs 64a and 64b are able to receive fasteners that are only slightly longer than the distance separating the tabs 46, 48 and the base portion 40.
The electrical box portion 12 and the cover plate 14 may be made of steel or plastic, among other possible materials.
As shown in Figures 1-3, the first and second side walls 18 and 20 of the electrical box portion 12 are suitable for supporting one or more mounting brackets 70.
The mounting brackets 70 may be welded or riveted to the side walls 18 and 20 of the electrical box portion 12, or may be attached in any other manner known in the art.
The mounting brackets 70 may be of any suitable shape and or size depending on the required application, in order to enable the electrical box portion 12 to be positioned and secured within a wall. The present invention is not limited by the shape, size and type of mounting brackets 70 that are attached to the electrical box portion 12.
While specific embodiments of the present invention have been described and illustrated, it will be apparent to those skilled in the art that numerous modifications and variations may be made without departing from the scope of the invention as defined in the appended claims.
Claims (41)
1. An electrical box assembly, comprising:
a. a box portion having a 4 inch trade size height, the box portion having a back wall, a first side wall, a second side wall opposite to the first side wall, a top wall, a bottom wall opposite to the top wall and an open front face;
b. a cover plate suitable for covering the open front face of the box portion, the cover plate comprising:
i. a base portion;
ii. an opening in the base portion for receiving an electrical device;
iii. first and second tabs spaced from the base portion, the first and second tabs having first and second apertures respectively for receiving fasteners for mounting the electrical device to the cover plate, the first and second apertures being spaced from one another by a distance of about 3.5 inches, a distance between an outer surface of the top wall and a center of an adjacent one of the first and second apertures being less than about 0.29 inches when the cover plate is secured to the box portion;
iv. the first and second apertures are threaded for receiving threaded fasteners to mount the electrical device to the cover plate;
v. the base portion includes a first fastener-receiving opening and a second fastener-receiving opening registering with the first and the second apertures, respectively, the first and second fastener-receiving openings receiving the respective threaded fasteners when the threaded fasteners are engaged in the first and second apertures.
a. a box portion having a 4 inch trade size height, the box portion having a back wall, a first side wall, a second side wall opposite to the first side wall, a top wall, a bottom wall opposite to the top wall and an open front face;
b. a cover plate suitable for covering the open front face of the box portion, the cover plate comprising:
i. a base portion;
ii. an opening in the base portion for receiving an electrical device;
iii. first and second tabs spaced from the base portion, the first and second tabs having first and second apertures respectively for receiving fasteners for mounting the electrical device to the cover plate, the first and second apertures being spaced from one another by a distance of about 3.5 inches, a distance between an outer surface of the top wall and a center of an adjacent one of the first and second apertures being less than about 0.29 inches when the cover plate is secured to the box portion;
iv. the first and second apertures are threaded for receiving threaded fasteners to mount the electrical device to the cover plate;
v. the base portion includes a first fastener-receiving opening and a second fastener-receiving opening registering with the first and the second apertures, respectively, the first and second fastener-receiving openings receiving the respective threaded fasteners when the threaded fasteners are engaged in the first and second apertures.
2. An electrical box assembly as defined in claim 1, wherein the electrical box assembly is rated at 347 Volts.
3. An electrical box assembly as defined in claim 1, wherein the base portion is generally flat.
4. An electrical box assembly as defined in claim 3, comprising a raised rim portion extending along at least a portion of a periphery of the opening.
5. An electrical box assembly as defined in claim 4, wherein the raised rim portion has a height of about 1/8 inches.
6. An electrical box assembly as defined in claim 4, wherein the raised rim portion has a height of about 1/2 inches.
7. An electrical box assembly as defined in claim 4, wherein the raised rim portion has a height of about 5/8 inches.
8. An electrical box assembly as defined in claim 4, wherein the raised rim portion has a height of about 3/4 inches.
9. An electrical box assembly as defined in claim 4, wherein the raised rim portion has a height of about 7/8 inches.
10.An electrical box assembly as defined in claim 4, wherein the raised rim portion has a height of about 1 inch.
11. An electrical box assembly as defined in claim 4, wherein the raised rim portion has a height of about 1/4 inch.
12.An electrical box assembly as defined in claim 4, wherein the raised rim portion has a height of about 1 1/4 inches.
13.An electrical box assembly as defined in claim 4, wherein the raised rim portion has a height of about 1 1/2 inches.
14.An electrical box assembly as defined in claim 4, wherein the raised rim portion has a height of about 2 inches.
15.An electrical box assembly as defined in claim 4, wherein the first and second tabs are mounted to the rim portion.
16.An electrical box assembly as defined in claim 15, wherein the first and the second tabs extend in a direction away from the opening.
17.An electrical box assembly as defined in claim 15, wherein the first and the second tabs extend generally parallel to the base portion.
18.An electrical box assembly as defined in claim 1, wherein the box portion is a 4 inch square trade size box portion.
19.An electrical box assembly as defined in claim 1, wherein the first and second fastener-receiving openings are non-threaded.
20.An electrical box assembly as defined in claim 1, wherein a first channel is formed between the base portion and the first tab and a second channel is formed between the base portion and the second tab.
21. An electrical box assembly as defined in claim 1, wherein at least one of the top wall and the bottom wall comprises at least one knockout, the first side wall and the second side wall being free of knockouts.
22. An electrical box assembly, comprising:
a. a cover plate having a base portion;
b. first and second tabs in a spaced apart relationship with the base portion;
c. first and second threaded apertures on the first and second tabs, respectively for receiving threaded fasteners for mounting an electrical device to the cover plate;
d. first and second fastener-receiving openings on said base portion registering with the first and second apertures respectively, the first and second fastener-receiving openings receiving the respective threaded fasteners when the threaded fasteners are engaged in the first and second threaded apertures.
a. a cover plate having a base portion;
b. first and second tabs in a spaced apart relationship with the base portion;
c. first and second threaded apertures on the first and second tabs, respectively for receiving threaded fasteners for mounting an electrical device to the cover plate;
d. first and second fastener-receiving openings on said base portion registering with the first and second apertures respectively, the first and second fastener-receiving openings receiving the respective threaded fasteners when the threaded fasteners are engaged in the first and second threaded apertures.
23.An electrical box assembly as defined in claim 22, including a box portion mounted to the cover plate, the box portion is generally square having a 4 inch trade size.
24.An electrical box assembly as defined in claim 23, wherein the first and second threaded apertures are spaced apart by a distance of about 3.5 inches.
25.An electrical box assembly as defined in claim 24, wherein the first and second fastener-receiving openings are non-threaded.
26.A cover plate for an electrical box, comprising:
a. a base portion for mounting the cover plate to the electrical box;
b. an opening for receiving an electrical device, the opening having a periphery;
c. a rim portion that projects from the base portion, the rim portion extending along at least a portion of the periphery;
d. a first tab that extends from the rim portion in a direction away from the opening, the first tab comprising a first aperture for receiving a first electrical device fastening screw; and e. a second tab that extends from the rim portion in a direction away from the opening, the second tab comprising a second aperture for receiving a second electrical device fastening screw;
d. a first fastener-receiving opening on the base portion registering with the first aperture to receive the first screw when the first screw is threadedly engaged in the first aperture;
e. a second fastener-receiving opening on the base portion registering with the second aperture to receive the second screw when the second screw is threadedly engaged in the second aperture.
a. a base portion for mounting the cover plate to the electrical box;
b. an opening for receiving an electrical device, the opening having a periphery;
c. a rim portion that projects from the base portion, the rim portion extending along at least a portion of the periphery;
d. a first tab that extends from the rim portion in a direction away from the opening, the first tab comprising a first aperture for receiving a first electrical device fastening screw; and e. a second tab that extends from the rim portion in a direction away from the opening, the second tab comprising a second aperture for receiving a second electrical device fastening screw;
d. a first fastener-receiving opening on the base portion registering with the first aperture to receive the first screw when the first screw is threadedly engaged in the first aperture;
e. a second fastener-receiving opening on the base portion registering with the second aperture to receive the second screw when the second screw is threadedly engaged in the second aperture.
27.A cover plate as defined in claim 26, comprising a first side edge, a second side edge generally parallel to the first side edge, a top edge and a bottom edge generally parallel to the top edge, the cover plate having a 4 inch trade size height, a center of the first aperture being positioned less than about 0.29"
from the top edge of the cover plate and a center of the second aperture being positioned less than about 0.29" from the bottom edge of the cover plate.
from the top edge of the cover plate and a center of the second aperture being positioned less than about 0.29" from the bottom edge of the cover plate.
28.A cover plate as defined in claim 27, wherein a distance between the center of the first aperture and the center of the second aperture is of about 3.53".
29.A cover plate as defined in claim 27, wherein the first tab and the second tab extend generally parallel to the base portion.
30.A cover plate as defined in claim 26, the cover plate is a generally square plate having a 4 inch square trade size.
31.A cover plate as defined in claim 30, the cover plate being a high voltage cover plate suitable for 347V ac applications.
32.A cover plate as defined in claim 26, wherein the rim portion projects one of 1/8", 1/4" , 1/2" 5/8", 3/4", 7/8" and 1 inch from the base portion.
33.A cover plate as defined in claim 26, wherein the cover plate is made from at least one of steel and plastic.
34.A cover plate for an electrical box, comprising:
a. a base portion for mounting the cover plate to the electrical box;
b. an opening for receiving an electrical device, the opening having a periphery;
c. a rim portion that projects from the base portion, the rim portion extending along at least a portion of the periphery;
d. a first tab that extends from the rim portion in a direction away from the opening, the first tab comprising a first aperture for receiving a first electrical device fastening screw;
e. a second tab that extends from the rim portion in a direction away from the opening, the second tab comprising a second aperture for receiving a second electrical device fastening screw;
f. a first fastener-receiving indentation on the base portion registering with the first aperture to receive the first screw when the first screw is threadedly engaged in the first aperture; and g. a second fastener-receiving indentation on the base portion registering with the second aperture to receive the second screw when the second screw is threadedly engaged in the second aperture.
a. a base portion for mounting the cover plate to the electrical box;
b. an opening for receiving an electrical device, the opening having a periphery;
c. a rim portion that projects from the base portion, the rim portion extending along at least a portion of the periphery;
d. a first tab that extends from the rim portion in a direction away from the opening, the first tab comprising a first aperture for receiving a first electrical device fastening screw;
e. a second tab that extends from the rim portion in a direction away from the opening, the second tab comprising a second aperture for receiving a second electrical device fastening screw;
f. a first fastener-receiving indentation on the base portion registering with the first aperture to receive the first screw when the first screw is threadedly engaged in the first aperture; and g. a second fastener-receiving indentation on the base portion registering with the second aperture to receive the second screw when the second screw is threadedly engaged in the second aperture.
35.A cover plate as defined in claim 34, comprising a first side edge, a second side edge generally parallel to the first side edge, a top edge and a bottom edge generally parallel to the top edge, the cover plate having a 4 inch trade size height, a center of the first aperture being positioned less than about 0.29"
from the top edge of the cover plate and a center of the second aperture being positioned less than about 0.29" from the bottom edge of the cover plate.
from the top edge of the cover plate and a center of the second aperture being positioned less than about 0.29" from the bottom edge of the cover plate.
36. A cover plate as defined in claim 35, wherein a distance between the center of the first aperture and the center of the second aperture is of about 3.53".
37.A cover plate as defined in claim 35, wherein the first tab and the second tab extend generally parallel to the base portion.
38.A cover plate as defined in claim 34, the cover plate is a generally square plate having a 4 inch square trade size.
39.A cover plate as defined in claim 34, the cover plate being a high voltage cover plate suitable for 347V ac applications.
40.A cover plate as defined in claim 34, wherein the rim portion projects one of 1/8", 1/4" , 1/2" 5/8", 3/4", 7/8" and 1 inch from the base portion.
41.A cover plate as defined in claim 34, wherein the cover plate is made from at least one of steel and plastic.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA2695110A CA2695110C (en) | 2010-03-01 | 2010-03-01 | An electrical box assembly |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA2695110A CA2695110C (en) | 2010-03-01 | 2010-03-01 | An electrical box assembly |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2695110A1 CA2695110A1 (en) | 2011-09-01 |
| CA2695110C true CA2695110C (en) | 2014-06-03 |
Family
ID=44515258
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA2695110A Active CA2695110C (en) | 2010-03-01 | 2010-03-01 | An electrical box assembly |
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| Country | Link |
|---|---|
| CA (1) | CA2695110C (en) |
Families Citing this family (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN102646530A (en) * | 2012-05-07 | 2012-08-22 | 江苏姑苏净化科技有限公司 | Clean room touch switch |
-
2010
- 2010-03-01 CA CA2695110A patent/CA2695110C/en active Active
Also Published As
| Publication number | Publication date |
|---|---|
| CA2695110A1 (en) | 2011-09-01 |
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