Electrical junction box with built-in isolation transformer

• US 20140090865A1
• Filed: 10/03/2012
• Published: 04/03/2014
• Est. Priority Date: 10/03/2012
• Status: Active Grant

• Current Assignee: Hayward Industries, Inc.
• Original Assignee: Hayward Industries, Inc.
• Inventors: Potucek, Kevin, Carter, James, Fournier, Gregory
• Granted Patent: US 9,392,711 B2
• Time in Patent Office: Days
• US Class Current: 174/50.51
• CPC Class Codes: H02G 3/081 Bases, casings or covers
• CPC Class Codes: H02G 3/083 Inlets
• CPC Class Codes: H02G 3/088 Dustproof, splashproof, drip-proof, waterproof, or flameproof casings or inlets
• CPC Class Codes: H02G 3/14 Fastening of cover or lid to box
• CPC Class Codes: H05K 5/061 sealed by a gasket held between a removable cover and a body, e.g. O-ring, packing

Abstract

An electrical junction box with a built-in isolation transformer is provided. The junction box comprises an interior base portion having at least one opening, a transformer secured to the interior base portion and in electrical communication with low-voltage and high-voltage terminals, a cover configured to attach to a junction box base plate and housing the interior base portion and the transformer, and a gasket providing a watertight seal between the cover and the junction box base plate.

Claims

1. An electrical junction box, comprising:

a cover including a peripheral flange shaped and sized to receive a base plate of an existing junction box installation, the cover removably attachable to the base plate and defining an interior cavity;

a high-voltage section and a low-voltage section defined within the cover, the high-voltage section isolated from the low-voltage section; and

a transformer positioned within the cover and in electrical communication with high-voltage terminals and low-voltage terminals, the high-voltage terminals positioned in the high-voltage section and the low-voltage terminals positioned in the low-voltage section.

2. The electrical junction box of claim 1, further comprising a base portion for separating the high-voltage section from the low-voltage section.

3. The electrical junction box of claim 2, wherein the cover and the base portion have generally rectangular, square, or oval cross-sectional shapes.

4. The electrical junction box of claim 2, further comprising a second transformer attached to the base portion.

5. The electrical junction box of claim 2, wherein the base portion further comprises an upper top surface having a first opening and a lower top surface having a second opening, and an inner sidewall connecting the upper and lower top surfaces.

6. The electrical junction box of claim 5, further comprising low-voltage wires connecting the transformer to the low-voltage terminals and high-voltage wires connecting the transformer to the high-voltage terminals.

7. The electrical junction box of claim 6, wherein the low-voltage wires extend through the first opening.

8. The electrical junction box of claim 7, wherein a second set of high-voltage wires extends through the second opening and is in electrical communication with the high-voltage terminals.

9. The electrical junction box of claim 2, wherein the base portion further comprises one or more stand-offs extending from the lower top surface to a height level with the upper top surface.

10. The electrical junction box of claim 9, wherein the transformer includes a plurality of mounting tabs, two of the plurality of mounting tabs attached to the stand-offs and two of the plurality of mounting tabs attached to the upper top surface of the base portion.

11. The electrical junction box of claim 1, further comprising a gasket configured to provide a watertight seal between the cover and the base plate.

12. The electrical junction box of claim 1, wherein the transformer comprises an isolation step-down transformer for providing low-voltage electrical power to an underwater pool or spa light.

13. The electrical junction box of claim 1, further comprising an electronic circuit board for controlling a device external to the junction box, the electronic circuit board positioned within the cover.

14. The electrical junction box of claim 1, further comprising a communications coupler positioned within the cover and in electrical communication with said high-voltage terminals and said low-voltage terminals, said communications coupler transmitting a power line carrier signal from said high voltage terminals to said low voltage terminals for a remote control device exterior to the junction box.

15. The electrical junction box of claim 14, wherein said communications coupler is positioned within said high-voltage section of said junction box.