Method for manufacturing electrical boxes

• US 20070051527A1
• Filed: 08/22/2006
• Published: 03/08/2007
• Est. Priority Date: 09/02/2005
• Status: Active Grant

• Current Assignee: Thomas & Betts International LLC (ABB Limited)
• Original Assignee: Thomas & Betts International Incorporated (ABB Limited)
• Inventors: Lupsa, Ioan, Lalancette, Daniel
• Granted Patent: US 7,368,661 B2
• Time in Patent Office: Days
• US Class Current: 174/50
• CPC Class Codes: H02G 3/08 Distribution boxes; Connection or junction boxes
• CPC Class Codes: Y10S 248/906 Electrical outlet box support

Abstract

The present invention is directed to a method of manufacturing an electrical box to reduce the amount of scrap material therefrom. More particularly, the present invention provides a metallic electrical outlet box that is formed from a sheet of material and folded into an electrical box.

Claims

1. A method of manufacturing an electrical box comprising the steps of:

providing a sheet material;

positioning a die for stamping out a first blank from said sheet material, said first blank includes two first side wall portions attached to either side of a first back wall portion at opposing first folded edges by material continuity, and one first end wall portion is attached to each first side wall portion by material continuity and extending in opposite directions from said first side wall portions, said first back wall portion being defined by two first opposing free edges and said two first opposing folded edges; and

stamping said first blank out of said sheet material.

2. The method of claim 1 further including the step of folding said first blank into a box shape to provide an electrical box.

3. The method of claim 1 further including the steps of:

aligning said die relative to a said sheet material to stamp a second blank from said sheet material; and

stamping said second blank out of said sheet material.

4. The method of claim 3 wherein said second blank includes two second side wall portions attached to either side of a second back wall portion at opposing folded second edges by material continuity, and one second end wall portion is attached to each second side wall portion by material continuity and extending in opposite directions from said second side wall portion, and said second back wall portion being defined by two opposing second free edges and two opposing second folded edges.

5. The method of claim 4 wherein said aligning step includes aligning one of said second end wall portion of said second blank with one of said first end wall portion of said first blank.

6. The method of claim 4 wherein said aligning step includes aligning said first side wall with said second end wall.

7. The method of claim 4 wherein said aligning step includes aligning said first back wall being aligned with said second back wall, and said first sidewall being aligned with said second end wall to minimize scrap material between said first blank and said second blank.

8. The method of claim 7 further including the step of folding said second blank into a box shape to provide an electrical box therefrom.

11. The blank of claim 3 wherein each of said end wall portions is planar square shaped.

9. A blank for forming an electrical box comprising two side wall portions attached to either side of a back wall portion at opposing folded edges by material continuity, and one end wall portion attached to each side wall portion by material continuity and extending in opposite directions from said side wall portion, said back wall portion being defined by two opposing free edges and said two opposing folded edges.

10. The blank of claim 9 wherein each of said side wall portions are planar rectangular shape.

12. The blank of claim 9 wherein said back wall portion is similar in shape to said side wall portions.

13. The blank of claim 9 wherein said back wall portion includes at least one receiving slot for attachment of said end wall portions.

14. The blank of claim 13 wherein at least one of said end walls includes a first tab protruding therefrom to provide engagement with said at least one receiving slot of said back wall.

15. The blank of claim 9 wherein said side wall portions include at least one coupling flap extending therefrom for attachment of said side wall to an opposing end wall.

16. The blank of claim 9 wherein said end wall includes at least one end coupling flap extending therefrom for attachment to an opposing side wall.