Note: Descriptions are shown in the official language in which they were submitted.
CA 02507586 2007-12-05
WALL RECESSED OUTLET BOX ASSEMBLY
BACKGROUND OF THE INVENTION
[00011 The present invention relates generally to outlet boxes for mounting
electrical
outlets and connectors on wall structures, and more particularly, to such an
outlet box in which
the electrical outlet and connector is recessed from the wall structure.
[00021 Electrical outlet boxes which support an electrical receptacle and a
connector are
known. Such outlet boxes may support the electrical receptacle in the plane of
the outer surface
of the wall structure. As a result, when a plug is inserted into the
electrical receptacle which is
so supported, the plug extends outward of the wall surface. The electrical
plug is thereby
exposed to being struck by a transverse force such as from a person, piece of
furniture or other
object which may move along the side of the wall structure in close proximity
thereto. If such a
transverse force is sufficient, it may dislodge the plug from the electrical
receptacle, either
partially or completely, or cause damage to the plug or receptacle, as well as
a combination
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thereof. Additionally, extension of the electrical plug beyond the outer
surface of the wall
structure normally prevents the positioning of a piece of furniture, wall
hanging or similar object
in close proximity to the outer surface of the wall in the vicinity of the
electrical receptacle.
Such an object may, for example, be a television which would desirably be
positioned close to
the outer surface of the wall structure in front of and adjacent to the
electrical receptacle. This
would enable the power cable from the television to extend to the electrical
receptacle for
connection thereto and for the power cable and electrical receptacle to be
obstructed from view
by the television.
[00031 To reduce the extension of the electrical plug beyond the outer surface
of the wall
structure, electrical boxes may be configured to support the electrical
receptacle in a recessed
position relative to the outer surface of the wall structure. This recessed
position of the electrical
receptacle reduces or, if sufficient, eliminates entirely the exposure of the
electrical plug to the
aforementioned undesirable forcible contact.
[00041 Additionally, electronic devices frequently require connection to an
electrical
power source and a separate connection to a communication network, such as a
telephone or
television network, or a local area network (LAN) or the internet for
computers. Examples of
such electrical devices include telephones, televisions, answering machines
and personal
computers. Such requirements typically result in separate electrical cables
extending from the
electronic devices where the power cable is connected to an electrical
receptacle and the
communication cable is connected to a separate connector, such as a telephone
jack, or a
connector for digital data transmission or for a coaxial cable.
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[0005] To provide the required connection for such cables, the electrical
outlet box may
have an additional connector for such a cable. Such a cable typically has a
cable plug which is
coupled to the additional connector. The additional connector may be recessed
from the outer
surface of the wall structure to reduce the extension of the cable plug which
is coupled thereto.
This reduction of the extension of the cable plug may limit or eliminate
entirely the exposure
thereof to undesirable forcible contact, and the unfavorable consequences,
similar to those which
may befall an electrical plug which extends beyond the outer surface of the
wall structure, as
described herein above.
[0006] The electrical receptacle may be supported within the outlet box by
securing the
front surface of the electrical receptacle to a vertical flange or similar
structure within the outlet
box. This may be the only support provided to the electrical receptacle within
the outlet box.
This limited support may result from clearances being provided between the
outer surfaces of the
electrical receptacle which do not contact the vertical flange or other
support structure within the
outlet box. This limited support may necessitate a high strength connection
between the limited
surface of the electrical receptacle which is directly attached to the outlet
box. In the absence of
such a high strength connection, the electrical receptacle may undesirably
translate or pivot
relative to the outlet box, such as when the electrical plug is inserted into
the electrical receptacle
or if the electrical plug, after insertion thereof into the electrical
receptacle, is contacted by an
external force.
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SUMMARY OF THE INVENTION
[0007] The outlet box assembly of the present invention includes an outer
faceplate
having an interior opening. An inner faceplate is connected to the outer
faceplate such that the
inner faceplate is recessed from the outer faceplate and access to the inner
faceplate is provided
through the interior opening. The inner faceplate has an outlet port and a
communication port.
[0008] The outlet box assembly further includes a support housing having an
inner
surface and an interior region bounded by the inner surface. The support
housing is connected to
a rear surface of the inner faceplate such that the outlet port provides
access to the interior
region. The support housing is configured to allow insertion of an electrical
receptacle into the
interior region and to provide an enclosure for the electrical receptacle.
[0009] The enclosure of the electrical receptacle by the support housing
provides
protection to the electrical receptacle and limits access thereto which is
normally desirable. The
connection of the support housing to the rear surface of the inner faceplate,
and the recess of the
inner faceplate from the outer faceplate provides for the recess of the
electrical receptacle from
the outer faceplate. Consequently, an electrical plug, which may be inserted
into the electrical
receptacle, is recessed from the outer faceplate thereby reducing the the
likelihood of the
electrical plug being contacted by an external force. Also, the recess of the
inner faceplate from
the outer faceplate results in the communication port being recessed from the
outer faceplate. A
receptacle may be supported in the communication port and a cable plug may be
inserted into the
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receptacle. The recess of the communication port results in the cable plug
being recessed
which reduces the likelihood of the cable plug being contacted by an external
force.
[0009.1 ] According to one aspect of the present invention there is provided
an
outlet box assembly comprising an outer faceplate having an interior opening,
the interior
opening having an outer periphery; an inner faceplate connected to the outer
faceplate
such that the inner faceplate is recessed from the outer faceplate and access
to the inner
faceplate is provided through the interior opening, the inner faceplate having
a planar
front surface which is separated from the outer periphery by a distance which
is
orthogonal relative to the front surface of the outer faceplate, the distance
being constant
along the outer periphery, the inner faceplate having an outlet port and a
communication
port; and a support housing having an inner surface and an interior region
bounded by the
inner surface, the support housing being connected to a rear surface of the
inner faceplate
such that the outlet port provides access to the interior region, the support
housing being
configured to allow insertion of an electrical receptacle into the interior
region and to
provide an enclosure for the electrical receptacle; the inner faceplate having
at least a first
portion extending beyond the support housing, the first portion including the
communication port, the first portion being disposed outside of the support
housing and
having a rear surface that is unenclosed wherein access to the communication
port via the
rear surface is unrestricted by a housing.
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[0009.2] According to a further aspect of the present invention there is
provided an
outlet box assembly comprising a support housing having an interior for
receiving an
electrical receptacle; an inner faceplate extending outwardly from the support
housing
and defining an opening to the support housing interior, the inner faceplate
having a first
portion including a communication port adapted to receive a receptacle, the
communication port being disposed outside the support housing, the inner face
plate first
portion and the opening to the support housing interior lying in a common
plane; a flange
extending from the inner faceplate, the flange and inner faceplate forming a
chamber
adapted to contain an electrical plug, the inner faceplate first portion
having an upper
surface bounding the chamber and an opposed lower surface, the lower surface
being
unenclosed and wherein access to the receptacle received in the communication
port is
permitted from the exterior of the outlet box assembly; an outer faceplate
disposed on the
flange, wherein the inner faceplate is recessed from the outer faceplate.
[0009.3] According to another aspect of the present invention there is
provided an
outlet box assembly comprising a support housing having an opening for
receiving an
electrical receptacle and the opening lying in a first plane, the support
housing including
an exterior; an inner faceplate extending outwardly from the support housing,
the inner
faceplate having a first portion lying in a second plane, the first portion
including a
communication port adapted to receive a receptacle, the first plane and the
second planes
being substantially parallel to each other, the communication port being
disposed outside
the support housing, the inner face plate having an exterior surface; a flange
extending
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from the inner faceplate, the flange and inner faceplate forming a chamber
adapted to
contain an electrical plug, the flange having an exterior surface; the inner
faceplate first
portion having an upper surface bounding the chamber and an opposed lower
surface, the
lower surface being unenclosed and wherein access to the receptacle received
in the
communication port is permitted from the exterior of the outlet box assembly;
an outer
faceplate disposed on the flange, wherein the inner faceplate is recessed from
the outer
faceplate.
[0010] These and other features of the invention will be more fully understood
from the following description of specific embodiments of the invention taken
together
with the accompanying drawings.
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BRIEF DESCRIPTION OF THE DRAWINGS
[0011] In the drawings:
[0012] Fig. 1 is a front perspective view of the wall recessed outlet box
assembly of the
present invention before assembly of the electrical receptacle and interior
faceplate thereto and
removal of the knockouts from the outer faceplate;
[0013] Fig. 2 is a front elevation view of the outlet box assembly of Fig. 1;
[0014] Fig. 3 is a rear elevation view of the outlet box assembly of Fig. 1
showing the
arms in the retracted and clamped positions;
[0015] Fig. 4 is a right side elevation view of the outlet box assembly of
Fig. 1 showing
the arms in the clamped positions;
[0016] Fig. 5 is a left side elevation view of the outlet box assembly of Fig.
1 showing
the arms in the clamped positions;
[0017] Fig. 6 is a top plan view of the outlet box assembly of Fig. 1;
[0018] Fig. 7 is a bottom plan view of the outlet box assembly of Fig. 1;
[0019] Fig. 8 is a front elevation view of the outlet box assembly of Fig. 1
after assembly
of the electrical receptacle and interior faceplate thereto and removal of the
knockouts from the
outer faceplate;
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[0020] Fig. 9 is a rear elevation view of the outlet box assembly of Fig. 8
showing the
arms in the retracted and clamped positions;
[0021] Fig. 10 is a front elevation view of an alternative second embodiment
of the outlet
box assembly of Fig. 1 after assembly of the electrical receptacle and
interior faceplate thereto
and removal of the knockouts from the outer faceplate, the outlet box assembly
having an
alternative configuration of the communication ports;
[0022] Fig. 11 is a rear elevation view of the outlet box assembly of Fig. 10
showing the
arms in the retracted and clamped positions;
[0023] Fig. 12 is a front elevation view of an alternative third embodiment of
the outlet
box assembly of Fig. 1 after assembly of the electrical receptacle and
interior faceplate thereto
and removal of the knockouts from the outer faceplate, the outlet box assembly
having an
alternative configuration of the communication ports;
[0024] Fig. 13 is a rear elevation view of the outlet box assembly of Fig. 12
showing the
arms in the retracted and clamped positions;
[0025] Fig. 14 is a front elevation view of an alternative fourth embodiment
of the outlet
box assembly of Fig. 1 after assembly of the electrical receptacle and
interior faceplate thereto
and removal of the knockouts from the outer faceplate, the outlet box assembly
having an
alternative configuration of the communication ports;
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[0026] Fig. 15 is a rear elevation view of the outlet box assembly of Fig. 14
showing the
arms in the retracted and clamped positions;
[0027] Fig. 16 is a front elevation view of an alternative fifth embodiment of
the outlet
box assembly of Fig. 1 after assembly of the electrical receptacle and
interior faceplate thereto
and removal of the knockouts from the outer faceplate, the outlet box assembly
having an
alternative configuration of the communication ports;
[0028] Fig. 17 is a rear elevation view of the outlet box assembly of Fig. 16
showing the
arms in the retracted and clamped positions;
[0029] Fig. 18 is a front elevation view of an alternative sixth embodiment of
the outlet
box assembly of Fig. 1 after assembly of the electrical receptacle and
interior faceplate thereto
and removal of the knockouts from the outer faceplate, the outlet box assembly
having an
alternative configuration of the communication ports; and
[0030] Fig. 19 is a rear elevation view of the outlet box assembly of Fig. 18
showing the
arms in the retracted and clamped positions.
[0031] Corresponding reference characters indicate corresponding parts
throughout the
several views of the drawings.
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DETAILED DESCRIPTION OF THE INVENTION
[0032] Referring to the drawings and more particularly to Figs. I to 7, a wall
recessed
outlet box assembly 10 is shown for mounting to a wall structure 12, such as
the vertical wall
board of an interior wall of a building structure.
[0033] The outlet box assembly 10 includes an outer faceplate 14 which has an
interior
opening 16 and a rear surface 18. The outer faceplate 14 is planar and has an
outer edge which
may be beveled.
[0034] A flange structure 20 is fixed to the rear surface 18 and has a top
flange 22, a pair
of side flanges 24, and a bottom flange 26 which are fixed to one another such
that each of the
side flanges is between the top and bottom flanges in perpendicular relation
thereto. This results
in the flange structure 20 having a vertical cross-section which is
rectangular.
[0035] The outlet box assembly 10 includes an inner faceplate 28 having a
front surface
30 which is fixed to the rear edges of the flange structure 20 such that the
inner faceplate is
recessed from the outer faceplate 14. The inner faceplate 28 is planar and
parallel to the outer
faceplate. Access to the inner faceplate 28 is provided through the interior
opening 16.
[0036] The inner faceplate 28 has an outlet port 31 and knockouts 33. The
outer
peripheries of the knockouts 33 are indented in the rearward direction to form
grooves 34 as
shown in Fig. 2. The grooves 34 may be indented by a dimension, such as 50
mils. The rear
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ends of the knockouts 33 do not extend to the rear surface 35 of the inner
faceplate 28 resulting
in the knockouts being indented in the forward direction. These indentations
of the knockouts 33
may be by a dimension, such as 50 mils. The knockouts 33 are removed to
provide
communication ports 36 in the inner faceplate 28. The communication ports 36
provide
openings in which receptacles, such as telephone jacks, co-axial cable
connectors or plugs for
electrical cables, may be supported. Such cables may be for telephone, cable
television, personal
computers, data transmissions or digital communications. The communication
ports 36 may be
referred to as data ports.
[00371 The cross-sections of the communication ports 36 may vary in shape to
be
compatible with the connectors to be supported therein. For example, as shown
Fig. 8, the
communication ports 36 may include rectangular communication ports 37 each of
which has a
rectangular cross-section. The communication ports 36 may further include
circular/hexagonal
communication ports 38 each of which has a forward end 40 which intersects the
front surface 30
of the inner faceplate 28, as shown in Fig. 9. Each forward end 40 has a
circular cross-section.
The circular/hexagonal communication ports 38 each have a rear end 42 which
intersects the rear
surface 35 of the inner faceplate 28, as shown in Fig. 9. Each rear end 42 has
a hexagonal cross-
section.
[00381 Additionally, the communication ports 36 may vary in number and in
configuration relative to the outlet port 31. For example, as shown in Figs. 2
and 3, the
communication ports 36 are arranged such that two of the rectangular
communication ports 37
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are arranged above two of the circular/hexagonal communication ports 38 in
respective columns
on either side of the outlet port 31.
[0039] Other configurations for the communication ports 36 are possible as
shown in the
alternative embodiments of Figs. 10 to 19. Parts illustrated in Figs. 10 to 19
which correspond to
parts illustrated in Figs. 1 to 9 have the same reference numeral as in Figs.
1 to 9 with the
addition of the suffix "a" in Figs. 10 and 11, suffix "b" in Figs. 12 and 13,
suffix "c" in Figs. 14
and 15, suffix "d" in Figs. 16 and 17, and suffix "e" in Figs. 18 and 19.
[0040] Referring now to Figs. 1, 4 and 5, the outlet box assembly 10 includes
a support
housing 46 having an outlet box 48 including a top wall 50, a pair of side
walls 52, and a bottom
wall 54 each of which has a front edge which is fixed to the rear surface 35
of the inner faceplate
28 such that the top, side and bottom walls are perpendicular to the inner
faceplate 28. The top
wall 50, side walls 52 and bottom wall 54 are fixed to one another such that
each of the side
walls is between the top and bottom walls in perpendicular relation thereto.
This results in the
outlet box 48 having a vertical cross-section which is rectangular.
[0041] The outlet box 48 includes a rear wall 56 fixed to the rear edges of
the top wall
50, side walls 52 and bottom wall 54 such that the top, side and bottom walls
are between the
rear wall and inner faceplate 28 and the rear wall 56 is parallel to the inner
faceplate 28. The
rear wall 56 has a dome-shaped protrusion 58 extending inwardly from the front
surface thereof
and a corresponding indentation on the rear surface of the rear wall. Elongate
support ribs 60 are
secured to the front surface of the rear wall 56. The support ribs 60 bisect
the front surface both
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horizontally and vertically and intersect the dome-shaped protrusion 58. The
dome-shaped
protrusion 58 and support ribs 60 provide structural support to the rear wall
56.
[00421 The top wall 50, side walls 52, bottom wall 54, and rear wall 56 each
have an
inner surface each of which defines a portion of the inner surface 62 of the
support housing 46.
The inner surface 62 bounds an interior region 64 of the support housing 46.
Access to the
interior region 64 is provided by the outlet port 31.
[00431 The support housing 46 includes an upper shoulder 66 which extends
downwardly
from the lower surface of the top wall 50, and a lower shoulder 68 which
extends upwardly from
the upper surface of the bottom wall 54. The upper and lower shoulders 66, 68
are formed by
elongate recesses in the upper surface of the top wall 50 and lower surface of
the bottom wall 54,
as shown in Fig. 3. The upper and lower shoulders 66, 68 are perpendicular to
the plane of the
inner faceplate 28 and are equidistant from the side walls 52.
[00441 The inner faceplate 28 has upper and lower tab portions 70, 72 which
extend
downwardly and upwardly, respectively, to cover the forward ends of the upper
and lower
shoulders 66, 68. Each of the tab portions 70, 72 has an opening through which
an elongate
fastener may be inserted.
[0045] The top and bottom walls 50, 54 each have a pair of notches 74 at the
corners
formed by the intersection of the rear wall 56 with the top wall 50, side
walls 52 and bottom wall
54. The forward ends of the notches 74 terminate at wire ports 76.
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[0046] The outlet box assembly 10 includes a pair of clips 78 each of which
has a post 80
and an arm 82 pivotally connected to the post in perpendicular relation
thereto. Each post 80 is
connected to the front surface 30 of the inner faceplate 28 adjacent to
opposing corners thereof,
as shown in Figs. 1 and 2. Each of the arms 82 is coupled to an elongate
member, such as a pin
84, which extends through an elongate cavity in the post 80, as shown in Figs.
2 and 3. The
forward end of the pin 84 has a head 86 to which may be coupled a tool for
rotating the pin.
Such coupling may be provided, for example, by forming in the front surface of
the head 86 a
recess which may be engaged by a screw driver. Rotation of the pin 84, such as
by a screw
driver, causes pivoting of the arm 82 about the associated post 80. Each of
the arms 82 may be
thereby be swung between a retracted position 88 in which the arm is within
the outer periphery
90 of the inner faceplate 28 and a clamped position 92 in which the arm
extends beyond the outer
periphery 90.
[0047] The outlet box assembly 10 is prepared for mounting to the wall
structure 12 by
removing the knockouts 33, such as by applying a force thereto which is
sufficient to fracture the
knockouts from the inner faceplate 28. Such fracturing will occur along the
grooves 34 resulting
in the cross-sections of the communication ports 36 having the specific shapes
shown in Figs. 2,
3, and 10 to 19. Alternatively, the knockouts 33 may be removed by cutting the
outer peripheries
thereof at the grooves 34. Knockouts 33 which are removed by such cutting may
be referred to
as cutouts.
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[0048] The preparation of the outlet box assembly 10 for mounting to the wall
structure
12 further includes assembling an electrical receptacle 94 to the outlet box
assembly. Such
assembly may be either before or after the removal of the knockouts 33 from
the inner faceplate
28.
[0049] The electrical receptacle 94 is assembled to the outlet box assembly 10
by
insertion of the electrical receptacle 94 through the interior opening 16 and
outlet port 31 into the
interior region 64 of the support housing 46. The electrical receptacle 94 has
an outer surface 96
and elongate slots 98 to receive the prongs of an electrical plug. When the
electrical plug is
inserted into the electrical receptacle 94, at least a portion of the plug or
possibly the entire plug
is contained within the flange structure 20.
[0050] The wire ports 76 provide a pathway for wires to extend from the
electrical
receptacle 94 within the interior region 64 to a location outside of the
support housing 46.
Provision of the wire ports 76 at the top and bottom walls 50, 54 accommodates
wires which are
connected to the top or bottom of the electrical receptacle 94, typically to
the rear thereof. Such
wires typically extend to the power source for the provision of electrical
power to the electrical
receptacle 94. This results in electrical power being supplied to an
electrical plug inserted in the
electrical receptacle 94.
[0051] The insertion of the electrical receptacle 94 into the interior region
64 is
facilitated by the configuration of the support housing 46. For example, the
configuration of the
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