GB2546756A - Electrical back-box alignment spacer and method - Google Patents

Abstract

An electrical back-box alignment spacer 10 is provided for assisting with positioning and levelling adjacent electrical back-boxes 12 in or on a surface. The spacer comprises: a levelling body member 16 with a longitudinal extent adapted to span between neighbouring electrical back-boxes 12; a spacing body member 18 which extends from the levelling body member 16 and is adapted to uniformly space apart the neighbouring electrical back-boxes; and a plurality of receiver elements (32a, 32b Figure 1) each of which is adapted to receive or be received by portions of an electrical back-box or an associated component. Preferably the positioning spacer is either T-shaped or cruciform shaped- like figure 3. The levelling body member may comprise a spirit level 34. The receiver elements may be recesses which receive the corners of the neighbouring back-boxes, or the screws (144, Figure 4) of the back boxes.

Description

Electrical Back-Box Alignment Spacer and Method

The present invention relates to an alignment spacer for electrical back-boxes, in particular for electrical knockout boxes having over-folded comer portions. The invention further relates to a method of neighbouring adjacent electrical back-boxes using such a spacer.

An electrical back-box, such as an electrical knockout box, is positioned in a wall of a building structure or similar surface to allow user access to the electrical supply of a building. A standard knockout box comprises a polygonal, usually either square or rectangular, metallic container having at least a substantially continuous minor perimeter wall, an open user-facing side, and a closed back side. One or more removable sections are typically provided in the perimeter wall and/or the back side to enable electrical cables to be terminated to be inserted into the cavity defined by the container. The knockout box also generally includes engagement means, typically in the form of a female-part screw-threaded fastening, for connecting an insulated access cover thereby protecting a person in close proximity vicinity from a potential electrical shock. The access cover may include one or more switches, for example, allowing user-control of an associated lighting circuit, or the access cover may simply be a blanking plate devoid of a user-interface which simply safely closes or seals off one or more terminated or loose electrical cables embedded within the wall or surface.

Often, such electrical back-boxes are placed, for convenience, close to one another. This also serves to improve the appearance of a room in which such electrical boxes are installed. However, in order to create an aesthetically appealing installation, an electrician must install the electrical boxes so as to be neatly spaced from one another, and also level to the horizontal, particularly if access covers with switches are to be mounted thereto. Since such boxes are often positioned near to a skirting board in a house, misalignment to the horizontal can be very visually jarring.

For knockout boxes in particular, the process by which they are manufactured results in projecting comer portions on an upper edge of the box. This makes it difficult to successfully balance a spirit level on top of the box in order to ensure that it is correctly levelled.

Similarly, for electrical back-boxes which are installed post-plastering in a building, the electrical back-boxes will be near-flush to the wall. As such, it can be difficult for the installer to find sufficient purchase upon which to balance their spirit level. This can lead to the installation of electrical boxes which are not levelled.

It is therefore an object of the invention to provide an electrical back-box alignment spacer which is capable of obviating and/or limiting the above-mentioned problems.

According to a first aspect of the invention, there is provided an electrical back-box alignment spacer for assisting with positioning and levelling adjacent electrical back-boxes in or on a surface, the electrical back-box alignment spacer comprising: a levelling body member having a longitudinal extent adapted to span between neighbouring electrical back-boxes; a spacing body member which extends from the levelling body member and is adapted to uniformly space apart the neighbouring electrical back-boxes; and a plurality of receiver elements, each of which is adapted to receive or be received by portions of an electrical back-box or an associated component.

The term ‘back box’ is used herein and throughout and is intended to also mean ‘knockout box’. A back box is defined as an electrical enclosure mounted on or in a surface for receiving at least one electrical cable therein and to which an electrically insulating face plate is mountable. The faceplate may include one or more switches and/or sockets, or may be a blanking plate devoid of a user-interface or electrical-equipment interface.

By providing an alignment spacer which has a spacing body member positionable between neighbouring electrical back-boxes, laterally extending elements of a levelling body member can be provided which are engageable with portions of the electrical back-box which would otherwise not be suitable for resting a spirit level thereon. A level of the spacer can then be measured instead of the back-box itself, allowing the indirect measurement of the level of adjacent electrical back-boxes. In doing so, it is beneficially possible to simultaneously space apart and level multiple electrical back-boxes, thereby improving the accessibility and appearance of the electrical back-boxes, and consequently the appearance of the finally mounted electrically-insulating access cover.

Preferably, the spacing body member may depend from a lower surface of the levelling body member. The levelling body member may comprise first and second lateral body elements extending in opposite directions from the spacing body member, in which case each lateral body element may have a planar or substantially planar lower surface adapted to rest upon an electrical back-box. One said receiver element may be positioned at or adjacent to the spacing body member in or on each of the planar lower surfaces of the lateral body elements, and/or the lower surfaces of the lateral body elements may be co-planar with one another. Optionally, a lateral extent of each of the first and second lateral body elements may be identical. In one preferable embodiment, the receiver elements are formed as recesses in at least one of the levelling body member and the spacing body member.

Planar lower surfaces of the lateral body elements are able to sit on a top wall of an electrical back-box, with the receiver elements accommodating the projections on the top wall which are formed as part of the manufacturing process of the electrical back-box. This overcomes the difficulty associated with attempting to take a level from the non-planar top wall of the electrical back-box.

The spacer may preferably be ‘T’-shaped, first and second said receiver elements being respectively positioned at inner corners of the ‘Τ’.

Such an arrangement permits the user to easily rest the levelling body member on top of the neighbouring electrical back-boxes, spanning both, whilst the spacing body member provides the stem of the T, nestling between the two electrical back-boxes.

Preferably, the levelling body member may have a planar upper surface. Additionally or alternatively, an extent of the levelling body member may be greater than that of the spacing body member.

By providing a wide and planar upper surface for the alignment spacer, it becomes simple for an installer to rest a separate spirit level thereon so as to measure a horizontal aspect of the electrical back-boxes more efficiently.

In another preferable embodiment, the spacing body member may extend from upper and lower surfaces of the levelling body member. The receiver elements may be adapted to be engagable with at least one aperture of electrical back-boxes, in which case, the receiver elements may be formed as screw guides in or through the levelling body member. A depth of the spacing body member may be at least in part greater than a depth of the levelling body member, and/or the alignment spacer may be or substantially be cruciform.

This embodiment advantageously allows the installer to insert the spacer between adjacent electrical back-boxes following the plastering of a given wall, where there might not otherwise be sufficient clearance on a top wall of the electrical back-box to rest a lower surface of each of the first and second horizontal body elements. Such a tool beneficially increases the opportunity for an installer to efficiently align and level electrical back-boxes in a number of different potential scenarios.

The alignment spacer may further comprise a spirit level integrated into the spacer, and/or the alignment spacer may be at least in part magnetic or magnetisable.

The alignment spacer may be formed of or include a magnetically engagable material. This is advantageous in allowing a spirit level with an integrated magnet to releasably attach to the spacer, thereby providing added security against unintentionally dropping items whilst the installer is working. Additionally or alternatively, the electrical back-box alignment spacer may include an integrated spirit level, thereby dispensing with the need for a separate spirit level.

Preferably, the levelling body member and spacer body member may be unitarily formed with one another. Furthermore, the levelling body member may be or may substantially be horizontal in use, the spacing body member may be or substantially be vertical in use. A single tool which can be used to ensure alignment and levelling of neighbouring electrical back-boxes would greatly simplify the ease with which an installer may ensure neat positioning of such electrical back-boxes.

According to a second aspect of the invention, there is provided a method of aligning neighbouring electrical back-boxes, the method comprising the steps of: a] providing an electrical back-box alignment spacer, preferably in accordance with the first aspect of the invention; b] inserting the spacing body member between two neighbouring electrical back-boxes; c] re-positioning the two neighbouring electrical back-boxes until the levelling body member is in a desired alignment; d] securing the electrical back-boxes into position; and c] extracting the electrical back-box alignment spacer.

During step b], the levelling body member may be positioned so as to rest on top edges of the neighbouring electrical back-boxes, or alternatively, during step b], the receiver elements may be aligned with faceplate apertures of the neighbouring electrical back-boxes.

In providing such alignment spacers, it becomes possible for an electrician to utilise a single tool to enable both accurate spacing of adjacent electrical back-boxes whilst simultaneously levelling both electrical back-boxes. This simplifies the process of installation, thereby reducing the time required to attend to the installation of such electrical back-boxes.

According to a third aspect of the invention, there is provided an electrical back-box alignment spacer for assisting with positioning and levelling adjacent electrical back-boxes in or on a surface, the electrical back-box alignment spacer comprising: a levelling body member having a longitudinal extent adapted to span between neighbouring electrical back-boxes; and a spacing body member which extends from the levelling body member and is adapted to uniformly space apart the neighbouring electrical back-boxes.

It may be possible to provide an alignment tool which can be used without the receiver elements, if the clamping between neighbouring electrical back-boxes is sufficient so as to permit levelling thereof without fixing of the alignment spacer. This would further simplify the installation process for the electrician.

The invention will now be more particularly described, by way of example only, with reference to the accompanying drawings, in which:

Figure 1 shows a perspective representation of a first embodiment of an electrical back-box alignment spacer, in accordance with the first aspect of the invention;

Figure 2 shows a front view of the alignment spacer of Figure 1, in use with two electrical knockout boxes;

Figure 3 shows a perspective representation of a second embodiment of an electrical back-box alignment spacer in accordance with the first aspect of the invention; and

Figure 4 shows a front view of the alignment spacer of Figure 3, in use with two electrical back-boxes.

Referring to Figure 1, there is shown globally an electrical back-box alignment spacer 10 for use in the installation of electrical back-boxes. The embodiment illustrated is of particular use in the installation of electrical knockout boxes 12, as can be seen from Figure 2, which shows the alignment spacer 10 in use.

The alignment spacer 10 is here formed having a ‘Τ’-shaped body 14, which may be unitarily formed from a single piece of material, typically metal or plastics material. A multi-part electrical back-box alignment spacer could be considered, however.

The body 14 here comprises a levelling body member 16 which has first and second lateral body elements 16a, 16b, which extend in opposite directions to one another about a spacing body member 18 which depends in a downward direction from the levelling body member 16.

The spacing body member 18 is here formed as a preferably cuboidal block having a uniform width in the direction of extent of the first and second lateral body elements 16a, 16b, and is sized to provide a predetermined and uniform separation between two adjacent electrical back-boxes 12 to be installed. The spacing body member 18 therefore has two opposite side surfaces 20 which are co-planar, and positionable against a side wall 22 of an electrical back-box 12 in use. A plurality of alignment spacers 10, each having a different width of vertical body element 18, may be provided to allow an installer to select a desired separation between neighbouring electrical back-boxes 12.

As illustrated, the first and second lateral body elements 16a, 16b of the levelling body member 16 are formed so as to be mirror images of one another; however, it may be desirable, for example, for ease of storage, to provide asymmetric first and second lateral body elements 16a, 16b, which may improve the stackability of such an alignment spacer.

The levelling body member 16 is formed as a preferably cuboidal block, and has upper and lower surfaces 24, 26. As illustrated, the upper surface 24 may define a continuous planar upper surface across the both of the lateral body elements 16a, 16b.

The lower surface 26 has first and second separate lower surface portions 28a, 28b which are respectively associated with the first and second lateral body elements 16a, 16b. Each lower surface portion 28a, 28b may be at least in part planar, and the first and second lateral body elements 16a, 16b are dimensioned such that the planar portions of the first and second lower surface portions 28a, 28b are co-planar. This allows the alignment spacer 10 to rest the first and second lower surface portions 26a, 26b respectively on top walls 30 of adjacent electrical back-boxes 12 to assist with the alignment thereof. The levelling body member 16 is therefore dimensioned so as to have an extent which can span between such neighbouring electrical back-boxes 12.

At or adjacent to the spacing body member 18 in the first and second lower surface portions 28a, 28b of the first and second lateral body elements 16a, 16b may be formed receiver elements which are adapted to receive or be received by portions of the electrical back-box 12 or an associated component. Here, said receiver elements are respectively formed as first and second recesses 32a, 32b, being arced portions cut into the first and second lateral body elements 16a, 16b. These first and second recesses 32a, 32b are effectively formed at the inner comers of the ‘Τ’ of the body 14 of the alignment spacer 10 in the depicted embodiment. As such, the first and second recesses 32a, 32b may at least partially extend into the side surfaces 20 of the spacing body member 18, and/or may potentially be formed only in the levelling body member 16 or the spacing body member 18, dependent upon the shape of the electrical back-boxes 12 with which the alignment spacer 10 is to be used.

It may be preferable to incorporate one or more spirit levels 34 directly into the alignment spacer 10, as can be seen in Figures 1 and 2, so as to ensure that the alignment spacer 10 is levelled when in use. In this case, the spirit level 34 is provided at or adjacent to the upper surface 24 of the levelling body member 16 to determine a horizontal aspect. However, an additional spirit level may be provided at the spacing body member 18 for determining a vertical aspect of the alignment spacer 10 when in use.

The integrated spirit level or levels may be dispensed with or supplemented. The continuous planar upper surface 24 of the alignment spacer 10 may be sized so as to be able to accommodate a separate spirit level thereon. In this case, a magnetic and/or magnetisable element may be integrated within the levelling body member 16 and/or the spacing body member 18. This is beneficial in magnetically engaging a separate spirit level having an incorporated magnet.

The primary use of the depicted alignment spacer 10 is as shown in Figure 2, that is, to provide a means for aligning adjacent electrical knockout boxes 12 having upper and lower over-folded corner portions 36a, 36b which would otherwise prevent the easy resting of a spirit level thereacross.

In use, the two electrical back-boxes 12 are positioned in approximately correct positions in or on the wall to which they are to be installed. The spacing body member 18 is then positioned between the two electrical back-boxes 12 such that the parallel side surfaces 20 of the spacing body member 18 respectively contact the side walls 22 of the electrical back-boxes 12. Preferably, and as illustrated in Figure 2, the spacing body member 18 is sized so as to extend along a majority, but not the entirety, of the height of the side wall 22 of the electrical back-box 12, which is typically of the order of 70mm in height. This ensures that the separation between the two electrical back-boxes 12 is as uniform as possible, without the spacing body member 18 interfering with the lower over-folded corner portions 36b. A typical length of spacing body member 18 might be in the range of 35mm to 60mm; as such, the extent of the levelling body member 16 will typically be greater than that of the spacing body member 18.

The levelling body member 16 is here perpendicular to and extending across the top of the spacing body member 18, thus defining the first and second lateral body elements 16a, 16b, and is arranged so as to be able to sit on the top walls 30 of the electrical back-boxes 12, with the first and second recesses 32a, 32b accommodating the protruding upper over-folded corner portions 36a of the electrical back-boxes 12. This allows the lower surface portions 28a, 28b of the first and second lateral body elements 16a, 16b to rest level.

The positions of the electrical back-boxes 12 can then be adjusted until the spirit level 34 indicates that the pair of electrical back-boxes 12 are, as a whole, level. The spacing body member 18 then ensures that the spacing between the two electrical back-boxes 12 remains uniform whilst the levelling occurs. The electrical back-boxes 12 can then be fixed in position, for instance by filling and plastering, before the alignment spacer 10 is removed once the boxes 12 are secure. A second embodiment of the invention is illustrated globally in Figure 3 at 110. This alignment spacer 110 is intended for use in positioning adjacent electrical back-boxes 112 where the plastering of a wall may already be complete, and therefore the alignment spacer 110 is unable to be rested onto the top walls 120 of the electrical back-boxes 112. For this second embodiment, identical and similar components will be referred to utilising identical and similar references, respectively, and therefore further detail description will be omitted for brevity.

The alignment spacer 110 here preferably has a cruciform body 114, having a levelling body member 116 which is crossed by the spacing body member 118. As a result, the spacing body member 118 defines upper and lower body elements 118a, 118b which respectively project above and below the levelling body member 116 when it is horizontally aligned. Lateral body elements 116a, 116b of the levelling body member 116 thus extend away from the spacing body member 118 in a similar manner.

As illustrated, the spacing body member 118 has an increased depth with respect to the levelling body member 116, resulting in a deeper portion 138 thereof, so as to allow the upper and lower body elements 118a, 118b to be positioned between adjacent electrical back-boxes 112 with the first and second lateral body elements 116a, 116b each lying over a front face of the electrical back-boxes 112. It will be appreciated, however, that the entire extent of the upper and lower body elements 118a, 118b need not necessarily be deeper than the first and second lateral body elements 116a, 116b. For example, deeper portions may be provided at a top end 140 of the upper body element 118a and at a bottom end 142 of the lower body element 118b.

In use, the alignment spacer 110 is here designed to act as a guide for aligning electrical back-boxes 112 where the top walls 120 thereof cannot be used as rests for the levelling body member 116. The deeper portion 138 of the spacing member 118 may be inserted between and pushed into contact with side walls 120 of the electrical back-boxes 112, thereby ensuring a uniform separation between the two electrical back-boxes 112.

The receiver elements of the alignment spacer 110 are here formed as first and second screw guides 132a, 132b positioned in the lower surfaces 128a, 128b of the first and second lateral body elements 116a, 116b, and are positioned to as to be capable of aligning with faceplate screw-threaded apertures 144 of the electrical back-boxes 112 when in contact with the side walls 120 thereof. During installation, the first and second screw guides 132a, 132b can be temporarily secured to the electrical back-boxes 112 using screw-threaded fasteners, which will then ensure a correct relative alignment of the electrical back-boxes 112.

It will be appreciated, however, that the screw guides could feasibly be formed through the first and second lateral body elements 116a, 116b, if so desired, rather than on the lower surfaces 128a, 128b. Furthermore, although screw guides 132a, 132b are suggested, projections, such as pins, may be utilised as an alternative or in addition, the projections being receivable in the apertures 144 as a sliding close fit. The projections would therefore preferably be integrally formed with back surfaces of the lateral body elements 116a, 116b.

The two conjoined and aligned electrical back-boxes 112 can then be levelled using a spirit level, which could potentially be incorporated into the body 114; however, this is not the case for the depicted embodiment. The fact that the upper body element 118a projects forwardly of the front faces of the electrical back-boxes 112 ensures that the top end 140 thereof can act as a rest upon which a spirit level can be positioned in order to ensure a perfect level of the electrical back-boxes 112.

Once level, the electrical back-boxes 112 can be secured into the wall in which they are being installed. The screw-threaded fasteners, if applicable, can then be removed, and the alignment spacer 110 extracted without difficulty.

It will be appreciated that the alignment spacer 10, 110 as described could readily be used only to provide for a predetermined spacing and alignment between adjacent electrical back-boxes 12, 112. There is no specific need to ensure that the electrical back-boxes 12, 112 are level to the horizontal, for instance. It will therefore be apparent that, within the context of the present invention, the levelling body element 16, 116 will likely be positioned so as to be horizontal or substantially horizontal in use, and similarly the spacing body element 18, 118 will likely be positioned so as to be vertical in use.

It is therefore possible to provide an alignment spacer which has at least a levelling body member and a spacing body member, each of which is contactable with an electrical back-box which is to be installed in a wall or similar surface, so as to permit an installer to accurately space the electrical back-boxes relative to one another, as well as maintaining a level of the boxes relative to the horizontal. Receiver elements may ideally be provided so as to assist with coupling the alignment spacer to the neighbouring electrical back-boxes.

The words ‘comprises/comprising’ and the words ‘having/including’ when used herein with reference to the present invention are used to specify the presence of stated features, integers, steps or components, but do not preclude the presence or addition of one or more other features, integers, steps, components or groups thereof.

It is appreciated that certain features of the invention, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable sub-combination.

The embodiments described above are provided by way of examples only, and various other modifications will be apparent to persons skilled in the field without departing from the scope of the invention herein described and defined.

Claims (26)

Claims

1. An electrical back-box alignment spacer for assisting with positioning and levelling adjacent electrical back-boxes in or on a surface, the electrical back-box alignment spacer comprising: a levelling body member having a longitudinal extent adapted to span between neighbouring electrical back-boxes; a spacing body member which extends from the levelling body member and is adapted to uniformly space apart the neighbouring electrical back-boxes; and a plurality of receiver elements, each of which is adapted to receive or be received by portions of an electrical back-box or an associated component.

2. An electrical back-box alignment spacer as claimed in claim 1, wherein the spacing body member depends from a lower surface of the levelling body member.

3. An electrical back-box alignment spacer as claimed in claim 1 or claim 2, wherein the levelling body member comprises first and second lateral body elements extending in opposite directions from the spacing body member.

4. An electrical back-box alignment spacer as claimed in claim 3, wherein each lateral body element has a planar or substantially planar lower surface adapted to rest upon an electrical back-box.

5. An electrical back-box alignment spacer as claimed in claim 4, wherein one said receiver element is positioned at or adjacent to the spacing body member in or on each of the planar lower surfaces of the lateral body elements.

6. An electrical back-box alignment spacer as claimed in claim 5, wherein the lower surfaces of the lateral body elements are co-planar with one another.

7. An electrical back-box alignment spacer as claimed in any one of claims 3 to 5, wherein lateral extent of each of the first and second lateral body elements is identical.

8. An electrical back-box alignment spacer as claimed in any one of the preceding claims, wherein the receiver elements are formed as recesses in at least one of the levelling body member and the spacing body member.

9. An electrical back-box alignment spacer as claimed in any one of the preceding claims, wherein the spacer is ‘T’-shaped, first and second said receiver elements being respectively positioned at inner corners of the ‘Τ’.

10. An electrical back-box alignment spacer as claimed in any one of the preceding claims, wherein the levelling body member has a planar upper surface.

11. An electrical back-box alignment spacer as claimed in any one of the preceding claims, wherein an extent of levelling body member is greater than that of the spacing body member.

12. An electrical back-box alignment spacer as claimed in claim 1, wherein the spacing body member extends from upper and lower surfaces of the levelling body member.

13. An electrical back-box alignment spacer as claimed in claim 12, wherein the receiver elements are adapted to be engagable with at least one aperture of electrical back-boxes.

14. An electrical back-box alignment spacer as claimed in claim 13, wherein the receiver elements are formed as screw guides in or through the levelling body member.

15. An electrical back-box alignment spacer as claimed in any one of claims 12 to 14, wherein a depth of the spacing body member is at least in part greater than a depth of the levelling body member.

16. An electrical back-box alignment spacer as claimed in any one of claims 12 to 15, wherein the alignment spacer is or is substantially cruciform.

17. An electrical back-box alignment spacer as claimed in any one of the preceding claims, further comprising a spirit level integrated into the spacer.

18. An electrical back-box alignment spacer as claimed in any one of the preceding claims, wherein the alignment spacer is at least in part magnetic or magnetisable.

19. An electrical back-box alignment spacer as claimed in any one of the preceding claims, wherein levelling body member and spacer body member are unitarily formed with one another.

20. An electrical back-box alignment spacer as claimed in any one of the preceding claims, wherein the levelling body member is or is substantially horizontal in use.

21. An electrical back-box alignment spacer as claimed in any one of the preceding claims, wherein the spacing body member is or is substantially vertical in use.

22. An electrical back-box alignment spacer substantially as hereinbefore described, with reference to Figures 1 and 2, or Figures 3 and 4.

23. A method of aligning neighbouring electrical back-boxes, the method comprising the steps of: a] providing an electrical back-box alignment spacer as claimed in any one of the preceding claims; b] inserting the spacing body member between two neighbouring electrical back-boxes; c] re-positioning the two neighbouring electrical back-boxes until the levelling body member is in a desired alignment; d] securing the electrical back-boxes into position; and e] extracting the electrical back-box alignment spacer.

24. A method as claimed in claim 23, wherein during step b], the levelling body member is positioned so as to rest on top edges of the neighbouring electrical back-boxes.

25. A method as claimed in claim 23, wherein during step b], the receiver elements are aligned with faceplate apertures of the neighbouring electrical back-boxes.

26. An electrical back-box alignment spacer for assisting with positioning and levelling adjacent electrical back-boxes in or on a surface, the electrical back-box alignment spacer comprising: a levelling body member having a longitudinal extent adapted to span between neighbouring electrical back-boxes; and a spacing body member which extends from the levelling body member and is adapted to uniformly space apart the neighbouring electrical back-boxes.