Note: Descriptions are shown in the official language in which they were submitted.
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DUAL HINGE RECESS WEATHERPROOF ELECTRICAL BOX
ASSEMBLY
FIELD OF THE INVENTION
[0002] The present invention generally relates to a hinged electrical box
assembly, and more
particularly to a dual hinge weatherproof electrical box assembly.
BACKGROUND OF THE INVENTION
[0003] Generally, electrical box assemblies are used for a variety of
applications and provide a
termination point for electrical wires for connection to an electrical
component. Depending on
the application and location, electrical box assemblies can be mounted on or
in a wall in either a
horizontal or vertical orientation. Once mounted, electrical wires are
installed and connected to
the electrical component. Typically, a face plate is provided that covers a
top opening of the
electrical box that may prevent damage to electrical components included
therein.
[0004] Some electrical box assemblies include a cover that permits the box to
be mounted in a
location where it can be exposed to wet conditions. For example, some
electrical boxes are
mounted outdoors and provide electrical power for lighting and power
equipment, even though
the electrical box may be exposed to moisture.
[0005] Although some of these assemblies include a cover that can operate to
inhibit some
moisture from entering the box and causing damage, moisture remains a problem
in that the
electronic components are positioned adjacent the face plate. As such, there
exists a need for an
improved weatherproof outdoor box assembly. Furthermore, it would be desirable
to provide an
improved weatherproof dual hinge electrical box assembly that includes a cover
which is adapted
to be opened when the box is oriented in either the horizontal or vertical
direction.
SUMMARY OF THE INVENTION
[0006] The present invention concerns a dual hinge recess weatherproof outdoor
electrical box
assembly for shielding and protecting electrical components from moisture. The
electrical box
assembly includes an electrical box having a plurality of hinge sockets, an
adapter plate that is
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recessed in the electrical box, and a cover having a plurality of hinge pins
for operable
engagement with the hinge sockets.
[0007] The adapter plate of the present invention is substantially planar, and
includes a perimeter
bounded by a substantially rectangular side edge. Preferably, the adapter
plate is recessed inside
the outlet box and includes at least one aperture for receiving an electrical
component. The
adapter plate may include one or more tabs that extend from a back surface of
the adapter plate
and engage a back portion of the box. Upon engagement with the back portion of
the box, the
adapter plate is removably secured to the box.
[0008] The electrical box includes a face plate having a first hinge socket
and a second hinge
socket each extending respectively from a side edge of the box and are
configured in a
substantially orthogonal orientation. The electrical box also includes at
least one knockout for
receiving and attaching an electrical wire to an electrical component. For
example, in one
preferred embodiment, a bottom portion of the electrical box includes a V-
shaped slot that is
adapted to receive electrical wires for attachment to electrical components.
In another
embodiment, a back wall of the electrical box includes one or more knockouts
that are adapted to
receive electrical wires for attachment to an electrical component. In yet
other embodiments,
both the V-shaped slot and the back wall knockouts are included on the
electrical box.
[0009] The cover of the present invention includes a front wall, an opposed
open end and a
substantially rectangular side wall defining a cover interior. Preferably, the
side wall includes a
rim bounding the open end. The cover also includes at least one access port
through the side
wall adjacent the open end for providing separate passageways into the
interior of the cover. For
example, an electrical cord may be set in each of the separate passageways.
[0010] Preferably, the cover includes a first hinge pin and a second hinge pin
extending
respectively from the side wall adjacent the open end in substantially
orthogonal orientation; and
the cover being pivotally affixed to the box by operative engagement of the
hinge socket with the
hinge pin of corresponding orientation and movable between an open and a
closed position and
wherein the hinge pin and the hinge socket that are not in operative
engagement are not aligned.
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BRIEF DESCRIPTION OF THE DRAWINGS
[0011 ] FIG. 1 is a perspective view of the electrical connector box and
attached cover in a
vertical open position, the adapter plate being shown detached from the
electrical connector box.
[0012] FIG. 2 is a perspective view of the electrical connector box and
attached cover in a
vertical open position, the adapter plate being recessed in the electrical
connector box.
[0013] FIG. 3 is a perspective view of the electrical connector box and
attached cover in a
vertical closed position.
[0014] FIG. 4 is a perspective view of the electrical connector box and
attached cover in a
horizontal open position, the adapter plate being shown recessed in the
electrical connector box.
[0015] FIG. 5 is a perspective view of the electrical connector box and
attached cover in a
horizontal closed position.
[0016] FIG. 6 is a rear perspective view of the electrical connector box.
[0017] Like reference symbols in the various drawings indicate like elements.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0018] Referring now to FIGS. 1-6, an electrical box assembly 10 according to
the present
invention is disclosed. The electrical box assembly 10 includes an electrical
connector box 28
having a face plate 32 attached thereto, a box cover 12 removably attached to
the face plate 32,
and an adapter plate 42 that is removably secured to a recessed inside portion
of the electrical
connector box 28.
[0019] The electrical connector box 28 of the present invention is a generally
rectangular box-
like member that includes a generally flat backwall 29 (see FIG. 6) with a
continuous sidewall
member (indicated generally at 34) upstanding therefrom. The sidewall member
34 includes a
pair of oppositely disposed endwall portions 34B, 34C and a pair of oppositely
disposed sidewall
portions 34A, 34D. The front edges of the endwall portions 34B, 34C and
sidewall portions 34A,
34D preferably define a generally planar open front for the electrical
connector box 28.
[0020] As shown in FIG. 6, the back wall 29 of the electrical connector box 28
includes one or
more knockouts 62A, 62B for receiving and attaching an electrical wire to an
electrical
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component installed in the box 28. In one preferred embodiment, the electrical
connector box 28
includes one or more a V-shaped slots 64A, 64B that also may be adapted to
receive electrical
wires for attachment to electrical components positioned in the box 28.
Preferably, as shown in
FIG. 6, the V-shaped slots 64A, 64B are formed on the back wa1129 and end wall
portions 34B,
34C of the box 28. Of course, it will be appreciated by one skilled in the art
that one or more
knockouts and V-shaped slots may be included on the electrical connector box
28.
[0021] As shown in FIG. 6, in one preferred embodiment, the back edges of the
endwall portions
34B, 34C are preferably joined to sidewall portions 34A, 34D, respectively, to
define a recess
area 52 that provides clearance for one or more tabs 44 extending from the
adapter plate 42.
[0022] Referring now to FIGS. 1, 2 and 4, the adapter plate 42 of the present
invention is shown.
The adapter plate 42 is a generally rectangular member having a substantially
planar rectangular
top surface that is perimetrically bounded by an outer wal147. The outer wall
47 of the adapter
plate 42 is of dimensions suitable for insertion and attachment to an inside
recessed portion of
the box 28. As shown in FIGS. 1 and 2, the adapter plate includes openings 48
for attaching an
electronic component (not shown) to the adapter plate 42. For example, in one
preferred
embodiment, openings 48 are provided on the adapter plate 42 that are adapted
to accept a screw
to fasten an electronic component to the adapter plate 42. Preferably, the
electronic component
lies on top of the adapter plate 42. Afterwoods a typical cover plate (not
shown) covers both the
electrical component and opening 46 in the normal fashion.
[0023] In one preferred embodiment, as shown in FIG. 1, the adapter plate 42
includes one or
more tabs 44 extending perpendicularly from a back surface of the adapter
plate 42. The distal
end of each tab 44 may be used to secure the adapter plate 42 to an internal
portion of the box 28.
For example, in one preferred embodiment, as shown in FIGS. 1 and 6, recessed
area 52 of the
box 28 forms a shoulder 36 on an interior portion of the box 28. The shoulder
36 preferably
includes an opening 38 that is adapted to receive the distal end of one of the
tabs 44. Upon
insertion of the distal end of one of the tabs 44 into the opening 38, the
tab, and thereby the
adapter plate 42 is engageably locked and secured to the shoulder 36 of the
electrical connector
box 28. Preferably, one of the distal ends of the tabs 44 is press-fit into
the opening 38 and is
releasably locked to a back portion of the opening 38.
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[0024] One advantage of securing the adapter plate 42 to the shoulder 36, as
shown in FIGS. 2
and 4, is that electrical components are thereby recessed in the box 28 and
not positioned
adjacent the face plate 32. As a result, electrical components may be further
protected from any
moisture accumulating on the inside cover area 16 of the cover 12 and face
plate 32. Of course,
it will be appreciated by one skilled in the art that other techniques may be
used to secure the
adapter plate 42 to the shoulder 36 of the box. For example, the adapter plate
42 may be secured
to an internal portion of the box 28 via screws or via incorporating
mechanical structure located
on both the plate and the internal wall of the box..
[0025] The adapter plate 42 of the present invention is configured to
accomodate any number of
electrical components. For example, the adapter plate 42 can accommodate a
single duplex
receptacle mounted to threaded opening 48. Of course, it will be appreciated
by one skilled in
the art that the adapter plate 42 can also accommodate a variety of different
components
including GFCI receptacles or switches secured atop adapter plate 42. To
finish installation, a
typical cover plate is then installed over the electrical component in the
usual manner.
[0026] In one preferred embodiment, the face plate 32 of the present invention
is rigidly
mounted to the open front of the electrical box 28 and is used to mount the
electrical box
assembly 10 on or in a wall. For example, as shown in FIG. 1, openings 40 are
provided on the
face plate 32 that allow the assembly 10 to be secured to a wall using
fasteners, such as, but
limited to, nails, screws and bolts. Preferably, the face plate 32 has a
substantially planar
rectangular top surface. The perimeter of the face plate 32 is generally
greater than the
perimeter of the box 28. For example, as shown in the figures, in one
preferred embodiment, a
back surface of the face plate 32 is attached to the front edges of the
endwall portions 34B, 34C
and sidewall portions 34A, 34D of the box 28 resulting in the perimeter of the
face plate 32
being larger than the perimeter of the box 28.
[0027] As shown in the Figures, the face plate 32 preferably includes a
vertical hinge socket 24
and a horizontal hinge socket 30 each extending respectively from a side edge
of the box 28 and
are configured in a substantially orthogonal orientation. Preferably, each of
the hinge sockets 24,
30 is formed in an arched structure having an interior portion adapted to
concentrically receive a
hinge pin 23 or 26 of the cover 12.
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[0028] Preferably, the face plate 32 also includes one or more face plate
locking members 50A,
50B that may be used to lock the cover 12 to the face plate 32. Details of
locking the cover 12 to
the face plate 32 are discussed in connection with FIG. 3.
[0029] The cover 12 of the present invention is a generally rectangular box-
like member having
a substantially planar rectangular inner surface 16 that is perimetrically
bounded by an outer wall
14. As shown in FIGS. 1 and 2, the outer wall 14 is comprised of four
substantially planar side
walls having two sets of substantially parallel sides. The outer wall 14
extends around and help
define inner surface 16 and includes an outwardly flanged rim 15 extending
from an end thereof.
Preferably, the rim 15 is integrally formed on the cover 12 as a single piece
component and
operates to channel away any water that may fall on the cover 12 when the
cover 12 is in the
closed position.
[0030] In one preferred embodiment, as shown in FIGS. 1 and 2, the outer wall
14 of the cover
12 is configured to include one or more conventional plug knockouts 18, 22 of
a type generally
known in the art. Preferably, the knockouts 18, 22 are a partially cut through
opening or
removable wall section that create an opening through which a wire may pass
for electrical
connection to an enclosed electrical component.
[0031 ] Preferably, the outer wall 14 of the cover 12 is configured to include
a vertical cover
hinge pin 23 and a horizontal cover hinge pin 26 for pivotal engagement with
the vertical hinge
socket 24 and the horizontal hinge socket 30 of the face plate 32,
respectively. For example, as
shown in FIG. 1, the vertical hinge socket 24 is mounted on the face plate 32
such that the
interior portion of the socket 24 is oriented towards the front of face plate
32. By mounting the
vertical hinge socket in this way, the vertical cover hinge pin 23 can be
rotatably engaged to the
hinge socket 24. The cover 12 can thereby be pivoted to rotate into an open or
closed position.
[0032] The cover 12 of the present invention also includes a locking device 20
that may be
positioned in operative engagement with the face plate locking members 50A,
50B. As is well
known in the art, the cover 12 may be formed of a variety of materials. For
example, in one
preferred embodiment, the cover 12 is integrally formed of an injection
molded, high impact
synthetic plastic material, such as for example, clear Lexan.
[0033] A perspective view of the cover 12 pivotally engaged to the face plate
32 in a closed
vertical orientation is shown in connection with FIG. 3. In one preferred
embodiment, the
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locking devices 50A and 50B extend from diagonally opposed sides of the face
plate 32 and are
adapted to be fastened to the cover locking device 20. As shown in the FIG. 3
example, when
the electrical box assembly 10 is in the vertical closed position, the locking
device 50B is in
locking engagement with the cover locking device 20. As will be described and
shown in
connection with FIG. 4, the cover 12 can also be pivotally engaged to the face
plate 32 in a
horizontal orientation.
[0034] As shown in FIGS. 1 and 3, in one preferred embodiment, the cover
locking device 20
comprises a stanchion 74 supporting an annular ring 76. The face plate locking
device 50B
comprises a support stanchion 70, an annular ring 72, and a locking tab 78.
The annular ring 76
of the cover 12 is adapted to align concentrically with the complementary
structure on the face
plate locking device 50A or 50B, and provides a passage through which a
conventional lock
shank of a padlock or other locking device (not shown) may be inserted. The
lock can be a
padlock, opened by key or combination.
[0035] In operation, when the cover 12 is pivotally engaged to the face plate
32 and rotated to
the vertical closed position, the cover locking device 20 passes the face
plate locking device 50B
and the locking tab 78 is elastically deformed laterally away from the locking
device 50B until
the cover 12 is in the fully closed position. Once the cover 12 is fully
closed, the locking tab 78
flexes back to its original position to releasably secure the cover 12 on the
face plate 32. At the
same time, the annular rings 72, 76 are concentrically aligned to permit
insertion of a lock such
as a pad lock. To open the cover 12, the locking tab 78 is manually bent away
from the locking
device 50B thereby permitting opening of the cover 12. By providing the cover
12 and face plate
32 with a snap closure mechanism, the cover 12 can be closed securely and
tightly, thus
maintaining a tight seal between the cover 12 and face plate 32.
[0036] Referring now to FIGS. 4 and 5, the electrical box assembly 10 arranged
in an open and
closed horizontal orientation, respectively, is shown. As shown in FIG. 4, the
cover 12 is rotated
180 degrees from the vertical orientation depicted in FIGS. I and 2 with
respect to face plate 32.
In the horizontal orientation, the horizontal hinge pin 26 and horizontal
hinge socket 30 are
pivotally engaged. While in the horizontal position, the vertical hinge socket
24 and pin 23 are
positioned along opposite parallel sides of the face plate 32 and cover 12,
respectively. Such
arrangement prevents the unused hinge components from interfering with the
opening and
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closing of the cover 12. Furthermore, as shown in FIG. 5, in the horizontal
closed position, the
cover locking device 20 engages with the face plate locking device 50A. The
face plate locking
device 50B is not engaged in the horizontal orientation.
[0037] It should be understood that to affix the cover 12 to the face plate
32, either hinge socket
24, 30 is pivotally engaged to the corresponding horizonta126 or vertical 23
hinge pin
respectively. Furthermore, either set of hinges 24, 30 can be selectively
engaged without the
need to modify the adapter plate 42, face plate 32 or the cover 12. It should
also be understood
that other intermating structure are equally suitable such that the described
pin and socket
interconnection is not the only structure usable for securing the cover 12 to
the face plate 32.
Further, either inter-mating structure may be formed on either face plate 32
or cover 12.
[0038] For example, in one preferred embodiment, the pin structure described
is secured to the
face plate and the socket structure described previously is secured to the
cover. Bayonet, ball, as
well as male/female structures are equally suitable for this purpose.
Furthermore, there is no
necessity that the intermating structure on the face plate 32 be the same nor
is there any necessity
that the intermating structure on the cover 12 be the same. It is only
necessary that the respective
intermating structure on the cover and face plate be configured to engage each
other.
[0039] In the preferred embodiment of the present invention, the face plate
and cover are
mounted such that the cover opens by pivoting in an upward direction. For
example, the face
plate may be mounted to the box with either a vertical or horizontal hinge
socket positioned at
the top wherein the corresponding cover hinge pin is pivotally engaged to that
socket.
Alternately, it is also possible to open the cover in a downward or lateral
direction by positioning
a hinge socket at the bottom or side of the face plate respectively, and
pivotally engaging the
corresponding hinge socket. Either orientation can be achieved without any
modification to the
positioning of the adapter plate.
[0040] Although preferred embodiments of the present invention have been
described herein
with reference to the accompanying drawings, it is to be understood that the
invention is not
limited to those precise embodiments and that various other changes and
modifications may be
affected herein by one skilled in the art without departing from the scope or
spirit of the
invention, and that it is intended to claim all such changes and modifications
that fall within the
scope of the invention.
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