Electrical box with fitting flanges, and method of use

• US 8,598,454 B2
• Filed: 12/15/2011
• Issued: 12/03/2013
• Est. Priority Date: 12/15/2011
• Status: Active Grant

• Current Assignee: ERICO International Corporation (nVent Electric Plc)
• Original Assignee: ERICO International Corporation (nVent Electric Plc)
• Inventors: Laughlin, Raymond S.
• Primary Examiner(s): Estrada, Angel R
• Application Number:
  US13/326,639
• Publication Number:
  US 20130153256A1
• Time in Patent Office: 719 Days
• Field of Search: 174/480, 174/481, 174/50, 174/53, 174/57, 174/58, 174/61, 174/63, 220 32- 39, 220/4.02, 248/906, 248/200, 248/205.1, 248/230.9, 248/231.9
• US Class Current: 174/58
• CPC Class Codes: H02G 3/081 Bases, casings or covers
• CPC Class Codes: H02G 3/18 providing line outlets
• CPC Class Codes: Y10T 29/49778 with aligning, guiding, or instruction

Abstract

An electrical box has four sides that define a rectangular space. The box has flanges extending outward from opposite sides, for mounting the box to a stud or other structure. One of the flanges has one or more tabs, outward protrusion(s) that fit into one or more openings in the flange on the opposite side. The fitting of the one or more tabs into the one or more openings allows two such electrical boxes to be conveniently located at the same height, on opposite sides of the stud. The tab(s) and opening(s) automatically align the boxes with each other. The result is an easier and accurate installation, with less time and effort expended.

Claims

1. An electrical box comprising:

four sides defining a substantially rectangular volume, wherein the sides include a first side, a second side, a third side, and a fourth side;

a planar first flange extending outward from the first side; and

a planar second flange extending outward from the second side;

wherein the first flange has one or more tabs that correspond in shape to one or more openings in the second flange, enabling fitting of one of the flanges with a flange of another identical electrical box with which the electrical box is aligned.

2. The electrical box of claim 1,

wherein the first side and the second side are opposite one another;

and

wherein the third side and the fourth side are opposite one another.

3. The electrical box of claim 2, wherein the one or more tabs are symmetric about a plane passing through centerlines of the first side and the second side.

4. The electrical box of claim 1, wherein the one or more tabs include a pair of separate tabs.

5. The electrical box of claim 1, wherein the one or more tabs have a pair of holes configured to receive fasteners for coupling the electrical box to a stud.

6. The electrical box of claim 5, wherein the second flange has a pair of holes, on opposite sides of the opening, configured to receive fasteners for coupling the electrical box to a stud or other structure.

7. The electrical box of claim 1, wherein the first side is a split side that includes parts that overlap and are secured together there the parts overlap.

8. The electrical box of claim 7, wherein the one or more tabs include a pair of separate tabs that are portions of respective of the parts of the first side.

9. The electrical box of claim 1, further comprising mounting tabs extending from the third side and the fourth side into the substantially rectangular volume.

10. The electrical box of claim 1, wherein the one or more tabs together have a trapezoidal shape.

11. The electrical box of claim 10,

wherein the one or more openings is a trapezoidal opening;

and

wherein the trapezoidal shape of the one or more tabs has a distal edge that is shorter than a proximal length of the trapezoidal shape.

12. The electrical box of claim 1, further comprising:

a third flange extending outward from the third side; and

a fourth flange extending outward from the fourth side; and

wherein the third flange and the fourth flange each have a width that is less than a width of the first flange and the second flange.

13. The electrical box of claim 12, wherein a combined width of the third flange and the fourth flange is substantially the same as a combined width of the first flange and the second flange, when a width of the tab one or more tabs is excluded from the combined width of the first flange and the second flange.

14. The electrical box of claim 1, wherein the electrical box is a backless electrical box.

15. The electrical box of claim 1, wherein the electrical box is made of a single continuous piece of material.

16. The electrical box of claim 15, wherein the piece of material is steel.

17. An electrical box comprising:

four sides defining a substantially rectangular volume, wherein the sides include a first side, a second side, a third side, and a fourth side;

a first flange extending outward from the first side;

a second flange extending outward from the second side; and

mounting tabs extending from the third side and the fourth side into the substantially rectangular volume;

wherein the first flange has one or more tabs that correspond in shape to one or more openings in the second flange; and

wherein the mounting tabs include;

a first pair of mounting tabs for mounting and securing a mud ring to the electrical box; and

a second pair of mounting tabs for mounting and securing a back plate to the electrical box.

18. The electrical box of claim 17, further comprising a grounding tab bent inward from one of the sides.

19. A method of coupling a first electrical box and a second electrical box to a stud, the method comprising:

attaching the first electrical box to the stud;

aligning the second electrical box and the first electrical box, wherein the aligning includes fitting one or more tabs in a planar flange of one of the boxes, with a correspondingly-shaped one or more openings in a planar flange of the other of the electrical boxes; and

after the aligning, attaching the second electrical box to the stud.

20. The method of claim 19,

wherein the one or more tabs are trapezoidal;

wherein the one or more openings are trapezoidal; and

wherein the aligning includes fitting the one or more trapezoidal tabs with the one or more trapezoidal openings.