PREFABRICATED ELECTRICAL BOX

• US 20130248243A1
• Filed: 03/21/2013
• Published: 09/26/2013
• Est. Priority Date: 03/21/2012
• Status: Active Grant

• Current Assignee: Thomas & Betts International LLC (ABB Limited)
• Original Assignee: Thomas & Betts International Incorporated (ABB Limited)
• Inventors: Dinh, Cong Thanh, Beall, Christopher A.
• Granted Patent: US 10,411,450 B2
• Time in Patent Office: Days
• US Class Current: 174/535
• CPC Class Codes: H02G 1/00 Methods or apparatus specially adapted for installing, maintaining, repairing or dismantling electric cables or lines
• CPC Class Codes: H02G 3/081 Bases, casings or covers
• CPC Class Codes: H02G 3/086 Assembled boxes
• CPC Class Codes: H02G 3/14 Fastening of cover or lid to box
• CPC Class Codes: Y10T 29/49002 Electrical device making

Abstract

An improved electrical box is disclosed that incorporates a bracket and device cover as a single combined unit. The combined unit is simpler to manufacture and to install as opposed to three separate pieces.

Claims

1. An electrical housing assembly comprising:

a. an electrical box, said electrical box having four sides and a rear surface;

b. a mounting bracket extending from a side of said electrical box; and

c. a device cover, said device cover having a generally flat surface containing an opening configured to receive an electrical component and mounting holes for affixing said electrical component,

wherein said device cover is attached to said electrical box at a hinge that allows said device cover to rotate about said hinge from an open position to a closed position.

2. The electrical housing assembly of claim 1 wherein said hinge is a living hinge.

3. The electrical housing assembly of claim 1 wherein said mounting bracket extends perpendicularly from the side of said electrical box.

4. The electrical housing assembly of claim 1 wherein a tab extends from a side beyond the rear surface to form a far side support.

5. The electrical housing assembly of claim 4 wherein said far side support includes a notch to facilitate bending.

6. The electrical housing assembly of claim 1 wherein said electrical housing assembly is made from a single piece of stamped metal.

7. The electrical housing assembly of claim 1 wherein said electrical housing assembly is constructed from a first piece of metal comprising a vertical mounting bracket, a left sidewall, the rear surface, a right sidewall, the living hinge, and the device cover;

a second piece of metal comprising a top sidewall; and

a third piece of metal comprising a bottom sidewall.

8. The electrical housing assembly of claim 7 wherein said second piece of metal and said third piece of metal are identical.

9. The electrical housing assembly of claim 1 further comprising a retention mechanism for keeping said device cover in the closed position.

10. The electrical housing assembly of claim 9 wherein said retention mechanism comprises a locking tab extending from said device cover and a corresponding catch on said electrical box configured to receive said locking tab.

11. The electrical housing assembly of claim 1 further comprising knockouts located on the surface of the electrical box for easy removal of an area of said electrical box for the passage of wires.

12. The electrical housing assembly of claim 1 further comprising a hole configured to allow the passage of the threaded portion of a screw in said device cover and a corresponding cover attachment screw holes on said electrical box for receiving said threaded portion of a screw.

13. The electrical housing assembly of claim 1 wherein said device cover includes an extendable sleeve that may be extended to accommodate thicker walls.

14. A method for making an electrical housing assembly having an electrical box, cover, and mounting brackets comprising:

a. stamping sheet metal into a shape that can be formed into an electrical box having brackets extended three sides of the electrical box and a device cover extending from the fourth side of the electrical box; and

b. weakening the metal between said electrical box and said device cover to form a living hinge.

15. The method of claim 14 wherein said the step of weakening the metal between said electrical box and said device cover is performed by scoring the surface of said metal.

16. The method of claim 14 wherein said the living hinge is made by removing a portion of sheet metal at the intended location of the hinge to facilitate bending.

17. A method of making an electrical housing assembly having a left sidewall, right sidewall, top sidewall and bottom sidewall, and device cover comprising:

a. forming a first piece from stamped sheet metal, said first piece comprising the left sidewall, the rear surface, the right sidewall, and the device cover

b. forming a second piece of metal comprising the top sidewall;

c. forming a third piece of metal comprising the bottom sidewall; and

d. welding said second piece to said first piece, and said third piece to said first piece.

18. The method of claim 17 further comprising forming a living hinge between said cover and a sidewall by weakening the material between said device cover and sidewall.

19. The method of claim 17 wherein said second piece and third piece are interchangeable.

20. The method of claim 17 wherein said top sidewall, bottom sidewall, and left sidewall further comprise mounting brackets extending therefrom.