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WO 2004/013942 PCT/AU2003/000993 <br><br>
1 <br><br>
A JUNCTION BOX FIELD OF THE INVENTION <br><br>
This invention relates to a junction box for electrical cables and wiring. <br><br>
This invention has particular but not exclusive application, to a junction box for 5 use in steel-framed constructed buildings and for illustrative purposes reference will be made to such application. However, it is to be understood that this invention can also be used in wood-framed constructed buildings. <br><br>
BACKGROUND OF THE INVENTION Electrical junction boxes are commonly used in the construction industry for the 10 connection and termination of electrical conductors. Junction boxes are typically installed in the wall, floor or ceiling of a structure by fixing them to the structural members. Conventional junction boxes generally comprise a cover that is secured to a base forming a cavity for receiving electrical cables. The base has apertures for receiving nails or screws to attach the base to a support member such as a ceiling joist 15 or rafter, wall stud, floor joist or the like. After the required electrical connections are made, the cover is secured to the base enclosing the fasteners with the junction box cavity. <br><br>
With the advent of steel-framed constructed buildings there is presently no efficient means to secure a standard junction box to steel supports, as obviously 20 traditional nails and screws cannot be inserted into steel. Many electricians simply leave the junction box unsecured in the ceiling of a steel-framed constructed building. <br><br>
Thus, it will be appreciated that there is a need for a junction box which can be used with steel framed constructed buildings that can be easily manufactured and installed. Advantageously, the junction box can also be used in wood framed 25 constructed buildings. <br><br>
BACKGROUND OF THE INVENTION <br><br>
This invention in one aspect resides broadly in a junction box for electrical cables which is mountable to a support, the junction box including: <br><br>
a base; <br><br>
30 a cover attachable to the base so as to define a cavity; and at least one clip having a pair of legs interconnected by a bridging portion, wherein, in use, a first leg engages the base and the second leg straddles at least a portion of the support so as to mount the base to the support. <br><br>
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In the present specification and claims, the terms "electrical box" or "junction box" are used to include any box that will be attached to a support in a building construction. For example, "junction box", "mounting box", "receptacle", "electrical box", "fixture box", "ceiling box", "enclosure" and the like are to be understood as synonymous terms and 5 not intended to be limiting. <br><br>
Either the base and/or the cover may include side walls to define a cavity between the base and cover when the cover is attached to the base. Preferably, the cover has multiple sides forming a rectangular or square box, or may have a cylindrical side wall shape such as a circular or octagonal cylinder side wall to form the shape of 10 any common electrical junction box used in the industry. Of course, other box shapes are contemplated to be within the scope of the present invention. In this case, the base typically does not have side walls and may be in the form of a base plate. Alternatively, the base may have side walls and the cover may be a plate or top wall. In a further alternative, the base and cover may both have side walls extending therefrom wherein 15 the periphery surfaces of the side walls matchingly engage. <br><br>
The cover may be attached to the base by any suitable fastening means. For example, a complementary ridge and groove arrangement may be provided on the confronting surfaces of the base and cover to enable the cover to snap lock into locking position with the base. In a preferred embodiment, the cover may be fastened to the 20 base by a screw inserted through an aperture or opening in the cover corresponding to a threaded sleeve formed in pillars extending from the base. Other fastening mechanisms used with known junction boxes are also contemplated for use with the invention. <br><br>
The clip may enable the base to be mounted on the top, bottom or side portion of a support depending on where the support is located in a building construction. For 25 example, if the support is located in the ceiling, then the box may be mounted on the side of a support such as joist, rafter, cross brace or cross hanger, wherein one leg may straddle either the top or bottom of the support. Alternatively, if the base of the junction box is to be located in a wall space, provided that there is sufficient space such as in a brick veneer wall, then the base may be located along an appropriate side of a support 30 such as wall stud or a cross brace or cross hanger therebetween the studs. It is to be understood that a person skilled in the art would be able to determine a suitable position to mount the base in a constructed building. Once the base is mounted on a support, the cover may be attached to the base by the above described fastening means. <br><br>
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Depending on the size of the junction box, two or more clips may be required to support the junction box on the support. The clip may be made from any suitable resilient material such as spring steel or glass-filled polyester or a polymeric material such as flame resistant acetyl. The base and cover may be made from various plastics, 5 composite materials, metal or the like depending on the intended use. More suitably, the base and cover are molded from glass-filled polyester or a polymeric material such as flame resistant polystyrene. Preferably, the clip may be made from glass-filled nylon and the base and the cover may be made from flame resistant ABS. <br><br>
In order to mount the base to a support, the bridging portion may extend over the 10 base and support and the second leg may engage the support. As such, the size of the bridging portion may be at least enough to accommodate the thickness of the base and the support. <br><br>
The shape of the legs and bridging portion may vary depending on the shape of the support to which the junction box is to be mounted. Suitable supports used to mount 15 junction boxes include wall studs, floor joists, ceiling joists or rafter, braces or other similar beams. In a preferred embodiment, the junction box of the invention may be suitably mounted to an I-beam, a Z-section beam, or the like. It is to be understood that person skilled in the art could easily modify the shape of the legs and bridging portion of the clip in order to straddle beams of different type sections. <br><br>
20 Depending on the shape of the support, the bridging portion and adjacent adjoining portion of the second leg may substantially correspond to the shape of the portion of the support straddled thereby. The extremity of the second leg may extend inwardly or outwardly of the support to assist the leg to grip or lock into the support. For example, the second leg may be suitably shaped and resiliently biased toward the leg 25 engaging the base so that a portion of the straddling leg locks against, or grips a corresponding portion of the support. <br><br>
The first leg which in use engages the base may be detachable from the base or may be integrally formed, or permanently fixed to the base. In one embodiment, the first may include at least one projection or recess which in use may be received by or 30 receive a recess or projection in the base. <br><br>
The base and the cover may include a plurality of apertures to receive conduit or wiring. The apertures may be partially blanked in which a blank section remains to be <br><br>
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knocked out to open an aperture for use. Such blanked apertures are often known in the art as "knock outs". <br><br>
The base may also include mounting holes orfastener receiving apertures of the type used in conventional junction boxes that are mounted to wooden supports. Screws 5 or nails may be provided to extend through the mounting holes in the base to allow lateral connection to mount the junction box into a joist, stud or the like. This enables a labourer or electrician to utilise the present junction box of the invention with either wood or steel framed building constructions as desired. <br><br>
Where the base is in the form of a base plate, the junction box may be provided 10 with still at least one further fastener receiving aperture, in addition to, or in place of, the conventional type mounting holes as discussed above. This further or alternative at least one fastener receiving aperture is located on the base plate, which is external to a cover attached thereto. <br><br>
The external at least one fastener receiving aperture is adapted to receive a 15 fastener that enables connection to metal and in particular, steel. For example, the fastener may be a steel penetrating fastener, such as steel anchor screw, a rivet, bolt or the like. In one embodiment, the at least one fastener receiving aperture is located in a peripheral region of the base plate such that the cover may enclose a substantial portion of the base plate without enclosing the at least one fastener receiving aperture. It is to 20 be appreciated that the location of at least one fastener receiving aperture is dependent on the shape of the base plate and it would be apparent to a person skilled where to locate at least one fastener receiving aperture on the base plate to enable the base plate to be suitably secured to a support member. <br><br>
In an alternative embodiment, the base plate may include a main body portion 25 and an extension thereof, that includes the at least one fastener receiving aperture. For example, the base plate may include one or more flanges, tabs, ears, flap, ring, lip or the like including the at least one fastener receiving aperture. Suitably, the extension, protrusion or the like may be substantially coplanarto the base plate to enable the base plate to seat substantially flush with the support surface, where the base plate is being 30 attached. The base plate may include more than one fastener receiving aperture for attaching the base plate to the surface of a support member. In preferred embodiments, there are at least two fastener receiving apertures located in opposed sides of the base plate. <br><br>
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It may be desirable that the portion/s of the base plate that includes the at least one fastener receiving aperture that is external to the attached cover, may also be detachable from the base plate. For example, the portion/s of the base plate that includes the at least one fastener receiving aperture may be configured such that it can 5 be broken orsnapped off from a main portion of the base plate. This may be applicable where the external fastener receiving aperture/s are not required due to the inclusion of another type of fastening mechanism for attaching the junction box to the support member. In particular, if the portion of the base plate that includes the at least one fastener receiving aperture is a tab, then that tab may be frangibly connected to a main 10 potion of the base plate, such that it may snapped off or detached if that tab does not need to be utilized to attach the junction box to the support member. <br><br>
It may be seen that by positioning at least one fastener receiving aperture externally from the junction box cavity, metal penetrating fasteners for use in mounting the box to a steel support are isolated from electrical wiring within the cavity. On the 15 other hand, if internal fastener apertures are used to attach a box to a metal support and there is a live wire within the cavity, a short circuit may be created if the wire comes into contact with a fastener. <br><br>
it may be appreciated that by providing these further fastener receiving apertures, an operator or electrician has a still further option as a method for mounting the box to a 20 support. These further apertures in combination with suitable fasteners may be used to mount the box to a support that does not have a profile corresponding to the aforementioned clip. <br><br>
It will also be appreciated that in some applications, the clips may not be suitable or necessary. According to a further from of the invention, there is provided a junction 25 box for electrical cables including: <br><br>
a base plate including at least one fastener receiving aperture; and a cover having at least one side wall attachable to the base plate defining a cavity therebetween, wherein the at least one fastener receiving aperture is external to the cover when attached to the base plate. <br><br>
30 As an alternative, or in addition to, the external fastener receiving apertures, the junction box may include at least one internal fastener receiving aperture and an insulting shield for covering the aperture. <br><br>
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The insulating shield made of any suitable material having insulting properties such as rubber, rubber-like materials, polymers, composite materials, PVC, flame retarded ABS, orthe like. The insulating shield may take the form of cap, plug, stopper,, closure or the like that will cover or conceal the opening of the one or more fastener receiving aperture after the metal penetrating fastener has been secured to metal support member. <br><br>
Further, any fastener receiving aperture located internally within the attached cover to the base that may be utilized to enable fastening of the base to either a wood or metal support may also have an insulating shield, cap, cover, plug or the like. 10 Advantageously, once the insulating shield has been positioned over the fastener receiving aperture/s, there is no possibility that the metal penetrating fasteners, or the metal support can come into contact with any live wires, thereby retaining the insulating integrity of the junction box, even though metal penetrating fasteners maybe positioned within the cavity of junction box of the invention. <br><br>
15 BRIEF DESCRIPTION OF THE FIGURES <br><br>
FIG. 1 is a front perspective view of the junction box according to the invention as described attached to a support; <br><br>
FIG. 2 is a rear perspective view of the junction box shown in FIG. 1; <br><br>
FIG. 3 is a side view of a junction box shown in FIG. 1; <br><br>
20 FIG. 4 is a top view of the junction box shown in FIG. 1; <br><br>
FIG. 5 is a front view of the junction box shown in FIG. 1; <br><br>
FIG. 6 is a sectional view of the junction box, taken along the lines A-A shown in FIG 4; <br><br>
FIG. 7 is a sectional view of the junction box, taken along the lines B-B shown in <br><br>
25 FIG 4; <br><br>
FIG. 8 is sectional view of the junction box, taken along the lines D-D shown in <br><br>
FIG 5; <br><br>
FIG. 9 is a front perspective sectional view of the junction box shown in FIG. 1; FIG. 10 is a clip of the junction box of invention as described; 30 FIG 11 is a perspective view of a further preferred junction box of the invention mounted to a support; <br><br>
FIG 12 is a perspective view of the base of the junction box illustrated in FIG 11; FIG 13 is a front view of the base shown in FIG 12; <br><br>
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FIG 14 is an end view of the base, shown in FIG 12; <br><br>
FIG 15 is a view of the base shown in FIG 12; <br><br>
FIG 16 is a detail of region A of the base shown in FIG 15; <br><br>
FIG 17 is a perspective view of a base of a further preferred junction box of the 5 present invention; <br><br>
FIG 18 is a front view of the base shown in FIG 17; <br><br>
FIG is a top view of the base view of the base shown in FIG 17; <br><br>
FIG 20 is an end view of the base shown in FIG 17; <br><br>
FIG 21 is a schematic view of a further example of an insulating shield taking the 10 form of a plug; <br><br>
FIG 22 illustrates a further example of an insulating shield taking the form of a pillar extending from the cover forming a closure over a fastener receiving aperture; <br><br>
FIG 23 is a section of a further preferred junction box of the present invention; <br><br>
FIG. 24 is a bottom perspective view of a cover of the junction box shown in FIG 15 23; and <br><br>
FIG 25 is an open perspective view of the junction box having the base shown in FIG 17. <br><br>
Terms such as "front", "back", "base", "top", "side", "bottom" etc., refer to the orientation or configuration of the junction box when used according to the illustrations 20 and to assist in indicating points of reference when viewing the accompanying figures. It is to be understood that these terms do not limit the present invention to any specific orientation or configuration of the invention. <br><br>
FIGS. 1 to 9 illustrate a preferred embodiment of a junction box 10 mounted to a support 14. The junction box 10 includes a base 11, a cover 12 and two clips 13 used 25 to mount the box 11 to a support 14 in the frame-work of a building construction. <br><br>
The support 14 is a partially hollow I-beam ceiling joist having upper 32 and lower 33 profiled sections. <br><br>
The cover 12 has a front wall 18 and side, top and bottom walls 19. Front wall 18 includes two apertures 22 for receiving fasteners such as screws to fasten the cover 12 30 to the base 11. (This will be described in more detail below with respect to Figure 8). <br><br>
Figure 7 shows the base 11, which is a plate having a plurality of knockouts 15 that may provide openings for introducing electrical cables where desired. The base also includes a slot 7 for receiving each leg 25. This slot 7 (not shown in this figure but <br><br>
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may be seen with reference to Figure 15 below) serves to assist in locating leg 25 and minimizes lateral movement of leg 25 with respect to base 11. <br><br>
The cover 12 may also include knockouts or other wire access apertures (not shown) to allow wiring or cables to enter the junction box 10 for connection to 5 receptacles and other wires therein. The cover 12 also includes apertures 8 (see Figure 9) through which leg 25 of a clip may pass. This aperture 8 is protected by a knock out which may be removed if the junction box 10 is to be mounted to a support by the clips. (This knock out 72 may be seen in Figure 24). <br><br>
The base 11 includes four fastener receiving apertures 9. If the junction box 10 is 10 to be secured to a wooden support, conventional wood fastening screws or nails may be inserted through these apertures 9, so as to mount the box 10 to a.wooden support. <br><br>
The base 11 also a pillar 16 or other strengthening formations extending therefrom at about each of the four corner positions thereof. One pair of opposed pillars 16a have threaded sleeves 17a for receiving a fastener 23 for securing the cover 12 to 15 the base 11. <br><br>
In a similar manner as described for the base 11, the cover 12 has pillars 20 or like strengthening formations. In particular, a number of the pillars 20 correspond to the position of the threaded sleeves 17a in the base 11. As shown in Figure 8, these pillars 20 include a sleeve 21 with an opening 22 on the front wall 18 of the cover 12 for 20 receiving a fastener, such as screw 23. To secure the cover 12 to the base 11, the cover 12 is seated on the base 11 and the screw-receiving sleeves 21 on the cover 12 align with the threaded sleeves 17a on the base 11 allowing a screw 23 to be inserted into the opening 22 for attachment. As best illustrated in FIG. 8, the cover sleeve 21 includes a seat 24 to limit the movement of the screw 23 into the threaded sleeve 17 in 25 the, base. <br><br>
Figure 8 shows that the other pair of opposed base pillars 16b have a threaded recess 17b for receiving a screw that may provide a further alternative method of mounting the box 10 to support 14. <br><br>
The base 11 and cover 12 may be made from various plastics, composite 30 materials, metal or the like, depending on the intended use. More suitably, the base 11 and cover 12 are moulded from glass-filled polyester or a polymeric material. In a preferred embodiment, base 11 and the cover 12 are made from flame resistant ABS. <br><br>
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The junction box 10 is mounted to a support 14 though the use of one or more clips 13 as illustrated in FIG. 10 in detail. In the illustrated embodiment, two clips 13 are used to provide improved stability. The clip 13 utilised in the invention is generally an Reshaped member having a first leg 25 that is adapted to engage the base, a second leg <br><br>
26 that is adapted to straddle a support 14 and a bridging portion 27 interconnecting the legs 25 and 26. <br><br>
As best illustrated in FIG. 6, the lower free end of the first leg 25 has an extension 28 that snap-locks into a corresponding detent 29 formed in the base 11 to enable the first leg 25 to engage the base. There could, of course, be more than one k10 extension 28 and corresponding detents 29 in the base to provide additional engagement The first leg 25 is substantially planar to enable it to be located within slot 7. The length of the bridging portion 27 between the legs 25 and 26 is sufficient to accommodate the thickness of the base 11 and the support 14, as the bridging portion <br><br>
27 is seated on the top 32 of the support 14 when in use. The second leg 26 has a 15 rounded portion 30 that fits over a corresponding rounded portion on the top 32 portion of the support. The rounded portion 30 of the second leg 26 is followed by an outwardly curved end 31 that enables the second leg 26 to engage the support 14. Once the clip 13 is pushed downwardly over the support 14 due to the resilient material an inwardly compressive force is directed on the legs 25 and 26 tending them to hold onto the 20. support 14. <br><br>
To provide additional security to maintain the engagement of the first leg 25 of the clip 13 to the base 11, the cover 12 may include pillar extensions 34 that contact the first leg 25 when the cover 12 is secured to the base 11. This is best illustrated in FIGS. 6 and 9. <br><br>
25 The clip 13 may be made from any suitable resilient material such as spring steel or glass-filled polyester or a polymeric material. Preferably, the clip 13 is made from glass-filled nylon. <br><br>
FIG. 11 illustrates a further junction box 50 of the present invention. The box 50 is similar to that of Figures 1 to 9 and the same reference numerals will be used to 30 describe the same features. Junction box 50 includes tabs 51 extending from each side of the base 11. The base 11 is illustrated in further detail in Figures 12 to 16. Each tab 51 includes a pair of fastener receiving apertures 52. As shown in Figures 15 and 16, there is a weakened or narrower region in the base, which is in the form of a "V" shaped <br><br>
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cut-out portion 59. This "V" shaped cut-out portion 59 enables the tab 51 to act as a lever that can be moved up and down relative to the base 11 due to the narrower or weakened area that facilitates the tab 51 to snap off from the base 11. As such, should the tabs 51 not need to be utilized to enable attachment of the junction box 10 to a 5 support 14, they may be detached and discarded. <br><br>
Figures 17 to 25 show a further method by which a junction box 60 may be mounted to a support. Again, in these figures, the same reference numerals will be used to describe features as already discussed. Figure 17 shows the base 11 of junction box 60, which is similar to that as described with reference to the junction box in 10 the previous embodiment except that the base does not have an extending tab 51. <br><br>
The base 11 includes two diagonally opposed mounting pillars 16b each including a threaded sleeve 17b adapted to receive a metal penetrating screw 67. The threaded sleeve 17b extends through the bottom of base 11 to allow penetration through to support 14 to secure the junction box 60 to the support 14 (as shown in figures 22 15 and 23). Of course, it will be understood that metal penetrating fasteners, other than a screw, may be suitable such as a rivet, bolt or the like, depending upon the type of support 14. In orderto maintain the insulating integrity of the junction box 60, the metal fastener receiving apertures, if used, are covered by an insulating shield 64 that are adapted to be received by pillars 16b as shown in Figure 17. <br><br>
20 Figure 21 shows an alternative form of shield in the form of a plug 66 that fits over the head of screw 67. The plug 66 has a body portion 68 that is received within threaded recess 17b. <br><br>
Figure 22 shows an alternative means of shielding a screw 67, whereby the cover 12 includes a protrusion or pillar 70, which extends inwardly from front wall 18 of 25 the cover 12 in a position that corresponds to the fastener receiving threaded sleeve 17b, such that the opening of the thread 17b is closed or concealed when the cover 12 is attached to the base 11. <br><br>
Figure 23 shows a further arrangement similar to that of Figure 22, except that inwardly directed pillar 71 abuts against shield 64 so as to secure shield 64 in place 30 when the cover 12 is attached to the base 11. <br><br>
Figure 24 is an open perspective view of the cover of junction box 60 as shown in Figure 23. In this view pillar 71 may be seen. Also shown in this view are two rectangular knock out portions 72. These knock out portions may be removed so.as to <br><br>
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provide access apertures 8 to allow entry of the first leg of a clip 13 for mounting the box 60 to a support. It may be seen that when the dips 13 are not to be used, portions 72 may remain in place, thereby optimizing dust and moisture resistance of the box in use. <br><br>
The present invention is suitably used in steel framed building constructions. <br><br>
5 However, it is to be understood that the invention may be used in wood-framed building constructions in a similar manner, as described below, or the base may include a plurality of apertures, or mounting flange, to enable the nailing or screwing of the junction box to a timber support in a conventional manner. <br><br>
The junction box of the invention enables a labourer or an electrician to rapidly 10 and securely position the box to a structural member in a building before or after construction. It may be appreciated that advantageously junction boxes of the preferred forms of the invention have a plurality of fastening mechanism for mounting the junction box to a support. This provides an operator or electrician with a single multi-attaching junction box that can be utilized in numerous positions, depending upon whether the 15 support is wood or metal and in the latter case, the shape of the metal support. <br><br>
It will of course, be realized that while the foregoing has been given by way of illustrative example of this invention, all such and other modifications and variations thereto as would be apparent to persons skilled in the art are deemed to fall within the broad scope and ambit of this invention as is herein set forth. <br><br>
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