Electrical box for use with insulated concrete form building systems

• US 7,082,728 B1
• Filed: 06/13/2003
• Issued: 08/01/2006
• Est. Priority Date: 05/20/2002
• Status: Expired due to Fees

• Current Assignee: Plastilock Corporation
• Original Assignee: Plantilock Corporation
• Inventors: Hebig, Brad J., McConaughy, Drew B.
• Primary Examiner(s): Friedman, Carl D.
• Assistant Examiner(s): Manaf, Abdul
• Application Number:
  US10/461,752
• Time in Patent Office: 1,145 Days
• Field of Search: 522/201, 524/21, 524/15, 525/65, 174/50, 174/58, 174/48, 174/49, 264/259, 264/263, 264/271.1, 264/272.11, 264/273.12, 264/272.14, 264/272.15, 264/274
• US Class Current: 52/220.1
• CPC Class Codes: H02G 3/121 in plain walls

Abstract

An electrical box for use with insulated concrete form building systems includes a main body having an electrical box cavity for housing electrical outlets, switches, and electrical connections. The insulated concrete form building systems utilize insulated forms to form concrete and the insulated forms are left in place after the concrete has been poured thereby creating an overall insulated concrete element that includes the concrete and the insulated forms. In accordance with the method and the arrangement of the invention, the electrical box includes an arrangement for attaching the electrical box to the insulated form without requiring the use of any additional fasteners.

Claims

1. A method of installing an electrical box in insulated concrete form building systems that utilize insulated forms to form concrete elements, the insulated forms being left in place after the concrete has been poured thereby creating an overall insulated concrete element that includes the concrete and the insulated forms, the insulated form including foam insulation having a front and a back surface, the method comprising the steps of:

providing an electrical box having a main body that defines an electrical box cavity for housing electrical outlets, switches, and electrical connections, the electrical box including an attaching arrangement for attaching the electrical box to the insulated form, the attaching arrangement of the electrical box including opposing mounting flanges for gripping the foam insulation of the insulated forms,

before pouring concrete into the insulated concrete form, forming an opening into an edge of the foam insulation, and

before pouring concrete into the insulated concrete form, attaching the electrical box to the foam insulation of the insulated form without requiring the use of any additional fasteners to attach the electrical box to the insulated form by slipping the electrical box into the opening in the foam insulation such that the opposing mounting flanges grip the front and the back surfaces of the foam insulation and hold the electrical box within the opening formed into the edge of the foam insulation of the insulated form.

2. A method according to claim 1 wherein

the main body of the electric box includes at least one sidewalk and a back wall that together define the electrical box cavity for housing electrical connections,

the foam insulation of the insulated form defines an external planar surface of the insulated form, and

the attaching arrangement is configured such that, when the electrical box is attached to the foam insulation of the insulated form, the sidewall of the electrical box protrudes beyond the external planar surface of the insulated form by a predetermined distance.

3. A method according to claim 1 wherein the opposing mounting flanges are integrally formed as part of the electrical box.

4. A method according to claim 1 wherein the opposing mounting flanges are provided as at least one separate flange element configured to attach to the electrical box.

5. A method according to claim 1 wherein the foam insulation of the insulated form has a predetermined foam thickness and wherein the opposing mounting flanges of the attaching arrangement include at least one pair of opposing flanges that are spaced apart by a distance substantially equal to the thickness of the foam insulation.

6. A method according to claim 1 wherein the foam insulation of the insulated form has a predetermined foam thickness and wherein the opposing mounting flanges of the attaching arrangement include at least one pair of opposing flanges that are spaced apart by a distance greater than the thickness of the foam insulation, the attaching arrangement including a spacer configured to attach to one of the mounting flanges of the pair of opposing mounting flanges to reduce the spacing between the pair of opposing mounting flanges such that the resulting spacing between the spacer and the opposing mounting flange of the pair of opposing mounting flanges is substantially equal to the thickness of the foam insulation.

7. A method according to claim 1 wherein the electrical box is installed in the insulated form before the concrete is poured and wherein the main body of the electric box includes at least one sidewall and a back wall that together define the electrical box cavity for housing electrical connections, the back wall of the electrical box including a substantially clear window portion configured to prevent concrete from entering the electrical box cavity while concrete is being poured and to allow the viewing of the interior of the insulated form around the back wall of the electrical box while concrete is being poured thereby allowing a viewer to confirm that air pockets do not form in the concrete in the area around the back wall of the electrical box while concrete is being poured into the insulated forms.

8. A method according to claim 1 wherein

the electrical box is installed in the insulated form before the concrete is poured,

the electrical box is a molded plastic box and the main body of the electric box includes at least one sidewall and a back wall that together define the electrical box cavity for housing electrical connections, the back wall of the electrical box including at least one conduit socket extending outward from the back wall of the electrical box, the conduit socket being integrally formed as part of the electrical box and the conduit socket providing a port to allow for the entrance and exit of electrical conductors, the conduit socket being configured to mate with standard plastic electrical conduit, and

the method includes the step of installing electrical conduit to the electrical box within the insulated form before the concrete is poured, and thereafter, pouring the concrete and encapsulating the electrical conduit in the concrete.

9. A method according to claim 8 wherein the conduit socket is a substantially tubular shaped structure having an inside diameter and an outside diameter, the inside diameter of the conduit socket being a diameter that allows for the insertion and conventional attachment of standard ½

inch plastic electrical conduit within the conduit socket and the outside diameter of the conduit socket being a diameter that allows for the insertion and conventional attachment of standard ¾

inch plastic electrical conduit around the outside of the conduit socket.

10. A method according to claim 8 wherein the electrical box includes two conduit sockets extending outward from the back wall of the electrical box, the two conduit sockets being offset relative to one another both vertically and horizontally on the back wall of the electrical box.

11. A method according to claim 1 wherein the electrical box is a multiple gang electrical box including a main body having an electrical box cavity for housing multiple electrical connections.