Surface mount electrical box for shallow wall cavities

• US 8,686,287 B1
• Filed: 01/06/2011
• Issued: 04/01/2014
• Est. Priority Date: 01/06/2011
• Status: Active Grant

• Current Assignee: Arlington Industries Incorporated
• Original Assignee: Arlington Industries Incorporated
• Inventors: Gretz, Thomas J.
• Primary Examiner(s): Norris, Jeremy C
• Assistant Examiner(s): MILAKOVICH, NATHAN J
• Application Number:
  US12/930,399
• Time in Patent Office: 1,181 Days
• Field of Search: 174/50, 174/58, 174/502, 248/906, 439/535, 220/4.02
• US Class Current: 174/58
• CPC Class Codes: H01H 9/02 Bases, casings, or covers accommodating more than one switch or a switch and another electrical component H02B1/26
• CPC Class Codes: H02G 3/123 in thin walls

Abstract

A surface mount electrical box for mounting on walls with shallow wall cavities. The surface mount electrical box includes an outer frame with shallow sidewalls and a peripheral wall extending orthogonally from the sidewalls. Box sidewalls extend orthogonally from the peripheral wall and are closed by a back wall to form an electrical enclosure therein. Component connection points for an electrical component are included on the outer frame. A first fastening arrangement includes bosses on the outer frame for accepting fasteners therein for securing the surface mount box directly to the wall covering surrounding a shallow wall cavity. A second fastening arrangement includes apertures in the back wall for accepting fasteners therein for securing the surface mount box directly to the substrate underlying a shallow wall cavity.

Claims

1. A surface mount electrical box comprising:

an outer frame including sidewalls having a front face;

a peripheral wall extending orthogonally from said sidewalls to an inner periphery;

a box member including box sidewalls extending orthogonally from said inner periphery of said peripheral wall;

a back wall closing said box sidewalls and defining an electrical enclosure therein;

a first fastening arrangement on said outer frame for securing said surface mount electrical box to a wall having a wall covering capable of supporting fasteners therein;

said first fastening arrangement including a plurality of frame bosses on said outer frame and a fastener corresponding with each of said frame bosses;

a second fastening arrangement on said box member for securing said surface mount electrical box to a wall with a wall covering having an underlying substrate capable of supporting fasteners therein;

,

said peripheral wall includes a first mounting surface;

mounting said surface mount electrical box to a wall with said first fastening arrangement includes inserting said box sidewalls through an opening in the wall until said first mounting surface is flush against the wall surface;

said surface mount box includes a shallow depth thereby enabling it to accommodate bulky electrical components in shallow wall cavities; and

said depth of said surface mount electrical box is at most 2.06 inches.

2. The surface mount electrical box of claim 1 wherein said second fastening arrangement includes

a plurality of apertures in said back wall of said box member;

and

a fastener corresponding with each of said apertures.

3. The surface mount electrical box of claim 2 wherein

said back wall includes a second mounting surface;

and

mounting said surface mount electrical box to a wall with said second fastening arrangement includes placing said second mounting surface flush against the substrate.

4. The surface mount electrical box of claim 1 including

a plurality of component bosses extending from said peripheral wall to said front face of said outer frame;

and

a component connection bore in each of said component bosses.

5. The surface mount electrical box of claim 4 including a groove in each of said component bosses, said groove outward of said component bores and inward of said sidewall of said outer frame.

6. The surface mount electrical box of claim 2 including a protective wall extending from said back wall into said electrical enclosure, said protective wall surrounding each of said apertures and minimizing potential grounding from conductors within said electrical enclosure.

7. The surface mount electrical box of claim 1 including

a recessed area in said box sidewalls;

and

a removable wall portion said recessed area, said removable wall portion enabling the receipt an electrical fitting in said recessed area of said box sidewalls.

8. The surface mount electrical box of claim 1 wherein each of said frame bosses includes a bore therein, an outer end, and a countersunk entry at said outer end, whereby said countersunk entry enables the head of a countersunk screw to be recessed therein.

9. The surface mount electrical box of claim 1 wherein said outer frame includes four of said sidewalls and four corners at the juncture of said sidewalls.

10. The surface mount electrical box of claim 9 wherein each of said frame bosses is located at one of said corners.

11. The surface mount electrical box of claim 4 including

a plurality of channels formed in said box sidewalls and in said peripheral wall;

and

said channels are aligned behind said component bosses.

12. The surface mount electrical box of claim 1 wherein said outer frame is substantially shallow and includes a depth of no greater than 0.81 inch.

13. The surface mount electrical box of claim 1 wherein said box sidewalls are substantially shallow and includes a depth of no greater than 1.25 inches.

14. The surface mount electrical box of claim 1 wherein said electrical enclosure is substantially shallow and has an inside depth as measured from said front face to said back wall of at most 2.0 inches.

15. The surface mount electrical box of claim 1 wherein said electrical enclosure includes an internal volume of at least 20 cubic inches.

16. The surface mount electrical box of claim 1 wherein said surface mount electrical box is molded in one piece of plastic.

17. The surface mount electrical box of claim 16 wherein plastic is selected from the group including polycarbonate and polyvinylchloride.