Note: Descriptions are shown in the official language in which they were submitted.
78
S P E C I F I C A T I Q N
This invention relates to a cover for an electrical
box which prevents cold air from entering and heated air from
escaping therethrough and therearound and also prevents water
and moisture from entering.
At the present, electrical boxes are simply installed
in an opening in a wall or ceiling with the box nailed to a
stud or with various fastening flanges or hangers employed. In
such instances, cold air, particularly under windy conditions,
can enter the building through the various openings in the
electrical box, and, frequently, around the box through the
opening in the wall or ceiling. Similarly, heated air can es-
cape in the opposite direction. In addition, water or moisture
can enter the box from the outside and cause short circuits,
resulting in fires or electricutions.
The present invention provides a cover for an
electrical box which extends completely around the side walls
and back of the box and has a flange slanting away from the
cover so that the peripheral edge of the flange can ti~htly
contact the back sur~ace of the wall or ceiling in which the
box is mounted. In this manner, air and water or moisture
are prevented from entering through the box itself and also
through the opening in the wall or ceiling in which the box
is mounted. Similarly, heated air is prevented from escaping.
In one form of the invention, the cover is molded
directly on the electrical box and has a curved portion ex-
tending away from the box near the open face of the box. The
slanted flange is then connected to the curved portion which
enables the flange to be moved toward and away from the Gpen
face of the box. Thus, for example, when paneling is ~sed,
the open face of the box can extend a short distance beyond the
flange, such as one-quarter inch. When plaster board or wall
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board is employed, the open face of the box can extend farther beyond the
flange, such as one-half inch. For plastered walls, the open face can
extend even farther beyond the flange, such as three-quarters inch.
In another form, the cover can be specially shaped to fit an
electrical box having a functionally-integral fastening flange extending
rearwardly from one side thereof. The cover has a hollow projection which
receives the fastening flange and enables this flange to extend into the
projection varying distances to vary the extent to which the open face
of the box extends beyond the slanted flange of the cover.
In still another form, the cover can be designedto receive a
multiplicity of electrical boxes, such as switch boxes. In such an instance,
the cover can be equipped with pro~ections to back up the electrical boxes
and control the extent to which the open faces extend beyond the slanted
flange, which is common to all of the covers.
It is, therefore, a purpose of the invention to provide an
improved air and moisture cover for electrical boxes to prevent the passage
of air and moisture through and around the box.
Another purpose of the invention is to provide a cover for an
electrical box with means to adjuAt the open face of the box relative to
a slanted flange of the cover.
This invention relates to a vapor barrier device for use in
association with open faced metal electrical boxes and the like, said
vapor barrier device comprising flexible flange means to extend around the
perimeter of said electrical box near the open face of said box; said flange
means further positioned to slant outwardly and away from said box whereby
the peripheral edge of the flange can tightly contact the back surface of
a wall or the like when said wall is urged against said flange means thus
forming a vapor barrier; and spacing means whereby the relative distance
between the open face of said electrical box and said flange, after said
wall has been urged against said flange means, can be varied.
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This invention further relates to a vapor barrier device as
aforesaid wherein said device comprises a cover of flexible plastic material
having a receptacle portion to extend around and enclose the back and at
least a part of the sides of said electrical box, said cover further
incorporating said flange means around the perimeter of the open side of said
receptacle portion, said spacing means comprising curved portions of said :
cover extending around the perimeter of said cover connecting said flange
means to said cover, whereby said curved portions can collapse in a bellows-
like fashion when said wall is urged against said flange means.
Many other objects and advantages of the invention will be
apparent from the following detailed description of preferred embodiments ;
thereof, references being made to the accompanying drawings, in which:
Figure 1, is a view in perspective, with parts broken away, of
an electrical outlet box with a cover embodying the invention extending
therearound, with the combination molded together and fastened to a stud;
Figure 2, is a view in vertical cross section taken
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378
through the box and cover of Figure 1;
Figure 3, is a fragmentary view of the box and cover
in a completed installation;
Figure 4, is a view similar to Figure 3 but showing
the box and cover installed in a thinner wall;
Figure 5, is an exploded view in perspective of
another embodiment o~ an electrical box with a fastening flange
and a cover designed to fit over that box;
Figure 6, is a somewhat schematic view in cross section
of the electrical box and cover of Figure 5 installed in a
thin ceiling.
Figure 7, is an exploded view in perspective of an
electrical box cover and straps designed for two or more boxes,
with parts broken away and with parts in section;
Figure 8, is a fragmentary front view in elevation
of the cover of Figure 7 with electrical boxes installed therein;
Figure 9, is a fragmentary view in cross section
taken along the lie 9-9 of Figure 8; and
Figure 10, is a somewhat schematic view in elevation
similar to Figure 8 showing the cover used with electrical
boxes in a different position.
Referring to the drawings, and particularly to Figures
1-4, an electrical outlet box 10 is shown with a cover 12 and
affixed to a stud or other structural member 1~ by nails 16,
in this instance. The electrical box is of a substantially
conventional design, including ears 18 and holes 20 (Figure 3)
formed when knockout plugs are removed. Wire clamps 22 and
screws 24 hold wires 26 having insulation 28.
The cover 12 has a receptacle 30 molded directly on
30-~- the electrical box 10 and functionally integral therewith. The
receptacle 30 covers the entire back of the box along with
approximately two-thirds of the side walls. The cover also
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includes a slanted flange 32 which slants outwardly from the
electrical box 10 and tightly engages the back surface of a wall
or ceiling in which the electrical box is mounted. The slanted
flange 32 is connected to the receptacle 30 by a curved portion
5 or bellows 34. This curved portion enables the slanted flange
32 to be moved toward and away from the open side of the box 10
to vary the distance the open face extends beyond the flange.
Thus, in Figure 3, the cover 12 is shown with the open face of
the box 10 extending well beyond the flange 32, about three-
10 quarters of an inch. This is the position when the electricalbox is to be mounted in a plastered wall 36. In Figure 4, the
flange 32 is much closer to the open face of the electrical
box 10, being back only about one-quarter inch. This is the
position when the box is mounted in a thin panelled wall 38.
1~ In between, the open face of the box can project about one-
half inch, for plaster board or dry wall.
The cover 12 is of plastic material about 0.030 inch
to 0.050 inch thick, and preferably about 0.040 inch. However,
the curved portion 34 can be even thinner so that i~ part of
20 the curved portion 34 and the flange 32 are between the wall
and the stud 14, the amount of thich~ess is not objectionable.
Also , the plastic material is preferably transparent or
translucent so that an electrician can see the nail holes in
the electrical box 10 through the receptacle 30 of the cover 12.
25 The plastic material should also be flexible and substantially
uninflammable, or at least not readily prone to burn.
In installing the electrical box 10 with the cover 12
molded thereon, they are positioned with the open face of the
electrical box the desired distance beyond the front edge of
30 the stud 14. The nails 16 are then driven through the cover
and box and into the stud. Where the wires 26 are to enter
the box, the knockout plug was previously removed to leave
the opening 20 and the receptacle 30 is then pierced with a
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~ L~L~L9~8screwdriver or similar tool. The wires 26, preferably with the
insulation 28 thereon, are then pushed through the receptacle
aperture and through the opening 20 of the box 10. The nature
of the plastic material employed in the cover 12 is such that
5 the plastic of the receptacle 30 snugly fits around the
insulation 28 of the wires 26 to provide a substantially air
and moisture proof point of entry through the cover.
Referring to Figures 5 and 6, an octagonal electrical
box is indicated at 40 and includes a fastening flange 42
affixed thereto, extending rearwardly from an open face thereof,
and being provided with at least one nail hole 44.
An electrical box cover 46 is specially designed
to fit this type of electrical box. The cover has a receptacle
48 to receive the side walls and back of the box 40 and includes
15 a tapered, rearwardly-extending, hollow projection 50 which
is structurally integral with the receptacle. The cover 46
also includes a slanted flange 52 which slants outwardly from
the electrical box 40 and tightly engages the back surface of
a wall or ceiling 54 in which the electrical box is mounted.
The electrical box 40 is positioned in the cover 46
with the hollow projection 50 enabling the fastening ~lange 42
to extend therein a desired distance such that the open face
of the box can project a desired distance beyond the slanted
flange 52 so as to be adaptable for plastered walls, wall board
25 or dry wall, and panelling, as before. When properly adjusted,
a nail 56 can be driven through a wall of the projection 50, the
flange 42, and the other wall of the projection 50 into a joist
or other structural member 58.
The receptacle 48 can also be provided with a cy-
lindrical recess 60 as viewed from the back of the cover 46which projects toward the electrical box. As such, the cover
is readily adaptable for use with octagonal boxes to be used
with variable length bar hangers having studs, usually five-
eights inch in diameter, and wing nuts. The wall of the
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1978
recess 60 thereby tends to snugly contact the stud of the bar
hanger and more effectively act as a air and moisture barrier.
Referring to Figures 7-1o, a plurality of electrical
boxes, particularly switch boxes, indicated at 62 can be
adjacent or ganged together and used in a group of three, as
shown in Figure 8, or a pair as shown in Figure 10. The boxes
have outwardly extending ears 64 to receive switch plates or
A the like and flanges ~4 which can be adjusted toward and away
from the open faces of the electrical boxes 62. The boxes 62
also have the usual wire clamps 68 and screws 70, and knock
out plugs (not shown).
A vapor barrier cover for a plurality of the electrical
boxes 62 is indicated at 72. The cover 72 has a receptacle 74
extending around the backs and sides of the electrical boxes 62.
1~ The cover 72 also has a slanted flange 76 slanting outwardly
and away from the electrical boxes to tightly contact the back
surface of the wall or the like, as before. The receptacle 74
also has outwardly extending projections 78 with larger diameter
base portions 80 and smaller diameter tip portions 82 forming
20 shoulders 84 therebetween.
When the electrical boxes 62 are inserted in the
receptacle 74 with the backs of the boxes against the ends of
the projecting tips 82, the boxes will extend from the cover
72 about three-quarters of an inch so as to be effectively
25 positioned for plastered walls. When the tips 82 are cut off
at the shoulders 84, the boxes 62 will then extend about one-
half inch from the cover so as to be suitably positioned for
dry wall or plaster board. Finally, when the projections 72
are removed by cutting the base portions 80 at the back wall
of the receptacle 74, the boxes 62 will extend about one-
quarter inch, which is suitable for panelled walls.
When the boxes are positioned in the cover 72 at the
desired depth, mounting straps 86 are extended through the side
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walls of the receptacle 74 of the cover 72 and between the ears
64 and the adjustable flanges 66. The boxes 62 can then be
snugly held with the flanges pressing against the straps 86 and
the backs of the boxes being urged against the projections 78,
or portions thereof which are not cut away, or against the back
of the receptacle 74 itself. The boxes 62 can also be fast-
ened to the straps by screws 92. ~he straps 86 are then
suitably fastened to studs or other structural members 88 by
nails 90 or other suitable fasteners.
To facilitate penetration of the straps 86 through
the cover 72, the edges of the sides of the receptacle 74,
where they meet the slanted flange 76, have molded elongate
thin portions or areas 94. The plastic material of the cover
still snugly fits aruund the straps 86 when in the position to
minimize the passage of air or moisture therearound.
The thin portions 94 are also molded into the other
top walls of the.receptacle 74 of the cover 72. The cover 72
can then be turned 90, as shown in Figure 10, with the straps
86 extending through the other thin portions of the receptacle.
In this position, the cover readily accommodates a pair of the
boxes 62. The cover also has thin portions 96 to receive bar
hangers.
The covers can also be used for other boxes such as
telephone junction boxes and thermostats.
2~ Various modifications of the above described
embodiments of the invention will be apparent to those skilled
in the art and it is to be understood that such modifications
can be made without departing from the scope of the invention,
the embodiments shown and described being primarily for purposes
of illustration and not limitation.
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