GB2440371A

GB2440371A - Surface box having compressible ratchet teeth for mounting within an opening

Info

Publication number: GB2440371A
Application number: GB0614575A
Authority: GB
Inventors: Alasdair John Convery; Caroline Nancy Wrinch
Original assignee: Cableduct Ltd
Current assignee: Cableduct Ltd
Priority date: 2006-07-21
Filing date: 2006-07-21
Publication date: 2008-01-30
Anticipated expiration: 2026-07-21
Also published as: GB2440371B; GB0614575D0

Abstract

A surface box comprising a plurality of side walls, at least one of which includes a plurality of compressible teeth 17. When the surface box is inserted into an opening in a floor the teeth 17 compress. If the floor is sufficiently thin the teeth 17 will spring back to their original form after passing under the floor. An upper edge or surface 21 of a tooth 17 may then abut against the lower surface 22 of the floor to prevent removal of the surface box. The teeth 17 are preferably formed on a separate side panel which may attach to a side wall of the box at various positions to accommodate openings of different sizes. This side panel may be biased outwardly away from the surface box into engagement with the opening by a resilient member (15, figure 2a). When the user wishes to remove the surface box the teeth 17 may be retracted towards the centre of the surface box. The floor mounted surface box requires no installation tools. Independent claims are included for a ratchet, or hook and latch mechanism used to attach a trim unit to the main portion of the surface box (figure 4). The outlet flaps formed on the trim unit may be biased into a shut position using, for example, a spring (figure 5).

Description

SURFACE BOXES

This invention relates to surface boxes that provide electrical and data terminals to under floor cabling systems. Flying leads connect to the boxes from above floor devices such as telephones and computers.

Surface boxes generally comprise a main portion for holding the electrical leads and components and a trim portion for covering the surface box. The trim portion generally comprises a main flap for accessing the electrical components and leads and one or more outlet flaps through which leads can be fed.

This invention dramatically decreases the installation time of the surface box, with no noticeable increase in price and an increase in quality by its further feature of spring closing outlet flaps. This solves a common problem of outlet flaps being knocked out by being left open when the box is not in use. Furthermore, it is intended that the spring, should the flap be knocked out, will retain the flap preventing loss.

Surface boxes usually need to deliver five main features: 1. A trim that overlaps the carpet and stops the box falling through the hole; 2. A lid that opens up allowing access to the electrical and data terminals; 3. An outlet flap which allows cables to pass through the box when the lid is closed; 4. A base box to hold the electrical and data terminals; 5. A means of fixing the box to the surface.

When installing a box the first thing that needs doing is to fix it to the desired surface. Once the necessary hole is cut in the floor the box must be inserted into the hole.

Previous methods for doing this have required tools, more than one manual operation, have had surface thickness limitations or operate by friction fit that could work itself free. Once these boxes have been fixed to a surface they typically cannot be removed without the aid of tools.

The present invention enables the box to be pushed flush with the surface and it automatically latches itself to the underside of the floor surface preventing the box from passing back up through the hole. Additionally, sufficient frictional forces with the side walls of the opening to prevent its removal. The latching devices are preferably arranged such that they will latch onto the underside of a floor of thickness up to approximately 50 mm.

However, advantageously, should the floor be thicker than this the frictional forces with the side walls of the opening will keep the surface box in position.

In addition, if the user wishes to remove the box, there are handles that when pulled will release the latching devices, sliding them in and allowing them to pass back up through the opening.

Once the box is installed and wire connections made, a carpet or other floor finish is usually laid. For this to happen the trim must be removed during carpet laying and then replaced over the carpet back onto the box. Previously this has required tools or a number of different parts attached to the trim and or base box.

In some cases where the quick fit to floor mechanism is fitted to the trim it is not possible to remove the frame without making the main portion of the surface box loose in the floor which puts the floor fitter at risk from the cables beneath.

The present invention operates by a latching (or ratchet) mechanism. For example, the trim may have one or more hooks for cooperation with one or more latches or louvers.

The hooks interfere with their matching set of louvers or latches, which are punched into the base box, stopping the trim from being lifted out of the box. When the trim is to be removed the hooks are disengaged from the louvers allowing the trim to pass up out of the box. This may conveniently be achieved by the hooks having sufficient flexibility and comprising handles.

Once a box has been fully installed and is being used, there is a tendency for the outlet flaps to get knocked out and then often lost, leaving a hazardous hole in the middle of the lid.

Outlet flaps are separate parts that when assembled sit in the lid to the box and when both the lid and flap are closed sit flush with the floor and the rest of the box. When cables need to run through the flap into the box the lid needs to be lifted, cables plugged in so that they run through the cable guides and then when the lid shuts the flap(s) open automatically.

In previous inventions only gravity is used to shut the flap when not in use. Thus frequently flaps are left open when not in use and get kicked out.

In the present invention, the outlet flaps are biased shut so that when there are no cables running through them they automatically pull closed. This is preferably achieved by spring loading. As outlet flaps can only get knocked out when open, ensuring that they are closed and flush with the floor when not in use dramatically decreases the chance for them to get knocked out. As a secondary measure if the flap gets knocked out when in use the spring will stretch and act as a retention cord keeping the flap connected to the box so it will not get lost and can be put back into position.

A number of drawings are used as reference to help describe the invention.

Figure 1 depicts an isometric view of the assembled surface box; Figure 2a, b show how a side panel clips onto the base box; Figure 2c shows a side panel in position on a base box; Figure 3a, b, c show how the surface box push fit mechanism operate; Figure 4 shows how the trim push fit mechanism operates; and Figure 5 depicts an outlet flap biasing mechanism.

The whole assembly needs to be mounted firmly into its designated opening, which is achieved by one or more side panels (5) that clip onto sides of the base box (4). Each surface box preferably comprises two side panels, arranged on opposite ends of the base box.

The side panels attach to the base box by bending the clips (6) slightly and poking them through their corresponding holes (7) on the base box. When in position an outward facing face (11) of clip (6) will snap over side wall (12) and keep the side panel from faIling back out of the base box. Clip (6) additionally comprises inward facing face (14) which protrudes laterally from clip (6). Inward facing face (14) abuts against the outer face of the sidewall of the base box (4) which keeps the side panel (5) a predetermined distance away from the sidewall (12) of the base box (4). As an alternative, or additionally clip (6) may comprise a plurality of inward facing faces (14) arranged in, for example, a saw tooth type arrangement.

This allows the side panel (5) to be positioned at a number of different predetermined distances from the sidewall (12) and could be used to accommodate the surface box in openings of slightly differing sizes.

The side panel may additionally comprise a flange (15) which is spring loaded away from the sides of the base box (4). This, together with outward facing face (11) keeps the side panel (5) firmly in position and prevents it from rattling around. The side panels (5) are flexible but may be given additional rigidity by a steel plate (16) attached to the side panel.

The side panel (5) comprises a plurality of louvers arranged vertically above one another (17) that protrude making the box as a whole bigger than the opening it needs to fit.

Each louver comprises an angled face (18) and a top face (21) which is substantially perpendicular to the main face of the side panel. To allow sufficient flexibility the louvers are preferably hollow. As the box is pushed into the opening the angled face (18) of each louver hits the top edge of the side wall (19) of the opening. Due to the hollow construction of the louvers each louver compresses allowing the box to get pushed in the opening. As the Jouvers pass the bottom edge (22) of the sidewall they will spring back to their original, undeformed shape due to the elastic nature of the material. A portion of the top face (21) of at least one of the louvers will therefore abut against the bottom edge (22) of the opening thus preventing the box from passing back through the opening if the floor is sufficiently thin for the louvers to extend beneath the floor. Base box (4) preferably comprises a flange (23) which protrudes out beyond the sidewalls. When the base box is fully inserted the flange (23) abuts against the floor and prevents the box from going any further through the opening.

The louvers should be sufficiently compressible that they do not provide an excessive resistance to insertion of the box into the opening as would hinder manual insertion without tools. They should also be more compressible than the material (which may be wood, plaster board, mdf or the like) of the floor or wall into which the box is to be mounted, so as not to damage the opening.

The top face of the louver prevents the louver folding downwards when the box is pulled out of the surface in which it is installed. This function may alternatively or in addition be performed by sidewalls or ties connecting the angled face (18) to the side panel at one or more points near its upper edge. As a further alternative, the angled face can be curved in plan so that the louver has the form of a half cup, which may be open or closed. * -5-

The surface box is thus kept in position by one or both of two methods, depending on the depth of the floor or other surface in which it is installed. Firstly, the abutting of at least a portion of a top face (21) of one of the louvers against the bottom face of the sidewall and secondly the outward force generated by the compression of the louvers which generates friction, and thus resistance to motion. Rather than have a single lug that bites into the sidewall, the invention uses the combined effect of a large number of louvers to give a high resistance to withdrawal, even if the frictional force exerted by each louver is relatively small.

In an embodiment of the invention there are preferably at least 10, more preferably from 10 to louvers, most preferably from 30 to 80 louvers per side panel, so that a sufficient number will engage the sidewall whatever its depth. A single design of surface box can therefore be used in openings in a variety of different floor depths. The plurality of louvers preferably extend over a depth of from about 40 to about 60mm and the lowest is positioned to allow the surface box to be fixed in position using the abutment of the louvers up to a desired maximum floor depth e.g. of about 55 to 75mm.

The distance that the louvers project from the side wall of the box should be sufficient to provide a grip on the back of the floor or wall into which the box is mounted and to accommodate tolerances in the size of the opening of, for example, up to 3mm. Thus the louvers may project a distance in the range of from 2 to 8mm, preferably from 4 to 6mm.

The side panel(s) may additionally comprise guides (8) which fit through corresponding holds (10) in the base box. The guides may each comprise a stopper (9) which prevents the side panel from disconnecting from the base box (4).

To remove the box from the floor the clips (6) on the side panel (5) need to be moved to shift inward facing face (14) out of abutment with the side wall of the base box allowing it to now fit through the hole (7) in the base box so when pulled inwards will do so. This moves the side panel towards the base box contracting the surface box as a whole to a size smaller than that of the opening allowing it to pass back up through it. The side panels can thus be moved in and out to releasably install and uninstall the surface box in an opening without the need for tools.

The trim unit comprises a hook (27) and the base box (4) comprises a plurality of latches (28, 30). Hook (27) has sufficient flexibility that when it is pushed past latches (28, 30) it will elastically deform. The trim unit comprises a flange (39) which protrudes beyond * -6-the perimeter of the base box (4). There are preferably a plurality of latches (28, 30) arranged at different heights such that the hook (27) will cooperate with a different hatch depending on the depth of the carpet. For example latch (28) may be used when there is no carpet or a very thin carpet whereas latch (30) may be used when there is a thicker carpet. To remove the trim unit hook (27) is bent back, taking it out of cooperation with the latches. To ease manoeuvrability of the hook a handle (25) may be provided.

The trim unit generally comprises a lid (2) which comprises one or more outlet flaps (3). The outlet flaps are attached to the lid by a hinge mechanism and there may additionally be guiding slots (32) for guiding the rotation of the outlet flap (3). The outlet flap comprises a biasing mechanism which is this embodiment is a spring (36). The spring (36) is attached to, by, for example, hooking over pegs (37, 38) on the main portion of the lid and the outlet flap.

Although described here as a separate unit the spring could also be integral with the lid and/or outlet flap(s).

Claims

CLAIMS

1. A surface box for electrical components for insertion into an opening, the surface box comprising a plurality of sidewalls, at least one of said sidewalls comprising a plurality of louvers, said louvers spaced apart in the direction away from the bottom of said surface box, each louver having an angled portion forming an acute angle with said sidewall, said angled portion having an upper edge, said louvers being compressible in a direction perpendicular to the plane of said sidewall to allow insertion into the opening substantially without damage thereto.

2. A surface box according to claim 1, wherein said upper edgeoLthe one of said louvers that is furthest from an open face of said box is nirethanabout 50 mm from said open face.

3. A surface box according to either claim 1 or claim 2, wherein said louvers are sufficiently resilient that when compressed by side walls of said opening they generate a frictional force resisting said surface box from being removed from said opening.

4. A surface box according to any one of claims Ito 3, wherein said plurality of louvers are sufficiently compressible to allow manual insertion of the box into the opening.

5. A surface box according to any one of claims 1 to 4, wherein said plurality of louvers can be moved in towards the centre of said surface box to allow said surface box to be removed.

6. A surface box according to claim 5, wherein said louvers are arranged on a plate, said plate being attached to said surface box by a releasable latching mechanism such that said plate can be positioned, using said latching mechanism, at a plurality of lateral positions.

7. A surface box according to any one of the preceding claims wherein said louvers further comprise an upper surface at the top of said angled portion.

8. A surface box according to claim 7 wherein said upper surfaces of said louvers are substantially perpendicular to said sidewall.

9. A surface box according to any one of the preceding claims wherein said louvers project from said side wall a distance in the range of from 2 to 8mm, preferably from 4 to 6mm.

10. A surface box according to any one of the preceding claims wherein there are at least 10 louvers, preferably between 10 and 100 louvers and most preterably 30 to 80 louvers per side panel.

11. A surface box for electrical components for insertion into a floor opening, said surface box comprising a pluralily of side walls, a trim unit for providing a cover to said surface box wherein said trim unit and at least one of said sidewalls are attached to each other by a releasable latch mechanism.

12. A surface box according to claim 11, wherein said trim unit comprises an opening.

13. A surface box according to either claim 11 or claim 12, wherein one of said trim unit and at least one sidewall comprises a hook and the other of said trim unit and said sidewall comprises a plurality of latches.

14. A surface box according to claim 13, wherein said hook is sufficiently flexible to be released from said latches.

15. A surface box according to claim 13, wherein said latches are sufficiently flexible to release said hook.

16. A surface box for electrical components for insertion into a floor opening, said surface box comprising an outlet flap for covering at least part of the top of said surface box wherein said outlet flap is biased into a shut position.

17. A surface box according to claim 16 further comprising a spring for biasing said outlet flap into a shut position.

18. A surface box according to claim 17, wherein said spring does not form an integral part of said outlet flap.

19. A surface box according to claim 17, wherein said spring forms an integral part of said outlet flap.

20. A surface box substantially as herein described with reference to the accompanying figures.