Folding electrical outlet box

• US 6,170,685 B1
• Filed: 04/14/2000
• Issued: 01/09/2001
• Est. Priority Date: 04/16/1999
• Status: Expired due to Fees

• Current Assignee: Forrest R. Currier
• Original Assignee: Forrest R. Currier
• Inventors: Currier, Forrest R.
• Primary Examiner(s): Pollard, Steven
• Application Number:
  US09/548,801
• Time in Patent Office: 270 Days
• Field of Search: 220/3.2, 220/3.4, 220/3.5, 220/3.6, 220/3.3, 220/6
• US Class Current: 220/3.3
• CPC Class Codes: H02G 3/086 Assembled boxes
• CPC Class Codes: H02G 3/121 in plain walls

Abstract

A foldable, electrical box kit for on-site assembly and installation in wallboard, with at least two opposing panels each having a pair of spaced apart front face flanges and respective, laterally centered on the panel, center-bored, retaining screw and rotating retainer clip assemblies. The unfolded box is configured with living hinge lines to permit easy folding and snap assembly of adjacent sidewall edges to form a rigid enclosure. Retainer clips are retracted by their retaining screws into clip slots in the panels for clearance. The box is inserted through wallboard as far as the front face flanges permit, then the retaining screws are rotated, the first quarter turn of which rotates their respective retaining clips from the retracted position to an extended position behind the wallboard. Further clockwise rotation of each screw brings its retaining clip forward into a firm, three point grip with its respective pair of flanges on the wallboard. Retaining screws are center-bored and threaded, and spaced to accept attaching screws for standard size devices being installed in the box, thereby providing both structure support and a convenient point for electrical ground bonding.

Claims

1. A foldable electrical enclosure for mounting in wallboard, comprising

a back panel hingedly edge connected to at least two pairs of opposing side panels, said side panels foldable to be at right angles to said back panel and having integral means for connecting adjacent panel edges so as to form a rigid, open face enclosure, said enclosure having at least one cable port through which electrical wires may be inserted,

each said panel of at least one pair of said opposing side panels configured with a pair of spaced apart front face outwardly projecting mounting flanges and a laterally centered and recessed tunnel structure supporting a retaining screw, the head of said retaining screw exposed for rotational manipulation with a screw driver, each said retaining screw having a retainer clip threaded thereon, said retainer clip being rotable from a retracted position to an extended centerline position by initial clockwise rotation of said retaining screw and being movable foreward towards said flanges by further clockwise rotation of said retaining screw, each said retaining screw being center bored and threaded for accepting mounting screws of devices normally installed in such enclosures.

2. A foldable electrical enclosure for mounting in wallboard according to claim 1, said at least two pairs of opposing side panels comprising two opposing side panels and a top and opposing bottom panel.

3. A foldable electrical enclosure for mounting in wallboard according to claim 2, said top and said bottom panel each configured with a said pair of spaced apart front face outwardly projecting mounting flanges and a said laterally centered and recessed tunnel structure supporting a retaining screw.

4. A foldable electrical enclosure for mounting in wallboard according to claim 3, said retaining clip comprising a nut, a mast, and a face plate, said face plate being parallel to said mounting flanges.

5. A foldable electrical enclosure for mounting in wallboard according to claim 4, said integral means for connecting adjacent panel edges comprising a keyed edge and locking channel system, a first panel of two adjacent panels configured with a said keyed edge, a second of said two adjacent panels configured with a said locking channel.

6. A foldable electrical enclosure for mounting in wallboard according to claim 5, said keyed edge comprising five uniformly spaced rectangular keyholes immediately adjacent to a straight panel edge, said locking channel comprising an open receiving channel structure within which on one wall are configured five uniformly spaced tapered locking lugs, the taper of which ramps upwards going into said channel, said lugs sized for interlocking fit with said keyholes of said keyed edge, said locking channel being sufficiently elastic for being forced open without damage by inserting said keyed edge into said channel until said lugs interlock with said keyholes and then closing thereon.

7. A foldable electrical enclosure for mounting in wallboard according to claim 5, said back panel hingedly edge connected to said side panels and said top and bottom panels by living hinge lines, said hinge lines comprising a V notch on the interior side of said panels, each said hinge line connecting said back panel to a said side panel reinforced with a first raised bead on the interior side of said back panel immediately adjacent and parallel to respective said V notch, and a second raised bead on the interior side of said side panel parallel to and spaced about one bead width from said V notch, the height and width of a said raised bead each being about the wall thickness of a said panel whereupon when said side panels are folded to right angles with said back panel said beads interlock without interference with folding.

8. A foldable electrical enclosure for mounting in wallboard according to claim 5, said at least one cable port comprising H pattern cutouts in said top panel and said bottom panel, said panels being sufficiently elastic for limited deforming without damage by insertion of wires through said cutouts.

9. A foldable electrical enclosure for mounting in wallboard according to claim 5, the spacing of said retaining screws conforming to standard mounting dimensions of said devices normally installed in such enclosures.

10. A foldable non-conductive electrical enclosure for mounting in wallboard comprising

a one piece molded plastic foldable open face enclosure consisting of a rectangular back panel hingedly connected by living hinge lines to left and right side panels and to top and bottom panels, said panels foldable to right angles with said back panel so as to form said open face enclosure, said panels configured with means for connecting adjacent panel edges, the front edge of said top and bottom panels each configured with two outwardly directed spaced apart mounting flanges, said top and bottom panels each configured with a laterally centered, recessed tunnel structure oriented perpendicular to and flush with said front edge of said panels and open to the exterior side of said panel, said top and bottom panels incorporating H pattern cable ports for inserting electrical cables,

a stationary retaining screw rotatingly installed within each said tunnel structure, the head of each said screw being accessible for rotational manipulation by a screwdriver, said retaining screws being center-bored and tapped for accepting smaller mounting screws, the spacing of said retaining screws conforming to standard mounting dimensions of devices normally installed in such enclosures, and

a retaining clip associated with each retaining screw, said clip comprising a nut, a mast, and a faceplate, said nut being threaded onto respective said retaining screw, said mast extending from said nut external of said enclosure and perpendicular to said retaining screw, said faceplate attached to said mast and oriented parallel to respective said mounting flanges, said retaining clip being rotable about one quarter turn between a retracted position against exterior surface of said panel and an extended centerline position by initial clockwise rotation of said retaining screw, said retaining clip being then movable forward towards said front edge by further clockwise rotation of said retaining screw.

11. A foldable non-conductive electrical enclosure for mounting in wallboard according to claim 10, said integral means for connecting adjacent panel edges comprising a keyed edge and locking system, a first panel of two adjacent panels configured with a said keyed edge, a second of said two adjacent panels configured with a said locking channel, said keyed edge comprising five uniformly spaced rectangular keyholes immediately adjacent to a straight panel edge, said locking channel comprising an open receiving channel structure within which on one wall are configured five uniformly spaced tapered locking lugs, the taper of which ramps upwards going into said channel, said lugs sized for interlocking fit with said keyholes of said keyed edge, said locking channel being sufficiently elastic for being forced open without damage by inserting said keyed edge into said channel until said lugs interlock with said keyholes and then closing thereon.

12. A foldable non-conductive electrical enclosure for mounting in wallboard according to claim 10, said living hinge lines comprising a V notch on the interior side of said panels, each said hinge line connecting said back panel to a said side panel reinforced with a first raised bead on the interior side of said back panel immediately adjacent and parallel to respective said V notch, and a second raised bead on the interior side of said side panel parallel to and spaced about one bead width from said V notch, the height and width of a said raised bead each being about the wall thickness of a said panel whereupon when said side panels are folded to right angles with said back panel said beads interlock without interference with folding.

17. A foldable non-conductive electrical enclosure for mounting in wallboard according to claim 10, said retaining screw being conductive for electrical bonding.

13. A foldable non-conductive electrical semi-enclosure for mounting in wallboard comprising

a one piece molded plastic foldable open face and single open side enclosure consisting of a rectangular back panel hingedly connected by living hinge lines to one side panel and to top and bottom panels, said panels foldable to right angles with said back panel so as to form said open face and single open side enclosure, said panels configured with means for connecting adjacent panel edges, the front edge of said top and bottom panels each configured with two outwardly directed spaced apart mounting flanges, said top and bottom panels each configured with a laterally centered, recessed tunnel structure oriented perpendicular to and flush with said front edge of said panels and open to the exterior side of said panel, said top and bottom panels incorporating H pattern cable ports for inserting electrical cables, panel edges adjacent said open side being configured with means for edge connecting to a second said one piece molded plastic foldable open face and single open side enclosure so as to form a double width enclosure,

a stationary retaining screw rotatingly installed within each said tunnel structure, the head of each said screw being accessible for rotational manipulation by a screwdriver, said retaining screws being center-bored and tapped for accepting smaller mounting screws, the spacing of said retaining screws conforming to standard mounting dimensions of devices normally installed in such enclosures, and

a retaining clip associated with each retaining screw, said clip comprising a nut, a mast, and a faceplate, said nut being threaded onto respective said retaining screw, said mast extending from said nut external of said enclosure and perpendicular to said retaining screw, said faceplate attached to said mast and oriented parallel to respective said mounting flanges, said retaining clip being rotable about one quarter turn between a retracted position against exterior surface of said panel and an extended centerline position by initial clockwise rotation of said retaining screw, said retaining clip being then movable forward towards said front edge by further clockwise rotation of said retaining screw.

14. A foldable non-conductive semi-enclosure for mounting in wallboard according to claim 13, said integral means for connecting adjacent panel edges comprising a keyed edge and locking channel system, a first panel of two adjacent panels configured with a said keyed edge, a second of said two adjacent panels configured with a said locking channel, said keyed edge comprising five uniformly spaced rectangular keyholes immediately adjacent to a straight panel edge, said locking channel comprising an open receiving channel structure within which on one wall are configured five uniformly spaced tapered locking lugs, the taper of which ramps upwards going into said channel, said lugs sized for interlocking fit with said keyholes of said keyed edge, said locking channel being sufficiently elastic for being forced open without damage by inserting said keyed edge into said channel until said lugs interlock with said keyholes and then closing thereon.

15. A foldable non-conductive semi-enclosure for mounting in wallboard according to claim 14, said means for edge connecting to a second said one piece molded plastic foldable open face and single open side enclosure so as to form a double width enclosure comprising a bipolar keyed edge and locking channel system, a first half of the full length of the open face edge of said semi-enclosure configured with a said keyed edge, a second half of said length of said open face edge with a said locking channel, said keyed edge comprising uniformly spaced rectangular keyholes immediately adjacent to a straight panel edge, said locking channel comprising an open receiving channel structure within which on one wall are configured uniformly spaced tapered locking lugs, the taper of which ramps upwards going into said channel, said lugs sized for interlocking fit with said keyholes of said keyed edge, said locking channel being sufficiently elastic for being forced open without damage by inserting said keyed edge into said channel until said lugs interlock with said keyholes and then closing thereon.

16. A foldable non-conductive electrical enclosure for mounting in wallboard according to claim 15, said living hinge lines comprising a V notch on the interior side of said panels, each said hinge line connecting said back panel to a said side panel reinforced with a first raised bead on the interior side of said back panel immediately adjacent and parallel to respective said V notch, and a second raised bead on the interior side of said side panel parallel to and spaced about one bead width from said V notch, the height and width of a said raised bead each being about the wall thickness of a said panel whereupon when said side panels are folded to right angles with said back panel said beads interlock without interference with folding.

18. A foldable non-conductive electrical enclosure for mounting in wallboard according to claim 13, said retaining screw being conductive for electrical bonding.

19. A foldable non-conductive electrical semi-enclosure for mounting in wallboard comprising

a one piece molded plastic foldable open face and open side enclosure consisting of a rectangular back panel hingedly connected by living hinge lines to top and bottom panels, said panels foldable to right angles with said back panel so as to form said open side enclosure, the front edge of said top and bottom panels each configured with two outwardly directed spaced apart mounting flanges, said top and bottom panels each configured with a laterally centered, recessed structure oriented perpendicular to and flush with said front edge of said panels and open to the exterior side of said panel, said top and bottom panels incorporating H pattern cable ports for inserting electrical cables, panel edges adjacent said open sides being configured with means for edge connecting to a similarly configured open side of other enclosures so as to form a multi-width enclosure,

a stationary retaining screw rotatingly installed within each said tunnel structure, the head of each said screw being accessible for rotational manipulation by a screwdriver, said retaining screws being center-bored and tapped for accepting smaller mounting screws, the spacing of said retaining screws conforming to standard mounting dimensions of devices normally installed in such enclosures, and

a retaining clip associated with each retaining screw, said clip comprising a nut, a mast, and a faceplate, said nut being threaded onto respective said retaining screw, said mast extending from said nut external of said enclosure and perpendicular to said retaining screw, said faceplate attached to said mast and oriented parallel to respective said mounting flanges, said retaining clip being rotable about one quarter turn between a retracted position against exterior surface of said panel and an extended centerline position by initial clockwise rotation of said retaining screw, said retaining clip being then movable forward towards said front edge by further clockwise rotation of said retaining screw.

20. A foldable non-conductive semi-enclosure for mounting in wallboard according to claim 19, said means for edge connecting comprising a bipolar keyed edge and locking channel system, a first half of the full length of the open face edges of said semi-enclosure configured with a said keyed edge, a second half of said length of said open face edge configured with a said locking channel, said keyed edge comprising uniformly spaced rectangular keyholes immediately adjacent to a straight panel edge, said locking channel comprising an open receiving channel structure within which on one wall are configured uniformly spaced tapered locking lugs, the taper of which ramps upwards going into said channel, said lugs sized for interlocking fit with said keyholes of said keyed edge, said locking channel being sufficiently elastic for being forced open without damage by inserting said keyed edge into said channel until said lugs interlock with said keyholes and then closing thereon.