Electrical box with recessed faceplate

• US 20040238197A1
• Filed: 05/06/2004
• Published: 12/02/2004
• Est. Priority Date: 11/08/2002
• Status: Active Grant

• Current Assignee: Clark H. Gates II
• Original Assignee: Clark H. Gates II
• Inventors: Gates, Clark H II
• Granted Patent: US 8,245,862 B2
• Time in Patent Office: Days
• US Class Current: 174/53
• CPC Class Codes: H01R 13/447 Shutter or cover plate
• CPC Class Codes: H01R 25/006 the coupling part being secured to apparatus or structure, e.g. duplex wall receptacle
• CPC Class Codes: H02G 3/121 in plain walls
• CPC Class Codes: H02G 3/14 Fastening of cover or lid to box

Abstract

An electrical box with recessed faceplate having a one-piece recessed faceplate (2) and adapted to accommodate a two-piece recessed faceplate (25). A rear portion (8) contains channels (9) on the top (5), bottom (6), and sides (7). A connecting wall (1503) attaches the rear portion (8) to the front portion (11). The connecting wall (1503) extends beyond the rear portion (8) and preferably contains one or more apertures (19, 20) to accommodate releasable fasteners such as screws (10). These apertures (19, 20) and the channels (9) assure that no screws (10) or analogous components or another type or relesable fastener are exposed within the box (1). The two-piece recessed faceplate (25) has an inner portion (45) and an outer portion (24) which slide along each other in order to enable the box (1) to be mounted at different distances from the mounting surface. Optionally, a removable cover (39) extends across the mouth (3) of the faceplate (2, 25). An extender (47) is also available for converting traditional electrical boxes (46) into a box that can accommodate a recessed faceplate (2, 25). And an alternative electrical box (600) holds switches (619) and is L-shaped.

Claims

1. An Electrical Box with Recessed Faceplate, which comprises:

a faceplate (2) comprising;

a rear wall (26) with a perimeter (1401) and a cross-sectional shape, the rear wall (26) containing one or more instrumentality apertures (127) and having a means for accommodating a releasable fastener for attaching said faceplate (2) to an electrical instrumentality (15);

a flange (33); and

an interior surface (1400) projecting generally forward from the rear wall (26) and connecting the rear wall (26) to the flange (33); and

a box (1) comprising;

a rear wall (4) having a perimeter (1501);

a lateral surface (1500) attached to and projecting generally forward from the perimeter (1501) of the rear wall (4) and having a top (5) containing a channel (9), a bottom (6) containing a channel (9), and sides (7) each containing a channel (9), with each channel (9) having an interior end (1001);

a connecting wall (1503) having a first end (1502) attached to the lateral surface (1500), the connecting wall (1503) having sides (1505) and a second end (1504) and said connecting wall (1503) extending generally outward from the lateral surface (1500); and

a front portion (11) having a first end (1506) attached to and projecting generally forward from the sides (1505) and the second end (1504) of the connecting wall (1503), the front portion (11) containing the interior ends (1001) of the channels (9), the front portion (11) having a second end (1507) forming an open mouth (3), the front portion (11) having substantially the same cross-sectional shape as does the rear wall (26) of said faceplate (2), and the front portion (11) having dimensions such that the flange (33) of the faceplate (2) extends from the interior surface (1400) to a position laterally beyond the front of the mouth (3); and

a means for accommodating a releasable fastener for attaching said box (1) to an electrical instrumentality (15).

2. The Electrical Box with Recessed Faceplate as recited in claim 1, wherein:

the means for accommodating a releasable fastener for attaching said faceplate (2) to an electrical instrumentality (15) which means comprises part of the faceplate (2) is one or more apertures (1003) in said faceplate (2) as well as one or more apertures (19, 20) in the connecting wall (1503) when the fastener for attaching said faceplate (2) to an electrical instrumentality (15) is a screw (10); and

the means for accommodating a releasable fastener for attaching said box (1) to an electrical instrumentality (15) is a covered interior end (1001) having a threaded aperture (1002) for the channel (9) on the top (5) of the lateral surface (1500) of the box (1) and a covered interior end (1001) having a threaded aperture (1002) for the channel (9) on the bottom (6) of the lateral surface (1500) of the box (1).

3. The Electrical Box with Recessed Faceplate as recited in claim 2, wherein:

said faceplate (2) and said box (1) each have a rectangular cross section.

4. The Electrical Box with Recessed Faceplate as recited in claim 3, further comprising:

a cover (39) having a front surface (141), a top (42) connected to the front surface (141), two sides (43) each of which is connected to the front surface (141), and longitudinal tabs (38) extending inward from each side (43);

and

wherein said flange (33) has sides (35), each side (35) containing a channel (36) running along an edge (37) of said flange (33) to accommodate the longitudinal tabs (38) of said cover (39).

5. The Electrical Box with Recessed Faceplate as recited in claim 1, wherein:

said faceplate (2) and said box (1) each have a rectangular cross section.

6. The Electrical Box with Recessed Faceplate as recited in claim 5, further comprising:

a cover (39) having a front surface (141), a top (42) connected to the front surface (141), two sides (43) each of which is connected to the front surface (141), and longitudinal tabs (38) extending inward from each side (43); and

wherein said flange (33) has sides (35), each side (35) containing a channel (36) running, along an edge (37) of said flange (33) to accommodate the longitudinal tabs (38) of said cover (39).

7. An Electrical Box with Recessed Faceplate, which comprises:

a faceplate (2) comprising;

a rear wall (26) with a perimeter (1401) and a cross-sectional shape, the rear wall (26) containing one or more instrumentality apertures (127) and having a means for accommodating a fastener for attaching said faceplate (2) to an electrical instrumentality (15) as well as a means for accommodating a releasable fastener;

a flange (33); and

an interior surface (1400) projecting generally forward from the rear wall (26) and connecting the rear wall (26) to the flange (33); and

a box (1) comprising;

a rear wall (4) having a perimeter (1501);

a lateral surface (1500) attached to and projecting generally forward from the perimeter (1501) of the rear wall (4) and having a top (5) containing a channel (9), a bottom (6) containing a channel (9), and sides (7) each containing a channel (9), with each channel (9) having an interior end (1001);

a connecting wall (1503) having a first end (1502) attached to the lateral surface (1500), the connecting wall (1503) having sides (1505) and a second end (1504) and said connecting wall (1503) extending generally outward from the lateral surface (1500); and

a front portion (11) having a first end (1506) attached to and projecting generally forward from the sides (1505) and the second end (1504) of the connecting wall (1503), the front portion (11) containing the interior ends (1001) of the channels (9), the front portion (11) having a second end (1507) forming an open mouth (3), the front portion (11) having substantially the same cross-sectional shape as does the rear wall (26) of said faceplate (2), and the front portion (11) having dimensions such that the flange (33) of the faceplate (2)extends from the interior surface (1400) to a position laterally beyond the front of the mouth (3); and

a means for accommodating a releasable fastener for attaching said box (1) to said faceplate (2).

8. The Electrical Box with Recessed Faceplate as recited in claim 7, wherein:

the means for accommodating a releasable fastener in the rear wall (26) of said faceplate (2) is one or more apertures (1003) in the rear wall (26) of said faceplate (2) when the releasable fastener is a screw (10); and

the means for accommodating a releasable fastener for attaching said box (1) to said faceplate (2) is a covered interior end (1001) having a threaded aperture (1002) for the channel (9) on the top (5) of the lateral surface (1500) of the box (1) and a covered interior end (1001) having a threaded aperture (1002) for the channel (9) on the bottom (6) of the lateral surface (1500) of the box (1) when the releasable fastener is a screw (10) that will pass through the one or more apertures (1003) in the rear wall (26) of said faceplate (2).

9. The Electrical Box with Recessed Faceplate as recited in claim 8, wherein:

said faceplate (2) and said box (1) each have a rectangular cross section.

10. The Electrical Box with Recessed Faceplate as recited in claim 9, further comprising:

a cover (39) having a front surface (141), a top (42) connected to the front surface (141), two sides (43) each of which is connected to the front surface (141), and longitudinal tabs (38) extending inward from each side (43); and

wherein said flange (33) has sides (35), each side (35) containing a channel (36) running along an edge (37) of said flange (33) to accommodate the longitudinal tabs (38) of said cover (39).

11. The Electrical Box with Recessed Faceplate as recited in claim 7, wherein:

said faceplate (2) and said box (1) each have a rectangular cross section.

12. The Electrical Box with Recessed Faceplate as recited in claim 11, further comprising:

a cover (39) having a front surface (141), a top (42) connected to the front surface (141), two sides (43) each of which is connected to the front surface (141), and longitudinal tabs (38) extending inward from each side (43); and

wherein said flange (33) has sides (35), each side (35) containing a channel (36) running along an edge (37) of said flange (933) to accommodate the longitudinal tabs (38) of said cover (39).

13. An Electrical Box with Recessed Faceplate, which comprises:

a faceplate (25) comprising;

an outer portion (24) comprising;

a flange (33);

an interior surface (1400) having sides (29), being attached to the flange (33), and projecting generally rearward from the flange (33); and

a longitudinal projection (201) extending inward from each side (29) of the interior surface (1400) and having a means for accommodating a releasable fastener; and

an inner portion (45) comprising;

a rear wall (26) with a perimeter (1401) and a cross-sectional shape, the rear wall (26) containing one or more instrumentality apertures (127) and having a means for accommodating a releasable fastener for attaching said faceplate (25) to an electrical instrumentality (15) as well as a means for accommodating a second releasable fastener; and

an interior surface (1400) projecting generally forward from the rear wall (26) and connected to the rear wall (26), with the dimensions of the interior surface (1400) of the inner portion (45) being such that the interior surface (1400) of the inner portion (45) will fit into and slide along the interior surface (1400) of the outer portion (24) with substantially no gaps between such interior surfaces (1400); and

a box (1) comprising;

a rear wall (4) having a perimeter (1501);

a lateral surface (1500) attached to and projecting generally forward from the perimeter (1501) of the rear wall (4) and having a top (5) containing a channel (9), a bottom (6) containing a channel (9), and sides (7) each containing a channel (9), with each channel (9) having an interior end (1001);

a connecting wall (1503) having a first end (1502) attached to the lateral surface (1500), the connecting wall (1503) having sides (1505) and a second end (1504) and said connecting wall (1503) extending generally outward from the lateral surface (1500); and

a front portion (11) having a first end (1506) attached to and projecting generally forward from the sides (1505) and the second end (1504) of the connecting wall (1503), the front portion (11) containing the interior ends (1001) of the channels (9), the front portion (11) having a second end (1507) forming an open mouth (3), the front portion (11) having substantially the same cross-sectional shape as does the rear wall (26) of said faceplate (25), and the front portion (11) having dimensions such that the flange (33) of said faceplate (25) extends from the interior surface (1400) to a position laterally beyond the front of the mouth (3);

a means for accommodating a releasable fastener for attaching said box (1) to an electrical instrumentality (15); and

a means for accommodating a releasable fastener for drawing toward said box (1) and releasably retaining the outer portion (24) of said faceplate (25).

14. The Electrical Box with Recessed Faceplate as recited in claim 13, wherein:

the means for accommodating a releasable fastener in the longitudinal projection (201) is an aperture (44) when the releasable fastener accommodated thereby is a screw (10);

the means for accommodating a releasable fastener for attaching said faceplate (25) to an electrical instrumentality (15) is one or more apertures (1003) in said faceplate (25) as well as one or more apertures (19, 20) in the connecting wall (1503) when the fastener for attaching said faceplate (25) to an electrical instrumentality (15) is a screw (10);

the means for accommodating a releasable fastener for attaching said box (1) to an electrical instrumentality (15) is a covered interior end (1001) having a threaded aperture (1002) for the channel (9) on the top (5) of the lateral surface (1500) of the box (1) and a covered interior end (1001) having a threaded aperture (1002) for the channel (9) on the bottom (6) of the lateral surface (1500) of the box (1);

the means for accommodating a releasable fastener for drawing toward said box (1) and releasably retaining the outer portion (24) of said faceplate (25) is a covered interior end (1001) having a threaded aperture (1002) for the channels (9) on the sides (7) of the lateral surface (1500) of the box (1) so that said threaded aperture (1002) can receive screws (10) which pass through the apertures (44) in the longitudinal projections (201); and

the means for accommodating a second releasable fastener in the rear wall (26) of said faceplate (25) is an aperture (46).

15. The Electrical Box with Recessed Faceplate as recited in claim 14, wherein:

said faceplate (25) and said box (1) each have a rectangular cross section.

16. The Electrical Box with Recessed Faceplate as recited in claim 15, further comprising:

a cover (39) having a front surface (141), a top (42) connected to the front surface (141), two sides (43) each of which is connected to the front surface (141), and longitudinal tabs (38) extending inward from each side (43); and

wherein said flange (33) has sides (35), each side (35) containing a channel (36) running, along an edge (37) of said flange (33) to accommodate the longitudinal tabs (38) of said cover (39).

17. The Electrical Box with Recessed Faceplate as recited in claim 13, wherein:

said faceplate (25) and said box (1) each have a rectangular cross section.

18. The Electrical Box with Recessed Faceplate as recited in claim 17, further comprising:

a cover (39) having a front surface (141), a top (42) connected to the front surface (141), two sides (43) each of which is connected to the front surface (141), and longitudinal tabs (38) extending inward from each side (43); and

wherein said flange (33) has sides (35), each side (35) containing a channel (36) running along an edge (37) of said flange (33) to accommodate the longitudinal tabs (38) of said cover (39).

19. An Electrical Box with Recessed Faceplate, which comprises:

a faceplate (25) comprising;

an outer portion (24) comprising;

a flange (33);

an interior surface (1400) having sides (29), being attached to the flange (33), and projecting generally rearward from the flange (33); and

a longitudinal projection (201) extending inward from each side (29) of the interior surface (1400) and having a means for accommodating a releasable fastener; and

an inner portion (45) comprising;

a rear wall (26) with a perimeter (1401) and a cross-sectional shape, the rear wall (26) containing one or more instrumentality apertures (127) and having a means for accommodating a fastener for attaching said faceplate (25) to an electrical instrumentality (15) as well as a means for accommodating a releasable fastener; and

an interior surface (1400) projecting generally forward from the rear wall (26) and connected to the rear wall (26), with the dimensions of the interior surface (1400) of the inner portion (45) being such that the interior surface (1400) of the inner portion (45) will fit into and slide along the interior surface (1400) of the outer portion (24) with substantially no gaps between such interior surfaces (1400); and

a box (1) comprising;

a rear wall (4) having a perimeter (1501);

a lateral surface (1500) attached to and projecting generally forward from the perimeter (1501) of the rear wall (4) and having a top (5) containing a channel (9), a bottom (6) containing a channel (9), and sides (7) each containing a channel (9), with each channel (9) having an interior end (1001);

a connecting wall (1503) having a first end (1502) attached to the lateral surface (1500), the connecting wall (1503) having sides (1505) and a second end (1504) and said connecting wall (1503) extending generally outward from the lateral surface (1500); and

a front portion (11) having a first end (1506) attached to and projecting generally forward from the sides (1505) and the second end (1504) of the connecting wall (1503), the front portion (11) containing the interior ends (1001) of the channels (9), the front portion (11) having a second end (1507) forming an open mouth (3), the front portion (11) having substantially the same cross-sectional shape as does the rear wall (26) of said faceplate (25), and the front portion (11) having dimensions such that the flange (33) of the faceplate (25) extends from the interior surface (1400) to a position laterally beyond the front of the mouth (3); and

a means for accommodating a releasable fastener for drawing toward said box (1) and releasably retaining the outer portion (24) of said faceplate (25).

20. The Electrical Box with Recessed Faceplate as recited in claim 19, wherein:

the means for accommodating a releasable fastener in the longitudinal projection (201) is an aperture (44) when the releasable fastener accommodated thereby is a screw (10);

the means for accommodating a releasable fastener in the rear wall (26) of said faceplate (25) is one or more apertures (46) in the rear wall (26) of said faceplate (25) when the releasable fastener is a screw (10); and

the means for accommodating a releasable fastener for drawing toward said box (1) and releasably retaining the outer portion (24) of said faceplate (25) is a covered interior end (1001) having a threaded aperture (1002) for the channels (9) on the sides (7) of the lateral surface (1500) of the box (1) so that said threaded aperture (1002) can receive screws (10) which pass through the apertures (44) in the longitudinal projections (201).

21. The Electrical Box with Recessed Faceplate as recited in claim 20, wherein:

said faceplate (25) and said box (1) each have a rectangular cross section.

22. The Electrical Box with Recessed Faceplate as recited in claim 21, further comprising:

a cover (39) having a front surface (141), a top (42) connected to the front surface (141), two sides (43) each of which is connected to the front surface (141), and longitudinal tabs (38) extending inward from each side (43), and

wherein said flange (33) has sides (35), each side (35) containing a channel (36) running, along an edge (37) of said flange (33) to accommodate the longitudinal tabs (38) of said cover (39).

23. The Electrical Box with Recessed Faceplate as recited in claim 19, wherein:

said faceplate (25) and said box (1) each have a rectangular cross section.

24. The Electrical Box with Recessed Faceplate as recited in claim 23, further comprising:

a cover (39) having a front surface (141), a top (42) connected to the front surface (141), two sides (43) each of which is connected to the front surface (141), and longitudinal tabs (38) extending inward from each side (43); and

wherein said flange (33) has sides (35), each side (35) containing a channel (36) running along an edge (37) of said flange (33) to accommodate the longitudinal tabs (38) of said cover (39).

25. An extender for a traditional electrical box, which comprises:

a first side (48) having a front (1022), a back (52), a top (55), and a bottom (54) with the top (55) and bottom (54) beyond the position of the top (5) and bottom (6) of a traditional electrical box (46), said first side (48) containing an aperture (301) that will be above a height equal to the top (5) and an aperture (302) that will be below the level of the bottom (6) of a traditional electrical box (46), with such apertures (301, 302) also being at a position that will be in general alignment with projections (134) on the top (5) and bottom (6) of a traditional electrical box (46);

a second side (49) having two channels (51) to accommodate projections (50) on a traditional electrical box (46) and also having a front (1022), a back (52), a top (55), and a bottom (54) with the top (55) and bottom (54) beyond the position of the top (5) and bottom (6) of a traditional electrical box (46), said second side (49) containing an aperture (301) that will be above a height equal to the top (5) and an aperture (302) that will be below the level of the bottom (6) of a traditional electrical box (46), with such apertures (301, 302) also being at a position that will be in general alignment with projections (134) on the top (5) and bottom (6) of a traditional electrical box (46);

a wall (53) attached, at a distance from the back (52) of the sides (48, 49) of the extender (47) greater than the distance between the open front (3) of a traditional electrical box (46) and the projections (134) for holding nails on the top (5) of a traditional electrical box (46), to said first side (48) and said second side (49) running from the bottom (54) to the top (55) of said first side (48) and said second side (49), containing one or more instrumentality apertures (154), having a lower aperture (55) and an upper aperture (56) that, when the extender (47) has been placed upon a traditional electrical box (46), will generally be aligned with an upper and a lower channel (9) of a traditional electrical box (46), said wall (53) also having a top (1021) and a bottom (1031);

an upper segment (1020) running along and attached to the top (1021) of said wall (53) between said first side (48) and said second side (49) of the extender (47) from said wall (53) to the front (1022) of said first side (48) and said second side (49), said upper segment (1020) also being attached to the top (55) of said first side (48) and said second side (49); and

a lower segment (1030) running along and attached to the bottom (1031) of said wall (53) between said first side (48) and said second side (49) of the extender (47) from said wall (53) to the front (1022) of said first side (48) and said second side (49), said lower segment (1030) also being attached to the bottom (54) of said first side (48) and said second side (49).

26. The extender for a traditional electrical box as recited in claim 25, further comprising:

one or more apertures (57, 59) in said wall (53) for accommodating one or more screws (10) for attaching a faceplate (2) to an electrical instrumentality (15).

27. The extender for a traditional electrical box as recited in claim 26, further comprising:

a faceplate (2) comprising;

a rear wall (26) with a perimeter (1401) and a cross-sectional shape, the rear wall (26) containing one or more instrumentality apertures (127) and having a means for accommodating a releasable fastener for attaching said faceplate to (2) an electrical instrumentality (15);

a flange (33); and

an interior surface (1400) projecting generally forward from the rear wall (26) and connecting the rear wall (26) to the flange (33).

28. An Electrical Box with Recessed Faceplate, which comprises:

two generally L-shaped sides (601), each having a first end (603), a second end (608), a bottom (605), a vertex (609), and a shorter leg (617) with an inside edge (616);

a back panel (602) running the length of and attached to the first end (603) of each of said L-shaped sides (601), said back panel(602) having a bottom (606);

a bottom panel (604) attached to and running between the bottoms (605) of said L-shaped sides (601) and also attached to the bottom (606) of the back panel (602);

a front panel (607), having a top (613) and attached to the second end (608) of each of said L-shaped sides (601) running between said L-shaped sides (601) from the bottoms (605) of said L-shaped sides (601) to the vertex (609) of the L and also attached to said bottom panel (604);

a U-shaped ledge (610) having two legs (615), having an inside (611) of a bottom (612) of said U-shaped ledge (610) attached to the top(613) of said front panel (607), having an outside (614) of the legs (615) of said U-shaped ledge (610) attached to the generally L-shaped sides (601) in substantial alignment with an inside edge (616) of the shorter leg (617) of each L, having a threaded aperture (620) in each leg (615) of said U-shaped ledge (610), and having a secondary threaded aperture (629) in at least one leg (615) of said U-shaped ledge (610);

an insert (622) slidably mounted above said U-shaped ledge (610), said insert (622) having a top (623), bottom (624) having ends (628), two sides (625), and outer edges (631), with an aperture (626) in the bottom (624) of said insert (622) to accommodate a switch (619) and an aperture (627) in one or more ends (628) of the bottom (624) of said insert (622) designed to be substantially aligned with one or more of the secondary threaded apertures (629) in one or more legs (615) of said U-shaped ledge (610) after said insert (622) has been slidably mounted above said U-shaped ledge (610); and

a flange (630) extending from the outer edges (631) of said insert (622) generally perpendicular to the top (623), bottom (624), and two sides (625) of said insert (622).