Recessed While-In-Use Electrical Box

• US 20090139742A1
• Filed: 12/04/2007
• Published: 06/04/2009
• Est. Priority Date: 12/04/2007
• Status: Active Grant

• Current Assignee: Pass & Seymour Incorporated (Legrand SA)
• Original Assignee: Pass & Seymour Incorporated (Legrand SA)
• Inventors: Bhosale, Vikramsinh P.
• Granted Patent: US 7,645,937 B2
• Time in Patent Office: Days
• US Class Current: 174/58
• CPC Class Codes: H02G 3/123 in thin walls
• CPC Class Codes: H02G 3/14 Fastening of cover or lid to box

Abstract

The present invention is directed to an electrical wiring box assembly that includes an inner wall box including a peripheral inner wall bounded and enclosed by a rear wall and open at a front end of the inner wall box to form an inner volume. The inner wall box also includes an inner wall flange extending in a substantially perpendicular direction from an exterior surface of the peripheral inner wall at predetermined distance from the front inner wall box end. The inner wall flange includes a plurality of apertures formed therein. The inner wall box further includes a plurality of device mounting bosses extending in a substantially perpendicular direction from an interior surface of the rear wall. An intermediate box includes a peripheral intermediate wall portion configured to fit within the inner volume. The peripheral intermediate wall is bounded by a rear ledge extending inwardly and perpendicularly from a back end of the peripheral intermediate wall to form an intermediate volume in communication with the inner volume at the back end and open at a front intermediate wall box end The intermediate box further includes an outer wall flange extending in a substantially perpendicular direction from an exterior surface of the peripheral intermediate wall at predetermined distance from the front end of the peripheral intermediate wall. A rear wall portion of the outer wall flange is configured to abut the front inner wall box end such that the rear edge is substantially aligned with the plurality of device mounting bosses. A cover assembly is removably coupled to the intermediate box, the cover assembly providing access to the intermediate volume in an open position and substantially sealing the intermediate volume and the inner volume in a closed position.

Claims

1. An electrical wiring box assembly comprising:

an inner wall box including a peripheral inner wall bounded and enclosed by a rear wall and open at a front end of the inner wall box to form an inner volume, the inner wall box also including an inner wall flange extending in a substantially perpendicular direction from an exterior surface of the peripheral inner wall at predetermined distance from the front inner wall box end, the inner wall flange including a plurality of apertures formed therein, the inner wall box further comprising a plurality of device mounting bosses extending in a substantially perpendicular direction from an interior surface of the rear wall;

an intermediate box including a peripheral intermediate wall portion configured to fit within the inner volume, the peripheral intermediate wall being bounded by a rear ledge extending inwardly and perpendicularly from a back end of the peripheral intermediate wall to form an intermediate volume in communication with the inner volume at the back end and open at a front intermediate wall box end, the intermediate box further comprising an outer wall flange extending in a substantially perpendicular direction from an exterior surface of the peripheral intermediate wall at predetermined distance from the front end of the peripheral intermediate wall, a rear wall portion of the outer wall flange being configured to abut the front inner wall box end such that the rear edge is substantially aligned with the plurality of device mounting bosses; and

a cover assembly removably coupled to the intermediate box, the cover assembly providing access to the intermediate volume in an open position and substantially sealing the intermediate volume and the inner volume in a closed position.

2. The assembly of claim 1, wherein at least some of the plurality of apertures are configured to accommodate fasteners to thereby mount the inner wall box to a wall structure.

3. The assembly of claim 2, wherein at least some of the plurality of apertures are configured to accommodate a viscous wall structure cover material.

4. The assembly of claim 3, wherein the viscous wall structure cover material is a stucco material.

5. The assembly of claim 1, wherein the cover assembly includes a door cover coupled to a mounting element, the cover assembly being coupled to the intermediate box.

6. The assembly of claim 5, wherein the mounting element includes a cover ring disposed on the outer wall.

7. The assembly of claim 6, wherein the cover ring is disposed over the peripheral intermediate wall abuttingly coupled to the outer wall flange, the cover ring and the door cover providing a weatherproof seal when the door cover is in the closed position.

8. The assembly of claim 7, wherein the door cover is removably connected to the cover ring by a hinge mechanism,

9. The assembly of claim 6, wherein the cover ring is attached to both the intermediate box and the inner box by way of mounting fasteners.

10. The assembly of claim 6, wherein the door cover and the cover ring include a wire entry port formed therein.

11. The assembly of claim 1, further comprising a collar wall extending in a substantially perpendicular direction from the inner wall flange, the collar wall being separated from the peripheral inner wall by a predetermined distance to form a water channel at the front end of the inner wall box.

12. The assembly of claim 11, further comprising a plurality of mounting bosses disposed at predetermined locations within the water channel, the plurality of mounting bosses being configured to accommodate a plurality of fasteners to thereby integrate the inner wall box, the intermediate wall box, and the cover assembly into an integrated assembly.

13. The assembly of claim 11 further comprising at least one drain aperture formed in a bottom portion of the collar wall.

14. The assembly of claim 1, further comprising a pattern formed in the inner wall flange, wherein the pattern includes indented regions configured to retain a viscous cover material such that the viscous cover material adheres to the inner wall flange.

15. The assembly of claim 14, wherein the pattern includes raised linear segments disposed in a cross-hatched pattern on the wall flange.

16. The assembly of claim 1, further comprising a sealing material disposed at a location where the rear portion of the outer flange wall abuts the front inner wall box end.

17. The assembly of claim 16, wherein the sealing material includes a gasket.

18. A temporary and disposable cover for use with the electrical box assembly of claim 1, the cover comprising:

a faceplate having a surface area substantially corresponding to a front portion of the electrical box assembly;

a plurality of sidewalls integrally coupled with said faceplate, the faceplate and the plurality of sidewalls being configured to substantially conform to and cover at least a portion of the electrical box assembly by frictional fit, at least one first sidewall of the plurality of sidewalls including a reverse draft that is configured to frictionally engage at least one first corresponding surface of the electrical assembly.

19. The cover of claim 18, further comprising:

at least one substantially planar portion coupled to the faceplate and the plurality of sidewalls, the at least one substantially planar portion being configured to substantially conform to and cover the outer wall flange, at least one second sidewall of the plurality of sidewalls including a reverse draft that is configured to frictionally engage at least one second corresponding surface of the electrical assembly.

20. The assembly of claim 1, wherein the distance between the inner wall flange and the outer wall flange is configured to accommodate a wall siding material.

21. An electrical wiring box assembly comprising:

a peripheral inner wall bounded and enclosed by a rear wall and open at a front end thereof to form an accessible volume,

a wall flange extending in a substantially perpendicular direction from an exterior surface of the peripheral wall at predetermined distance from the front inner wall box end, the wall flange including a plurality of apertures formed therein, at least some of the plurality of apertures being configured to accommodate fasteners to thereby mount the wall flange to a wall structure;

a collar wall extending toward the front end in a substantially perpendicular direction from the wall flange, the collar wall being separated from the peripheral inner wall by a predetermined distance to form a water channel;

a plurality of mounting bosses disposed at predetermined locations within the water channel; and

at least one drain aperture formed in the collar wall.

22. The assembly of claim 21, further comprising an intermediate box including a peripheral intermediate wall configured to fit within the accessible volume, the peripheral intermediate wall being bounded by a rear ledge extending inwardly and perpendicularly from a back end of the peripheral intermediate wall to form an intermediate volume in communication with the accessible volume at the back end and open at a front intermediate wall box end, the intermediate box further comprising an outer wall flange extending in a substantially perpendicular direction from an exterior surface of the peripheral intermediate wall at predetermined distance from the front end of the peripheral intermediate wall, a rear portion of the outer flange wall being configured to abut the front inner wall box end.

23. The assembly of claim 22, further comprising a plurality of device mounting bosses extending in a substantially perpendicular direction from an interior surface of the rear wall, the rear edge being substantially aligned with the plurality of device mounting bosses.

24. The assembly of claim 21, further comprising a pattern formed in the wall flange, the pattern being configured to accommodate a viscous cover material such that the viscous cover material adheres thereto.

25. An electrical wiring box assembly comprising:

a peripheral inner wall bounded and enclosed by a rear wall and open at a front end thereof to form an accessible volume;

a wall flange extending in a substantially perpendicular direction from an exterior surface of the peripheral inner wall at a predetermined distance from the front inner wall box end, the wall flange including a plurality of apertures formed therein; and

a pattern formed in the wall flange, the pattern being configured to accommodate a viscous material such that the viscous material adheres to the wall flange.

26. The assembly of claim 25, wherein the wall flange further includes a plurality of holes being configured such that a viscous material adheres thereto.

27. The assembly of claim 25, further comprising a collar wall extending in a substantially perpendicular direction from the wall flange, the collar wall being separated from the peripheral inner wall by a predetermined distance to form a water channel at the front end of the inner wall box.

28. The assembly of claim 27, further comprising at least one drain aperture formed in a bottom portion of the collar wall.

29. The assembly of claim 27, further comprising a plurality of mounting bosses disposed at predetermined locations within the water channel, the plurality of mounting bosses being configured to accommodate a plurality of fasteners.

30. The assembly of claim 25, further comprising an intermediate box including a peripheral intermediate wall portion configured to fit within the accessible volume, the peripheral intermediate wall being bounded by a rear ledge extending inwardly and perpendicularly from a back end of the peripheral intermediate wall to form an intermediate volume in communication with the accessible volume at the back end and open at a front intermediate wall box end, the intermediate box further comprising an outer wall flange extending in a substantially perpendicular direction from an exterior surface of the peripheral intermediate wall at a predetermined distance from the front end of the peripheral intermediate wall.

31. The assembly of claim 30, further comprising a cover assembly removably coupled to the intermediate box, the cover assembly including a door cover, the door cover providing access to the intermediate volume in an open position and substantially sealing the intermediate volume and the inner volume in a closed position.

32. The assembly of claim 31, wherein a plurality of fasteners couple the cover assembly to the mounting bosses.

33. A temporary and disposable cover for use with an electrical assembly, the cover comprising:

a faceplate having a surface area substantially corresponding to a front portion of the electrical assembly;

a plurality of sidewalls integrally formed with said faceplate, the faceplate and the plurality of sidewalls being configured to substantially conform to and cover at least a portion of the electrical assembly, at least one of the plurality of sidewalls including a reverse draft that is configured to frictionally engage at least one corresponding surface of the electrical assembly such that the disposable cover is attached to the electrical assembly by frictional fit.

34. The cover of claim 33, wherein the electrical assembly includes at least one electrical wiring device.

35. An electrical wiring box assembly comprising:

an inner wall box including a peripheral inner wall bounded and enclosed by a rear wall and open at a front end of the inner wall box to form an inner volume, the inner wall box also including an inner wall flange extending in a substantially perpendicular direction from an exterior surface of the peripheral inner wall at predetermined distance from the front inner wall box end, the inner wall flange including a plurality of apertures formed therein, the inner wall box also including a plurality of fastening structures coupled to the peripheral inner wall, the inner wall box further comprising a plurality of device mounting bosses extending in a substantially perpendicular direction from an interior surface of the rear wall; and

an intermediate box including a peripheral intermediate wall configured to fit within the inner volume, the peripheral intermediate wall being bounded by a rear ledge extending inwardly and perpendicularly from a back end of the peripheral intermediate wall to form an intermediate volume in communication with the inner volume at the back end and open at a front intermediate wall box end, the intermediate box further comprising an outer wall flange extending in a substantially perpendicular direction from an exterior surface of the peripheral intermediate wall at predetermined distance from the front end of the peripheral intermediate wall, a rear portion of the outer flange wall being configured to abut the front inner wall box end such that the rear edge is substantially aligned with the plurality of device mounting bosses.

36. The assembly of claim 35, wherein the intermediate box is fastened to the inner box by way of fasteners secured to the plurality of fastening structures.

37. The assembly of claim 35, further comprising a pattern formed in the inner wall flange, wherein the pattern includes indented regions configured to retain a viscous cover material such that the viscous cover material adheres to the inner wall flange.

38. The assembly of claim 37, wherein the pattern includes raised linear segments disposed in a cross-hatched pattern on the wall flange.

39. The assembly of claim 35, further including a cover assembly removably coupled to the intermediate box, the cover assembly including a door cover, the door cover providing access to the intermediate volume in an open position and substantially sealing the intermediate volume and the inner volume in a closed position.

40. The assembly of claim 39, wherein the cover assembly includes a door cover coupled to a cover ring, the cover assembly being replaceably coupled to the intermediate box.

41. The assembly of claim 39, wherein the cover assembly is coupled to the inner box by way of fasteners secured to the plurality of fastening structures.

42. The assembly of claim 35, further comprising a collar wall extending in a substantially perpendicular direction from the inner wall flange, the collar wall being separated from the peripheral inner wall by a predetermined distance to form a water channel at the front end of the inner wall box.

43. The assembly of claim 42 wherein the plurality of fastening structures are disposed at predetermined locations within the water channel.

44. The assembly of claim 35, further including a temporary and disposable electrical box cover, the cover comprising:

a faceplate having a surface area substantially corresponding to a front portion of the electrical box assembly;

a plurality of sidewalls integrally coupled with said faceplate, the faceplate and the plurality of sidewalls being configured to substantially conform to and cover at least a portion of the electrical box assembly by frictional fit, at least one first sidewall of the plurality of sidewalls including a reverse draft that is configured to frictionally engage at least one first corresponding surface of the electrical assembly.