Method and apparatus for pre-fab wiring

• US 8,168,887 B2
• Filed: 08/27/2008
• Issued: 05/01/2012
• Est. Priority Date: 09/27/2007
• Status: Active Grant

• Current Assignee: ERICO International Corporation (nVent Electric Plc)
• Original Assignee: Bruce G. Phillips
• Inventors: Phillips, Bruce G.
• Primary Examiner(s): Estrada, Angel R
• Application Number:
  US12/199,648
• Publication Number:
  US 20090084571A1
• Time in Patent Office: 1,343 Days
• Field of Search: 174/480, 174/481, 174/50, 174/53, 174/57, 174/58, 174/59, 174/66, 174/67, 174/112, 174/54, 220 32- 39, 220/4.02, 220/241, 220/242, 297/29, 297/45, 295/921, 295/92, 248/906
• US Class Current: 174/50
• CPC Class Codes: H02G 3/126 with supporting means for mounting on a single wall stud
• CPC Class Codes: Y10S 248/906 Electrical outlet box support
• CPC Class Codes: Y10T 29/5313 Means to assemble electrical device
• CPC Class Codes: Y10T 29/532 Conductor

Abstract

A bracket and junction box assembly and method allows simplified wiring at a prefab production facility and at a construction site. A junction box including a detachable and reattachable rear cover plate is pre-assembled with a plaster ring, electrical device, and leads attached to the switch or outlet, at a prefab facility. A Metal Clad (MC) cable may be attached to the junction box and wires carried in the MC Cable may be connected to the leads. A mounting bracket is generally sandwiched between the junction box and the plaster ring for mounting to framing members at the construction site. Following assembly at the prefab facility, the prefab junction box is shipped to the construction site where the bracket and junction box assembly is mounted to framing members. Connections to wires carried by MC Cables are then facilitated by removing the rear cover plate to access the interior of the junction box.

Claims

1. A prefab bracket and open back junction box assembly comprising:

an open back junction box having an open front for mounting an electrical device and plaster ring, and an open back comprising a single opening about the same size as the open front and opposite the open front for accepting a detachable rear cover plate;

a plaster ring attached to the open back junction box;

a mounting bracket sandwiched between the plaster ring and the junction box;

an electrical device attached to the plaster ring;

a protective cover over a face of the electrical device;

first ends of electrical leads attached to the electrical device;

labels proximal to a second end of each electrical lead identifying each lead;

wire nuts residing over free ends of each electrical lead; and

a detachable rear cover plate attached to the back of the open back junction box over the open back while leaving the second ends of the leads inside the junction box and unattached.

2. The prefab bracket and open back junction box assembly of claim 1, further including an electrical conduit attached to the open back junction box and carrying wires extending into the open back junction box, the wires attached to the electrical leads.

3. The assembly of claim 1, further including a first end of a grounding pigtail connected to the junction box and a first end of a grounding wire connected to the electrical device.

4. The assembly of claim 3, wherein the second ends of the grounding pigtail and grounding wire reside inside the junction box and unattached.

5. A method for prefab wiring comprising the steps of:

constructing a junction box assembly at a prefab production facility using an open back junction box having an open front for mounting an electrical device and plaster ring, and an open back opposite the open front for receiving a detachably attachable rear cover plate, constructing the junction box assembly comprising;

attaching an electrical device to a plaster ring; and

attaching the electrical device and plaster ring to the open back junction box;

shipping the junction box assembly to a construction site; and

installing the junction box assembly at a work site without disassembling the junction box, electrical device and mud ring, including the steps of;

mounting the junction box assembly to a framing member;

connecting a site electrical conduit to the open back junction box working through the open back of the open back junction box;

connecting site wires carried in the electrical conduit to the electrical device attached to the junction box working through the open back of the box; and

attaching the rear cover plate to the back of the open back junction box.

6. The method of claim 5, wherein attaching the electrical device and plaster ring to the open back junction box includes sandwiching a bracket between the electrical device and plaster ring and the open back junction box.

7. The method of claim 5, wherein constructing and installing the junction box assembly includes:

connecting first ends of leads to the electrical device at the prefab production facility leaving second ends of the leads opposite the first ends unterminated;

not detaching the leads from the electrical device at the work site; and

connecting the site wires to the second ends of the leads through the open back of the open back junction box.

8. The method of claim 5, wherein constructing the junction box assembly includes attaching a protective cover over a face of the electrical device.

9. The method of claim 5, wherein constructing the junction box assembly includes:

attaching a prefab electrical conduit to the open back box at the prefab production facility; and

not detaching the electrical conduit from the open back junction box at the work site.

10. The method of claim 9, wherein constructing the junction box assembly includes:

connecting first ends of leads to the electrical device at the prefab production facility leaving second ends of the leads opposite the first ends unterminated;

connecting prefab wires carried by the prefab electrical conduit to the leads at the prefab production facility; and

not detaching the leads from the electrical device at the work site.

11. The method of claim 10, wherein the electric conduit is selected from Metal Clad (MC) Cable and Electrical Metal Tubing (EMT).

12. The method of claim 5, wherein installing the junction box assembly at a work site further includes installing a fire putty pad through the open back of the open back junction box.

13. The method of claim 5, wherein attaching the rear cover plate to the back of the open back junction box comprises attaching the rear cover plate having a fire putty pad attached, to the back of the open back junction box.

14. The method of claim 7, wherein constructing the junction box assembly includes:

attaching labels to the leads proximal to the second ends of the leads to identify the leads.

15. The method of claim 5, wherein the open back is about the same size opening as the open front.

16. The assembly of claim 5, wherein the completed installation of the junction box assembly performed at the work site is performed without making electrical connections working through the open front of the junction box.

17. A method for constructing an open back prefab junction box assembly comprising the steps of:

constructing a junction box assembly at a prefab production facility using an open back junction box having an open front for mounting an electrical device and plaster ring, and an open back comprising a single opening about the same size as the open front and opposite the open front for accepting a detachably attachable rear cover plate, the constructing the junction box assembly comprising;

connecting first ends of leads to an electrical device;

attaching labels proximal to second ends opposite the first ends of the leads;

attaching the electrical device to a plaster ring;

attaching a protective cover over a face of the electrical device;

attaching the electrical device and plaster ring to the open front of the open back junction box; and

attaching the rear cover plate to the open back of the open back junction box while leaving the second ends of the leads inside the junction box and unattached.

18. The method of claim 17, wherein:

attaching the electrical device and plaster ring to the open front of the open back junction box comprises;

attaching the electrical device and plaster ring to the open front of the open back junction box comprises with a mounting bracket sandwiched between the plaster ring and the open back junction box.

19. The method of claim 17, further including connecting a grounding pigtail to the junction box and a grounding wire to the electrical device before attaching the electrical device and plaster ring to the open front of the open back junction box.

20. The method of claim 19, further including connecting attaching the rear cover plate to the open back of the open back junction box while leaving the grounding pigtail and the grounding wire inside the junction box.