Title: Outlet box for concrete walls
Abstract: An electrical outlet box having a generally rectangular box having a back wall, a perimetrical side wall surrounding the back wall defining an open front face and a box interior, the side wall comprised of a first and second set of generally parallel spaced apart wall portions, outwardly directed flanges extending from one set of parallel wall portions adjacent the open front face; and fastening structures integrally formed with and attached to the flanges for rigidly mounting the electrical outlet box to a structural member.
Patent Number: 6,894,222 Issued on 05/17/2005 to Lalancette, et al.
| Inventors:
|
Lalancette; Daniel (L'Acadie, CA);
Michaud; Alain (St. Luc, CA);
DiLillo; Mike (Laprairie, CA)
|
| Assignee:
|
Thomas & Betts International, Inc. (Sparks, NV)
|
| Appl. No.:
|
681008 |
| Filed:
|
October 8, 2003 |
| Current U.S. Class: |
174/58; 174/50; 174/53; 220/3.2; 220/3.9; 248/906 |
| Intern'l Class: |
H01H 009/02 |
| Field of Search: |
174/50,48,53,54,58,57,61,62,63,17 .R
220/32,33,34,36,37,394,392,39,38,402
248/906,318,343
33/DIG. 10,528
|
References Cited [Referenced By]
U.S. Patent Documents
| 4576431 | Mar., 1986 | Thayer.
| |
| 4757158 | Jul., 1988 | Lentz.
| |
| 5287665 | Feb., 1994 | Rath, Jr.
| |
| 5721394 | Feb., 1998 | Mulks.
| |
| 5773757 | Jun., 1998 | Kenney et al.
| |
| 5942726 | Aug., 1999 | Reiker.
| |
| 6194657 | Feb., 2001 | Gretz.
| |
| 6229087 | May., 2001 | Archer.
| |
| 6338225 | Jan., 2002 | Hayes.
| |
| 6660936 | Dec., 2003 | Jacks.
| |
Primary Examiner: Reichard; Dean A.
Assistant Examiner: Estrada; Angel R.
Attorney, Agent or Firm: Hoffmann & Baron, LLP
Parent Case Text
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 60/416,794
filed on Oct. 8, 2002.
Claims
1. An electrical outlet box for accommodating an electrical fixture comprising:
a generally rectangular box having a back wall, a perimetrical side wall surrounding
said back wall defining an open front face and a box interior, said side wall comprised
of a first and second set of generally parallel spaced apart wall portions, outwardly
directed flanges extending from one set of parallel wall portions adjacent said
open front face; and fastening structures integrally formed with and attached to
said flanges for rigidly mounting said electrical outlet box to a structural member
wherein said fastening structures have a first and second end, the first end attached
to said flange and a free second end.
2. An electrical outlet box of claim 1 wherein said fastening structures protrude
from said flanges away from said open front face.
3. An electrical outlet box of claim 1 wherein said fastening structures are
extendable from said flanges away from said open front face.
4. An electrical outlet box of claim 2, wherein said free end is pointed.
5. An electrical outlet box of claim 2, wherein said free end is sharp.
6. An electrical outlet box of claim 3, wherein said free end is pointed.
7. An electrical outlet box of claim 3, wherein said free end is sharp.
8. An electrical outlet box of claim 1, wherein said flanges have a plurality
of apertures for receiving a fastener, wherein said apertures have retaining structures
for temporarily securing said fastener.
9. An electrical outlet box according to claim 8 wherein said retaining structures
include frangible elements.
10. An electrical outlet box of claim 9 wherein said frangible element is defined
by a score line permitting detachment of said frangible element.
11. An electrical outlet box according to claim 8 wherein said retaining structures
include deformable elements.
12. An electrical outlet box of claim 11 wherein said deformable element is defined
by a malleable portion permitting bending of said deformable element.
13. An electrical outlet box according to claim 8, wherein said apertures are
configured to releasably retain said fastener.
14. An electrical outlet box according to claim 13, wherein said aperture has
at least one radially extended slot.
15. An electrical outlet box of claim 1 wherein said box is formed of conductive metal.
Description
FIELD OF THE INVENTION
The present invention relates generally to an electrical outlet box for housing
electrical fixtures such as a switch or a receptacle. More particularly, the present
invention relates to an improved electrical outlet box for use on concrete wall.
BACKGROUND OF THE INVENTION
It has long been known to house electrical fixtures such as switches and receptacles
in an electrical outlet box. The outlet box permits the insertion of electrical
wires into the box which are terminated to electrical fixtures. The fixtures then
may be mounted to the box which provides protection to the fixtures as well as
the wires terminated therein. The outlet box is then mounted to a wall at a convenient
location to provide access. Most outlet boxes accommodate one or more electrical
fixtures, which terminate standard 110 volt electrical wires.
Outlet boxes are available in a variety of configurations and sizes. The selection
of which type of box to use is dependant upon the specifics of the application.
The most commonly employed box is a single-gang outlet box, also referred to as
a standard outlet box. The single-gang box is ideal for applications in which only
one receptacle is required for the application. Standard outlet boxes have opening
dimensions of approximately 3″×2-¼″ and are available in
a variety of depths. Double-gang and triple-gang boxes are also available, and
they typically have the capacity to hold two and three receptacles respectively.
A four inch (4″) square box is also commonly employed for multiple receptacle applications.
Typically, outlet boxes are mounted by affixing mounting ears to a wall
stud or other structural member. However for some applications, such as exterior
uses, the outlet box, may be mounted within a concrete structure. This is accomplished
by attaching the box to a form in the desired location. The form is unusually a
wooden temporary structure used to contain the poured concrete in the desired shape
that is removed after the concrete has hardened. The outlet box remains in the
concrete after removal of the form.
It is necessary when using an outlet box in such an application to insure that
it is securely affixed to the form to resist being displaced during the concrete
pour. Presently, outlet boxes are affixed to the form using nails or screws. Current
design boxes usually provide holes on a flange for receiving a fastener such as
a nail to affix the box to a form. Upon removal of the forms, the nails (or screws)
remain in the concrete, and need to be cut away in order to avoid being in the
way during further work such as the installation of drywall. This requires an extra
step and can leave an undesirable sharp edge or projection where the fastener was cut.
Therefore it would be desirable to have an outlet box for use in concrete
walls, incorporating features which make cutting of the protruding nails or screws unnecessary.
SUMMARY OF THE INVENTION
Applicant has overcome the shortcomings of prior art outlet box with the
present invention by incorporating prongs that are adapted to being hammered into
a concrete form, prior to pouring concrete. Once the forms are removed, the prongs
can be hammered to a position that is parallel to the wall surface.
The present invention further provides for holes that are adapted to releasably
retain a fastener such that the it can be removed after the concrete has hardened.
Therefore there is provided an electrical outlet box having a generally
rectangular box having a back wall, a perimetrical side wall surrounding the back
wall defining an open front face and a box interior, the side wall comprised of
a first and second set of generally parallel spaced apart wall portions, outwardly
directed flanges extending from one set of parallel wall portions adjacent the
open front face; and fastening structures integrally formed with and attached to
the flanges for rigidly mounting the electrical outlet box to a structural member.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1
a-1
d show in side view, a typical installation of
the outlet box of the current invention.
FIG. 2 is a perspective view of one embodiment of the front of the outlet box
of the present invention.
FIG. 3 is a perspective view of the front of an alternate embodiment of the
present invention.
FIGS. 4 and 4
a-4
e show a perspective view of various alternate
embodiments of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
There will be detailed below the preferred embodiments of the present invention
with reference to the accompanying drawings. Like members are designated by like
reference characters in all figures.
Referring now to the drawings, there is shown in FIG. 1
a-
1d,
a typical installation of an outlet box
100 in a concrete wall application.
FIG. 1
a shows a front form
102 and rear form
104, used
to retain poured concrete to construct a vertical wall. As is well known, such
forms may be constructed of wood stud, planks or sheets such as plywood. The side
106 of outlet box
100 is fastened to front form
102. The outlet
box
100 must be securely fastened to the form when the concrete
108
is poured. Typically, the outlet box
100 is nailed to the form by driving
the fastener through apertures provided on exterior flanges, of outlet box into
the form. It should be noted that a wire, not shown in this view, would typically
be installed in the outlet box prior to the pouring of the concrete wall.
FIG. 1
b depicts the outlet box
100 positioned within the wall
116 after the concrete has been poured and hardened. Secure attachment of
the box
100 to the form
106 maintains the box
100 in proper
position during the concrete pour.
After the concrete has hardened, the forms are removed, as shown in FIG. 1
c,
thereby exposing the concrete wall front
110 and rear
112 surface.
Removal of the forms also exposes the front of outlet box, as well as the fasteners
114 used to affix the outlet box to front form
102. In a prior art
outlet box, the removal of the forms would expose the shank and point of the nail,
or the screw threads which would subsequently be cut away. In accordance with the
present invention, as will be explained further with reference to the FIGS. 2-4,
the fasteners can be removed or flattened flush with the wall surface. FIG. 1
d
depicts the finished installation of outlet box
100 after removal of
the fasteners, showing the concrete wall
116, furring strips
118,
drywall
120 and outlet box coverplate
122.
Turning now to FIG. 2, there is shown an embodiment of the outlet box of
the present invention. There is shown an outlet box
200 which is generally
a rectangular member having a back wall
202, a pair of spaced apart side
walls
204 extending from back wall
202, and opposed top and bottom
walls
206 and
208. Back wall
202, side walls
204 and
top and bottom walls
206 and
208 form a box interior
210 having
an open front face
212 which accommodates therein an electrical fixture.
Open front face
212 has a dimension substantially equivalent to the opening
of a double-gang outlet box. The interior length and width of the opening will
vary depending on if receptacle mounting flanges disposed on the box are interior
or exterior to the box opening. However, the outlet box depicted here is illustrative
and not intended to be limiting. It will be appreciated that it would be apparent
to have an outlet box according to the present invention having alternate dimensions
according to the application of such outlet box.
As is well known in the art, outlet box
200 may include one or more access
openings, typically known as knockouts
214 which permit entry of electrical
wires and cables (not shown) into box interior
210. The exterior surfaces
of top
206 and bottom walls
208 include mounting flanges
216
and
218 respectively which allow the box to be secured to a concrete form
or the like in conventional fashion by use of a fastener such as a nail or screw.
The interior surfaces of side walls
204 include component retaining flanges
220 and
222 which include apertures
224 for receiving fasteners,
usually screws, to securely mount electrical components within the outlet box and
screws
226 for securely attaching a ground wire to the outlet box. Mounting
flanges
216 and
218 are outwardly bent with respect to the top
206
and bottom
208 of the outlet box. Mounting flanges
216 and
218
include apertures
228 for affixing the outlet box to a concrete form in
the conventional way, such as for example, by placing outlet box open face
212
against a concrete form and driving a nail (not shown) through the apertures
228
to securely mount the box to the concrete form.
Alternately, the outlet box according to the present invention includes
retracted prongs
230 on mounting flanges
216 and
218 for securely
attaching outlet box to a concrete form. In this exemplary embodiment, the prongs
are tabs, formed from the flange material, being pointed at one end and attached
to the flange at the end opposite the pointed end. Each tab is folded back along
its length to form a "v" such that the pointed end is positioned toward the outlet
box opening and the apex of the "v" is extended toward the back wall
202.
In use outlet box open face
212 is placed against a concrete form and retracted
prongs
230 are driven into the form, typically by hammering the apex of
the prong to force the pointed end forward and into the form, thereby securely
affixing the outlet box to the form. Upon removal of the forms, prongs
230
can be hammered flush with flanges
216 and
218.
Turning now to FIG. 3, an alternate embodiment of the present invention is
shown. In the embodiment of FIG. 3, outside mounting flanges
216 and
218
extend from side walls
204, inside component retaining flanges extend from
top
206 and bottom
208 wall. In this embodiment flange
216
and
218 include slots
302 located at the uppermost side edge and
bottom of flanges
216 and
218 respectively. Slots
302 permit
the removal of a nail or screw, by providing a passage to slide out the nail head
from behind the outlet box after the forms have been removed. In use, the open
face
212 of outlet box
200 would be placed against a form and affixed
by driving a nail into the form through slot
302. After the concrete is
poured and hardened the form is removed leaving the exposed fastener point and
shank. The head of the fastener is retained behind the slot by the concrete. According
to the present invention, the fastener can be removed by gripping the shank of
the fastener, and forcibly moving it towards the open end of the slot until the
fastener head is released.
Alternately, the outlet box according to the present invention includes
prongs
304 on mounting flanges
216 and
218 for securely attaching
outlet box to a concrete form. In this exemplary embodiment, the prongs are tabs,
formed from the flange material, being pointed at one end and attached to the flange
at the end opposite the pointed end. Each tab protrudes orthogonally from the outlet
box flange having the pointed end extending outwardly from flange
216 and
218. In use, outlet box open face
212 is placed against a concrete
form and flange
216 and
218 are hammered towards the form whereby
prongs
304 are driven into the form. Upon removal of the form, prongs
304
can be hammered flush with the surface of flange
216 and
218.
Turning now to FIG. 4, another alternate embodiment of the present invention
is shown. In the embodiment of FIG. 4, outside mounting flanges
216 and
218 include apertures
402 for releasably retaining fasteners used
to affix the outlet box to a concrete form. Apertures
402 can comprise either
deformable or removable structures as described below.
More particularly, apertures
402 comprises a generally circular opening
having an upper and lower tab
404, each having a base
406 and a tip
408 extending towards the center of the opening. Tip
408 has a semicircular
profile adapted to concentrically receive the shank of a fastener such as a nail.
Tabs
404 can be a plastically deformable metallic material formed integrally
with flanges
216 and
218. The metallic material should be strong
enough to securely affix outlet box
100 to a concrete form while allowing
a fastener to be removed by pulling the head of the fastener through the aperture.
After the fastener is removed, the deformed tabs can be hammered flush with the
surface of flange
216 and
218. Alternately, tabs
404 can removable
structures wherein the base
406 is scored, i.e partially cut through, such
that the tab will break away when subjected to the force of the fastener head being
pulled through the aperture.
It will be appreciated that aperture
402 can be formed of a variety of
shapes and structures as shown in FIGS. 4
a-e, wherein various alternate
embodiments are depicted.
FIG. 4
a depicts aperture
410 having a generally circular shape
with three slots extending radially from the center of the aperture. In the preferred
embodiment of aperture
410, the radial slots define three deformable tabs
412 that are concentric with the central circular region. Tabs
412
can be alternately removable structures as previously described with respect to
apertures
402.
It should be further noted that it would be apparent to modify aperture
410
to include any number of radial slots, for example, in FIG. 4
c, there is
shown an aperture having two radial slots
414 extending from the generally
circular center region.
Similarly, FIG. 4
d, depicts an aperture having four radial slots
416 extending from the generally circular center region.
A further alternate embodiment is depicted in FIG. 4
b, wherein there is
shown a generally circular aperture
418, having a slot
420 extending
radially from the outer circumference of the circular opening wherein the slot
has a width less than the diameter of the center circular region. The slot
420
is adapted to receive the shank of a fastener, such as a nail. The slot
420
however, is smaller than the diameter of a nail head typically used it this type
of application. Whereas the generally circular aperture
418 has a larger
diameter than the head of a nail typically used for this type of application.
In use, the box according to the embodiment depicted in FIG. 4
b, is affixed
to a form by driving a nail into a form through the aperture provided. After the
concrete is poured and hardened the form is removed leaving the exposed fastener
point and shank, with the head of the fastener retained behind slot
420.
According to the present invention, the user can remove the exposed fastener by
gripping the fastener shank and moving the fastener towards the circular aperture
418 until the fastener head is released and thereby can be removed.
A further alternate embodiment is depicted in FIG. 4
e, wherein there is
shown an aperture
422 adapted to receive the shank of a nail or other such
fastener, but having a diameter smaller than the head of a fastener typically used
for this type of application. There is further provided a scored region
424
eccentrically surrounding aperture
422, defining a break away tab
426
that facilitates the removal of a portion of the flange to permit the fastener
head to be removed.
In use, the box according to the embodiment depicted in FIG. 4
e, is affixed
to a form by driving a nail into a form through the aperture provided. After the
concrete is poured and hardened the form is removed leaving the exposed fastener
point and shank. The head of the fastener is retained behind scored region
424.
According to the present invention, the user can remove the exposed fastener by
gripping the fastener shank and pulling the fastener away from the wall, whereby
the breakaway tab
426 is removed, and the fastener released.
It will be appreciated that the present invention has been described herein with
reference to certain preferred or exemplary embodiments. The preferred or exemplary
embodiments described herein may be modified, changed, added to or deviated from
without departing from the intent, spirit and scope of the present invention. It
is intended that all such additions, modifications, amendments, and/or deviations
be included within the scope of the claims appended hereto.
*
