WO2008098263A2

WO2008098263A2 - A protective cover for a connection box

Info

Publication number: WO2008098263A2
Application number: PCT/ZA2008/000009
Authority: WO
Inventors: George Johannes Smith
Original assignee: George Johannes Smith
Priority date: 2007-02-09
Filing date: 2008-02-08
Publication date: 2008-08-14
Also published as: WO2008098263A3

Abstract

A protective cover or insert (10, 10A) for use with a connection box (36, 36A), wich box has a side wall (44) wich defines a cavity (46) wich has a mouth (48). The insert (10, 10A) includes a body (12) and a base (14), wich base is insertable into the cavity (46) and wich frictionally engages with an inner wall of the side wall (44), and wherein the body (12) is positioned at the mouth (48) outside the box (36) when the base (14) is located in the cavity (46).

Description

A CONNECTION BOX INSERT

BACKGROUND OF THE INVENTION

[0001] The invention relates to a connection box insert which, for example, is used with electrical connection boxes.

[0002] During the construction of buildings, connection boxes of various kinds are installed, for example, in the walls of the building. These connection boxes form part of a network of conduits through which wiring such as electrical or communication cables extends throughout the building. A variety of fittings such as connectors in the form of plugs and switches are fitted to the connection boxes and are used to distribute and control the flow of electricity or communications signals.

[0003] Regardless of the type of material from which the building is constructed, the connection boxes are generally positioned in holes made in the walls and are accessible from outside the walls. For finishing spacing materials such as fillers, paper or foam are used to correctly position each connection box in its hole whereafter the wall can be plastered and/or painted. The plaster or paint can enter the connection boxes or conduits and can soil or block the connection box and conduits. The cleaning and unblocking of the connection boxes and conduits can be costly and time consuming.

[0004] The invention aims to provide a connection box insert which can be used with a connection box to alleviate some of the aforementioned problems. SUMMARY OF THE INVENTION

[0005] The invention provides a connection box insert for use with a connection box which has a side wall which defines a cavity and a mouth to the cavity, the insert including a body and a base which is insertable into the cavity through the mouth and which frictionally engages with an inner wall of the side wall, and wherein the body is positioned at the mouth outside the box when the base is located in the cavity.

[0006] The body may have an outline which is substantially the same as the connection box.

[0007] The side wall may define a rim which extends around the mouth and the body may abut against the rim when the base is located in the cavity.

[0008] The insert may include a shoulder which extends around the base at a junction of the base and the body and which abuts the rim when the base is located in the cavity.

[0009] The body may be manufactured from any suitable material and is preferably made from an expanded, foamed material such as polystyrene. The base may be manufactured from any suitable type of resiliently deformable material which allows the base to be inserted into the cavity. Preferably the base is made from the same type of material as the body and is integrally formed with the body. Alternatively, when the base and the body are manufactured from different materials, the base may be attached to the body in any suitable way such as using glue, heat welding, ties or the like.

[0010] The insert may include a plurality of recess formations which are formed into the base at predetermined, spaced apart locations so that tabs of the connection box align with and are insertable into the recess formations when the base is pushed into the cavity.

[0011] The invention also provides a connection box insert for use with an electrical connection box which has a side wall and at least one pair of opposed tabs which extend from the side wall, the insert including a body and a base which has a rectangular cross-sectional shape, which extends from the body and which has an outer periphery, and at least a first pair of opposed recess formations with each recess formation being formed into the outer periphery at a predetermined position so that the base is insertable into the box by registering the pair of opposed tabs with the pair of opposed recess formations.

[0012] The insert may be manufactured from an expanded, foamed material such as polystyrene.

[0013] The insert may include two sets or pairs of opposed recess formations which are formed at spaced apart locations into the periphery.

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] The invention is further described by way of examples with reference to the accompanying drawings in which :

Figure 1 is a perspective view of a connection box insert according to the invention; Figure 2 is a perspective view of an alternative embodiment of a connection box insert according to the invention;

Figure 3 is a perspective, schematic representation of the inserts of Figures 1 and 2 in use; Figure 4 is a cross-sectional side view of the insert of Figure 1 in use; and

Figure 5 is a perspective view of a different embodiment of a connection box insert according to the invention.

DESCRIPTION OF PREFERRED EMBODIMENTS

[0015] Figure 1 illustrates a connection box insert 10 which has a body 12 and a base 14 which extends from the body and which has an outer periphery 16 and a first set or pair 18 of opposed recesseses 20 and 22 which are formed in the outer periphery at predetermined locations.

[0016] The body 12 and the base 14 can be integrally or separately formed from any suitable material such as low density polystyrene or high density foam. It is preferred that the material or materials used in the manufacture of the insert 10 and, in particular, of the base 14 should be resiliently deformable with a high degree of firmness. Any appropriate technique can be used to attach the base to the body, when formed separately, such as gluing, sonic or heat welding, tying or the like.

[0017] The base 14 has a width 24 and a height 26 which is slightly less than a width 28 and a height 30 of the body 12 so that a shoulder 32 extends around the base at a junction 34 of the body and the base.

[0018] Figure 2 shows a variation 10A of the connection box insert. Reference numerals used in the connection box insert 10 are used to designate like components of the connection box insert 10A.

[0019] The connection box insert 10A has first and second pairs 18A and 18B, which are spaced apart, of opposed recesses 2OA, 2OB, 22A and 22B. [0020] Figure 3 shows the connection box inserts 10 and 1OA in use. Connection boxes 36 and 36A are positioned in respective holes or cavities 38 and 38A which are formed in a wall 40 which is constructed from conventional materials such as brick and mortar, timber or drywall panels.

[0021] The connection boxes 36 and 36A are interconnected by a plurality of conduits 42 to form an electricity network.

[0022] During the construction of the wall 40, each hole 38 and 38A is formed in any appropriate manner into the wall and the connection boxes 36 and 36A are positioned in respective holes so that each connection box is at least partly embedded in the wall. The insert 10 is engaged with the connection box 36 and the insert 10A is engaged with the connection box 36A before the connection boxes are finally grouted or plastered into position. It should be noted that each connection box can be associated with a respective insert after manufacture and can be transported in this way to the site where the connection box is to be installed.

[0023] The connection boxes 36 and 36A bear a strong resemblance and for this reason only the connection box 36 is described in greater detail hereinafter. However differences present in the connection box 36A are described when needed for an understanding of the invention.

[0024] The connection box 36 is of conventional construction and includes a side wall 44 which defines a cavity 46 which has a mouth 48. The side wall has a rim 50 which surrounds the mouth. [0025] The base 14 is dimensioned so that it can be inserted with a tight frictional fit into the cavity 46. The recesses 20 and 22 are formed at predetermined positions into the outer periphery 16 of the base so that opposed tabs 52 of the connection box 36 align with and are insertable into respective recess formations when the base is inserted into the cavity. Similarly, the first and second sets 18A and 18B of recesses of the insert 10A are registerable with respective tabs 52A, 52B, 52C and 52D.

[0026] Figure 4 shows the insert 10 fully inserted into the cavity 46. The base 14 has a predetermined depth 54 so that once the base has been inserted to a maximum extent into the cavity, the leading end 56 of the base is at a position in the cavity at which the base does not engage with any fitting 58 which is used to connect the connection box 36 to the conduit 42. The insert 10 can be pushed into the cavity 46 until the shoulder 32 abuts the rim 50. Any further insertion is prevented, at least to some extent, by the shoulder which indicates to the user, not shown, that the insert has been fully inserted.

[0027] The width 28 and the height 30 of the body 12 are suitably chosen so that the outline of the body greatly matches the outline of the box 36. This results in outer surfaces 60 of the body being substantially co-planar with outer surfaces 62 of the connection box 36.

[0028] The base 14 is manufactured from a resiliently deformable material which allows the base to be slightly compressed when inserted into the cavity 46. Thus the base is forced into frictional engagement with an innerwall 64 of the cavity 46. This reduces the likelihood that the insert 10 will inadvertently detach from the connection box 36. However, the frictional engagement of the base with the inner wall is dependent, to a considerable extent, on the firmness or hardness of the material. For example, if a hard polystyrene or a plastic is used, then the degree of difficulty encountered when the base is inserted into the cavity, is increased. Conversely, if the material is too soft, e.g. comprises a low density foam, the frictional lock which is established between the base and the inner wall may be too weak to keep the insert engaged with and covering the connection box 36. Additionally, the body 12 is the exposed part of the insert when the wall 40 is plastered or painted. If the material used in the manufacture of the body is too soft, the lifespan of the body is decreased. A balance must therefore be obtained between the required hardness, which increases the lifespan of the insert, and resilience.

[0029] Once the insert 10 is engaged with the connection box 36, the box is grouted or plastered into position and the remainder of the hole 38 between the connection box and the surrounding wall 40 is filled with an appropriate grout or plaster 66. The wall is then finished, for example, by painting the plaster 66. Each of the inserts 10 and 10A prevents dirt, plaster and paint from entering into the respective connection box 36 and 36A and allows plaster to be applied freely against each connection box and the body 12.

[0030] Either before or after the wall 40 is painted, the inserts 10 and 10A are removed from the respective connection boxes 36 and 36A. Since the inserts are manufactured from a resiliently deformable material, each insert is removable without a great deal of difficulty and becomes easily detached from any plaster 66 which may surround the respective bodies 12 and 12A. [0031] The cabling can now be installed and switches, connectors and cover plates can be installed in the connection boxes 36 and 36A in a known manner.

[0032] Figure 5 shows a variation 1OB of the connection box insert. Like reference numerals are used to designate like components. A height 26B of the base 14B is reduced with a predetermined amount so that the base can pass through the tabs 52 of the connection box 36 without engagement. The body 12B has a width 28B which is substantially equal to a width 24B of the base 14B and a height 68 (see Figure 4) which is substantially equal to the height 70 of the cavity 46. Thus, the body 12B will not abut the rim 32 of the connection box 36. However, due to the abutment of a leading end 72 of the body against tabs 52, the body will be positioned, once the base 14B is fully inserted into the cavity, at the mouth 48 of the cavity outside the box. Alternatively the height 68 is kept the same as the height 30 of the connection box 10 so that the body abuts at opposing ends against the rim 32. The depth 54B of the base 14B can be increased so that the leading end 56B abuts the blind end 74 (see Figure 4) of the cavity 46. This result in a greater contact area between the base and the inner wall 64 which increases the frictional lock with which the insert is engaged with the connection box 36.

[0033] The inserts 10 and 10A assist in obtaining a neat finish around each connection box 36 and 36A and prevent paint and plaster from entering the connection boxes 36 and 36A and the conduits 42. The outline of the body substantially matches that of the respective connection box so that a hole is formed into the plaster which allows the connection box to be easily accessed and which is neat in appearance.

Claims

1. A connection box insert for use with a connection box which has a side wall which defines a cavity and a mouth to the cavity, the insert including a body and a base which is insertable into the cavity through the mouth and which frictionally engages with an inner wall of the side wall, and wherein the body is positioned at the mouth outside the box when the base is located in the cavity.

2. An insert according to claim 1 wherein the side wall defines a rim which extends around the mouth and against which the body abuts when the base is inserted into the cavity.

3. An insert according to claim 1 or 2 which is manufactured from polystyrene.

4. An insert according to claim 1 or 2 wherein the body and the base are manufactured separately and the body is manufactured from polystyrene and the base is manufactured from a resiliently deformable material.

5. An insert according to claim 4 wherein the base is manufactured from a high density foam.

6. An insert according to claim 4 or 5 wherein the base is attached to the body using one of the following: glue, heat welding or ties.

7. An insert according to any one of claims 1 to 6 which includes a plurality of recess formations which are formed into the base at predetermined, spaced apart locations so that tabs of the connection box align with and are insertable into the recess formations when the base is pushed into the cavity.

8. An insert according to claim 2 wherein the base is differently sized relative to the body so that a shoulder extends around the base at a junction of the base and the body which abuts the rim when the base is inserted into the cavity.

9. An connection box insert for use with an electrical connection box which has a side wall and at least one pair of opposed tabs which extend from the side wall, the insert including a body and a base which has a rectangular cross-sectional shape, which extends from the body and which has an outer periphery, and at least a pair of opposed recess formations with each recess formation being formed into the outer periphery at a predetermined position so that the base is insertable into the box by registering the pair of opposed tabs with the pair of opposed recess formations.

10. An insert according to claim 9 which is made from an expanded, foamed material such as polystyrene.

11. An insert according to claim 9 or 10 which includes two sets of opposed recess formations.