IE20030065U1 - An electrical box - Google Patents

Abstract

ABSTRACT An electrical box (1) of sheet material for mounting a single socket or an electrical switch recessed in a stud wall comprises a base wall (5), a pair of spaced apart first and second side walls (6,7) and a pair of spaced apart first and second end walls (8,9) which together define a hollow interior region (10) for accommodating the socket or switch. First and second mounting lugs (l5, 16) extend from respective opposite ends of the first side wall (6), and third and fourth mounting lungs (18,19) extend from the first and second end walls (8,9) for facilitating mounting of the electrical box (1) to a stud of the stud wall. The first and second mounting lungs (15,16) are deformable so that they can be selectively aligned with each other and with the first side wall (7), or with the corresponding one of the third and fourth mounting lugs (18,19) and the corresponding one of the first and second end walls (8,9) for facilitating mounting of the electrical box (1) to the stud wall with either the first side wall (6) or one of the first and second end walls (8,9) abutting the stud of the stud wall.

Description

The present invention relates to an electrical box, and in particular, to an electrical box which is suitable for recess mounting an electrical fitting, for example, an electrical socket, an electrical switch or the like in a stud wall.

Electrical boxes for recess mounting sockets, switches, television cable terminals, telephone and computer terminals and the like, both double sockets and single sockets are well known. Typically, they are of sheet metal material, and are formed in one piece by appropriately cutting out a blank from the sheet metal, and then appropriately bending the blank. Such electrical boxes, typically are recessed into a masonry wall, and are secured in the recess for receiving the electrical fitting. While such electrical boxes are quite adequate for masonry walls, they are not particularly suitable for use in stud walls, and in particular, stud partition walls. In general, because of the construction of such stud walls, it is necessary to drill screw accommodating holes through a side or end wall of such electrical boxes for accommodating wood screws for securing the box to one of the studs of the stud wall, with a side or end wall of the electrical box abutting the stud. Alternatively, it is necessary to chisel a recess in one of the studs for recessing the electrical box into the stud. Irrespective of how such electrical boxes are secured to a stud in a stud wall, significant additional work is required in order to adequately secure the electrical box in the stud wall. This is undesirable, since it significantly adds to the time required to install power points, switches or the like in a stud wall. mm T» 0 3/ |E030065 There is therefore a need for an electrical box which overcomes these problems.

The present invention is directed towards providing such an electrical box.

According to the invention there is provided an electrical box for mounting an electrical fitting recessed into a stud wall, the electrical box comprising a base wall, spaced apart first and second side walls extending from the base wall, and spaced apart first and second end walls extending from the base wall and joining the side walls, two mounting lugs extending from respective opposite ends of the first side wall, and one mounting lug extending from the first end wall at an end thereof remote from the first side wall, the mounting lug extending from the first side wall at the end thereof adjacent the first end wall being aligned with one of the other two lugs for mounting the electrical box to a stud member of the stud wall with one of the first side and end walls extending parallel to the stud member, and being deformable for alignment with the other of the two mounting lugs for mounting the electrical box to a stud member of the stud wall with the other one of the first side and end walls extending parallel to the stud member.

In one embodiment of the invention the mounting lug extending from the first side wall at the end thereof adjacent the first end wall is aligned with the mounting lug extending from the other end of the first side wall.

In another embodiment of the invention a mounting lug is provided extending from each end wall at the end thereof remote from the first side wall, and both mounting |Ell3DU65 lugs extending from the first side wall are deformable to be alignable with the lug extending from the other end of the adjacent end wall.

In one embodiment of the invention each mounting lug extends from the corresponding one of the side and end walls in the same plane as the side or end wall. in another embodiment of the invention the side and end walls form with the base wall a hollow interior region, and the peripheral edges of the side and end walls define an open mouth to the hollow interior region. Preferably, the mounting lugs extend from the corresponding ones of the side and end walls at a location spaced apart from the peripheral edges thereof defining the open mouth for permitting a portion of the electrical box to project through a lining panel lining the stud wall.

In another embodiment of the invention the electrical box is formed of sheet metal material, and preferably, is formed from a single sheet of sheet metal material, and ideally, is formed from a blank cut from the sheet metal material and is formed by bending the blank.

In one embodiment of the invention the electrical box is for housing an electrical socket, and the electrical box is sized for housing a double socket. in another embodiment of the invention the electrical box is sized for housing a single socket.

IEUSUQ55 In a still further embodiment of the invention the electrical box is sized for housing an electrical switch.

In a still further embodiment of the invention the electrical box is suitable for housing an electrical connector for connecting cables.

In a still further embodiment of the invention the electrical box is suitable for housing a television socket, a telephone socket, a computer socket, or a socket comprising a combination of two or more of such sockets. in another embodiment of the invention the electrical box is for housing a single socket, and in a further embodiment of the invention the electrical box is for housing a double socket.

The invention will be more clearly understood from the following description of some embodiments thereof which are given by way of example only with reference to the accompanying drawings in which: Fig. 1 is a perspective view of an electrical box according to the invention suitable for housing a single electrical socket or an electrical switch, Fig. 2 is a front elevational view of the electrical box of Fig. 1, Fig. 3 is a side view of the electrical box of Fig. 1, Fig. 4 is an end view of the electrical box of Fig. 1, Fig. 5 is a transverse cross-sectional side elevational view of the electrical box of Fig. 1 on the line V—V of Fig. 2, Fig. 6 is a plan view of a blank from which the electrical box of Fig. 1 is formed, Fig. 7 is perspective view of a detail of the electrical box of Fig. 1, Fig. 8 is a perspective view of another detail of the electrical box of Fig. 1, Fig. 9 is a perspective view of an electrical box according to another embodiment of the invention, Fig. 10 is a front elevational view of the electrical box of Fig. 9, Fig. 11 is a perspective view of an electrical box according to another embodiment of the invention, and Fig. 12 is a front elevational view of the electrical box of Fig. 11.

Referring to the drawings and initially to Figs. 1 to 8 thereof, there is illustrated an electrical box according to the invention indicated generally by the reference numeral 1 for mounting a single socket or an electrical switch recessed in a stud wall. The electrical box 1 is formed of sheet metal from a sheet metal blank 2 by appropriately bending the blank 2 along fold lines 3, see Fig. 6. The electrical box 1 comprises a base wall 5, first and second side walls 6 and 7, respectively, extending from the base wall 5, and first and second end walls 8 and 9, respectively, extending from the base wall 5 joining the first and second side walls 6 and 7. The first and second side and end walls 6 to 9 define with the base wall 5 a hollow interior region 10 for accommodating the electrical socket or switch, as the case may be. The first and second side and end walls 6 and 9 terminate in a peripheral edge 12 which forms an open mouth 14 to the hollow interior region 10.

Two mounting lugs, namely, a first mounting lug 15 and a second mounting lug 16 extend from respective opposite ends of the first side wall 6 in the same plane as the first side wall 6 for mounting the electrical box 1 to a stud of a stud wall. Two more mounting lugs, namely, a third mounting lug 18 and a fourth mounting lug 19 extends respectively from the first and second end walls 8 and 9 at the ends of the end walls 8 and 9 remote from the first side wall 6 also for mounting the electrical box 1 to a stud of a stud wall. The third and fourth mounting lugs 18 and 19 extend from the corresponding first and second end walls 8 and 9 in the plane of the corresponding one of the end walls 8 and 9. Screw accommodating holes 20 are provided in each mounting lug 15 to 19 for accommodating wood screws, self tappers or other suitable fixings for securing the electrical box 1 to a stud of the stud wall. "$030065 The electrical box 1 is initially provided with the first and second mounting lugs 15 and 16 extending from and in the plane of the first side wall 6 for mounting the electrical box 1 to a stud of the stud wall with the first side wall 6 extending parallel to and abutting the stud. However, the first and second mounting lugs 15 and 16 are also deformable along a fold line 21 so that one or both of the first and second mounting lugs 15 and 16 can be aligned with the corresponding one of the third and fourth lugs 18 and 19 in the plane of the corresponding one of the first and second end walls 8 and 9 for facilitating mounting of the electrical box 1 to a stud member with the appropriate one of the first or second end walls 8 and 9 parallel to and abutting the stud.

The four mounting lugs 15 to 19 extend from the corresponding ones of the first side wall 6 and the first and second end walls 8 and 9 at respective locations spaced apart from the peripheral edge 12 of the electrical box 1 thereby permitting a portion of the electrical box 1 between the peripheral edge 12 and the mounting lugs 15 to 19 to extend through a lining panel of the stud wall. This permits a mounting flange of the electrical socket or switch to abut the peripheral edge 12 of the electrical box 1 when the flange of the socket or switch is abutting the lining panel of the stud wall. in this embodiment of the invention the third and fourth mounting lugs 18 and 19 are also deformable along corresponding fold lines 22 so that the third and fourth mounting lugs 18 and 19 may be folded along the fold line 22 into the same plane as IEUSUUB5 the second side wall 7 thereby facilitating mounting of the electrical box 1 to a stud with the second side wall 7 extending parallel to and abutting the stud.

Mounting tabs 23 extend into the hollow interior region 10 from the side and end walls 6 to 9, and are provided with threaded bores 24 for accommodating screws for securing the electrical socket or switch to the electrical box 1. An earth tab 25 with a threaded bore 26 extends into the hollow interior region 10 from the second side wall 7 for securing an earth lead to the electrical box 1 for earthing thereof. Lines of weakness 28 extends around discs 29 in the side and end walls 6 to 9 for facilitating knocking out of appropriate ones of the discs 29 to form cable entries 30 to the hollow interior region 10.

In use, where it is desired to mount the electrical box 1 to a stud of a stud wall with the first side wall 6 extending parallel to and abutting the stud, the electrical box 1 is offered up to the stud with the first side wall 6 abutting the stud. The first and second mounting lugs 15 and 16 are positioned on the stud so that the portion of the electrical box between the first and second mounting lugs 15 and 16 and the peripheral edge 12 extends proud of the stud. The electrical box 1 is then secured to the stud by screws or other suitable fixings extending through the holes 20 in the first and second mounting lugs 15 and 16.

Should it be desired to mount the electrical box 1 with the first end wall 8 abutting and extending parallel to the stud, the first mounting lug 15 is bent along the fold line to lie in the plane of the first end wall 8 and in the plane of the third mounting lug lElJ30lJ65 . The electrical box is then offered up to the stud with the first end wall 8 and the first and third lugs 15 and 18, respectively, abutting the stud, and with the portion of the electrical box 1 between the first and third lugs 15 and 18 and the peripheral edge 12 extending proud of the stud. The electrical box 1 is then secured to the stud by screws or other suitable fixings through the holes 20 in the first and third mounting lugs 15 and 18. Similarly if it is desired to mount the electrical box 1 with the second end wall 9 abutting the stud, the second mounting lug 16 is bent along the fold line 21 into alignment with the fourth mounting lug 19, and mounting of the electrical box 1 to the stud is as already described.

Should it be desired to mount the electrical box 1 to a stud with the second side wall 7 abutting the stud and parallel thereto, the third and fourth studs 18 and 19 are bent along the fold line 22 into alignment with the second side wall 7 and the electrical box 1 is then offered up to the stud with the second side wall 7 and the third and fourth mounting lugs 18 and 19 abutting the stud as already described and is similarly secured to the stud.

Referring now to Figs. 9 and 10 there is illustrated an electrical box according to another embodiment of the invention indicated generally by the reference numeral 40. The electrical box 40 is similar to the electrical box 1 and similar components are identified by the same reference numerals. The only difference between the electrical box 40 and the electrical box 1, is that the first and second end walls 8 and are longer than the first and second end walls of the electrical box 1, so that the IEUSDDBS electrical box 40 is suitable for mounting a double socket to be recessed in a stud wall.

Referring now to Figs. 11 and 12 there is illustrated an electrical box according to a further embodiment of the invention indicated generally by the reference numeral 50.

The electrical box 50 is essentially similar to the electrical box 1 and similar components are identified by the same reference numerals. In this embodiment of the invention the electrical box 50 is of substantially similar size to the electrical box 40, however, the main difference between the electrical box 50 and the electrical box 1 is that the first and second side walls 6 and 7 are longer than those of the electrical box 1 for accommodating two electrical fittings, for example, two switches.

Additionally, a transverse mounting member 51 extends between the first and second side walls 6 and 7 with mounting tab 52 for mounting the two electrical fittings. Threaded bores 53 extend through the mounting tabs 52 for receiving screws for securing the switches or other electrical fittings in the electrical box 50.

While the electrical boxes have been described as being formed from a single sheet metal blank, while this is preferable it is not essential, and other suitable methods for forming the electrical boxes according to the invention may be provided.

Additionally, while the electrical box has been described as being suitable for mounting an electrical switch or socket to a stud wall, the electrical box 1 could be used for mounting any other electrical fitting, connector or the like in a stud wall, for |Ei!5{%ll65 example, a television signal socket, a telephone socket, a computer socket or the like.

While each of the electrical boxes have been described as comprising four mounting lugs, it is envisaged in certain cases that three mounting lugs may be sufficient. in which case, first and second mounting lugs would be provided on the first side wall as already described, and a third mounting lug would be provided on the first end wall as already described. The first mounting lug would be deformable for alignment with the third mounting lug on the first end wall.

The invention is not limited to the embodiment hereinbefore described which may be varied in construction and detail.

F.F. GORMAN & CO.

Claims (5)

Claims

1. An electrical box for mounting an electrical fitting recessed into a stud wall, the electrical box comprising a base wall, spaced apart first and second side walls extending from the base wall, and spaced apart first and second end walls extending from the base wall and joining the side walls, two mounting lugs extending from respective opposite ends of the first side wall, and one mounting lug extending from the first end wall at an end thereof remote from the first side wall, the mounting lug extending from the first side wall at the end thereof adjacent the first end wall being aligned with one of the other two lugs for mounting the electrical box to a stud member of the stud wall with one of the first side and end walls extending parallel to the stud member, and being deformable for alignment with the other of the two mounting lugs for mounting the electrical box to a stud member of the stud wall with the other one of the first side and end walls extending parallel to the stud member.

2. An electrical box as claimed in Claim 1 in which the mounting lug extending from the first side wall at the end thereof adjacent the first end wall is aligned with the mounting lug extending from the other end of the first side wall.

3. An electrical box as claimed in Claim 1 or 2 in which a mounting lug is provided extending from each end wall at the end thereof remote from the first side wall, and both mounting lugs extending from the first side wall are deformable to be alignable with the lug extending from the other end of the adjacent end wall.

4. An electrical box as claimed in any preceding claim in which the side and end walls form with the base wall a hollow interior region, and the peripheral edges of the side and end walls define an open mouth to the hollow interior region, the mounting lugs extending from the corresponding ones of the side and end walls at a location spaced apart from the peripheral edges thereof defining the open mouth for permitting a portion of the electrical box to project through a lining panel lining the stud wall.

5. An electrical box for mounting an electrical fitting recessed into a stud wall, the electrical box being substantially as described herein with reference to and as illustrated in the accompanying drawings. F.F. GORMAN & CO.