Frame member and box combination for recessing an electrical box and cover assembly

This invention relates to electrical boxes and specifically to a frame member and outlet box combination for mounting the outlet box and its cover flush with or recessed from the wall of a building.

Conventional exterior electrical boxes for the mounting of duplex outlets, switches, and other electrical devices are typically installed essentially flush with the wall surface. The exterior electrical boxes usually include a hinged cover to cover the electrical device. Typically the hinged cover extends outward from the front of the electrical box and therefore also extends outward of the wall. Some types of conventional electrical box covers, known as bubble covers, extend a substantial amount from the wall surface.

Outward-extending electrical box and cover assemblies, though they cover the front of the box, are prone to damage by lawnmowers, vehicles, and other hazards as a result of the cover member extending substantially beyond the outer wall surface.

What is needed therefore is a device for mounting an electrical box in a manner that the electrical box and its cover are flush with or recessed from the outer wall surface. The box and cover member in the closed position are therefore protected against any accidental contact by lawn equipment, vehicles, or other hazards.

The invention is an electrical box assembly including a frame member and an outlet box assembly having an outlet box and a hinged cover. The frame member includes a peripheral flange and inward sloping sidewalls that extend to a rear panel having a central opening therein. The outlet box includes a flange and a rearward extending sidewall portion. The frame member can be secured to a wall and the rearward extending sidewall of the outlet box inserted into the central opening of the frame member until the flange of the outlet box seats against the rear panel of the frame member. The panel of the frame member is recessed a substantial distance from the front edge of the frame member, thereby ensuring that the outlet box assembly and hinged cover in a closed configuration will be flush with or recessed within the outer surface of the wall.

Several advantages are achieved with the frame member and electrical box combination of the present invention, including:

(1) The frame member recesses the electrical box and cover flush with or within the outer wall surface thereby protecting the box and cover assembly from dings and nicks. (2) In a stucco version of the frame member, a forward extending wall on the frame member provides a screed line for evenly applying stucco around the frame member. (3) In a stucco version of the frame member, a flange extending laterally from the periphery of the frame member includes a perforated surface for enhancing stucco adhesion to the frame member. (4) A further advantage is that the frame member and electrical box combination provides a first enclosure that positions the electrical device within the exterior wall, thereby shielding the electrical device from impacts, and a second enclosure for shielding the electrical device from rain and other environmental elements. (5) The current frame member and electrical box combination provides, when used to house a duplex outlet, an electrical box and a spacious protective enclosure for protecting the plug ends of electrical cords.

These and other objects and advantages of the present invention will be better understood by reading the following description along with reference to the drawings.

FIG. 1 is a perspective view of a preferred embodiment of a frame member that forms a portion of a frame member and electrical box combination according to the present invention.

FIG. 2 is a front view of the frame member of FIG. 1 .

FIG. 3 is a top view of the frame member of FIG. 2 .

FIG. 4 is a sectional view of the frame member taken along line 4 - 4 of FIG. 2 .

FIG. 5 is a side view of the frame member of FIG. 2 .

FIG. 6 is a sectional view of the frame member taken along line 6 - 6 of FIG. 2 .

FIG. 7 is a side view of a covered electrical box in alignment with the preferred embodiment of the frame member to which it will be secured to form the electrical box mounting assembly of the present invention.

FIG. 8 is a side view of a covered electrical box secured to a frame member.

FIG. 9 is a perspective view of a covered electrical box in alignment with the preferred embodiment of the frame member.

FIG. 10 is a perspective view of a covered electrical box secured to a frame member according to the present invention.

FIG. 11 is a bottom view of an electrical box according to the present invention.

FIG. 12 is a bottom view of a cover member according to the present invention.

FIG. 13 is a bottom view of the cover member of FIG. 12 in a closed configuration on the electrical box of FIG. 11 .

FIG. 14 is a front view of a second embodiment of a frame member according to the present invention.

FIG. 15 is a sectional view of the frame member taken along line 15 - 15 of FIG. 14 .

FIG. 16 is a sectional view of the frame member taken along line 16 - 16 of FIG. 14 .

FIG. 17 is a rear view of the frame member of FIG. 14 .

FIG. 18 is a top view of a covered electrical box in alignment with the second embodiment of the frame member to which it will be secured to form the electrical box mounting assembly of the present invention.

The following is a listing of part numbers used in the drawings along with a brief description:

The present invention comprises an electrical box assembly for securing an electrical device to the exterior wall of a building. The electrical box assembly enables mounting a covered outlet box to the wall in such a manner that the cover and box are either flush or recessed within the surface of the wall.

With reference to FIG. 9 there is shown a preferred embodiment of the electrical box mounting assembly 20 including a frame member 22 , and an outlet box assembly 23 including an outlet box 24 and a hinged cover 26 .

As shown in FIGS. 1 and 2 , the preferred embodiment of the frame member 22 includes sidewalls 28 , an outward extending peripheral flange 30 , a panel 32 , and a central opening 34 . Apertures 36 are provided in the panel 32 of the frame member 22 . The peripheral flange 30 of the frame member 22 includes a plurality of openings 38 and slots 40 therein. The peripheral flange 30 includes four corners 42 each and a slot 40 in each of the corners.

Referring to FIGS. 3-6 , sidewalls 28 of the frame member 22 include a rear end 44 with the panel 32 extending orthogonally inward from the rear end 44 of the sidewalls 28 . The sidewalls 28 include a first sidewall portion 46 extending forward from the peripheral flange 30 to a planar front edge 48 . A second sidewall portion 50 extends rearward from the peripheral flange 30 to the rear end 44 . Preferably the sidewalls 28 are sloped inwards and extend at an angle θ (see FIG. 6 ) of between 50 and 70 degrees with respect to the front edge 48 .

With reference to FIG. 7 there is shown a side view of the outlet box assembly 23 in alignment with a frame member 22 to which it will be secured to form the electrical box mounting assembly 20 of the present invention. The outlet box assembly 23 includes peripheral sidewalls 52 and a flange 54 extending outwardly from the sidewalls 52 . The outlet box assembly 23 includes a front sidewall portion 56 extending forward from the flange 54 to a front edge 57 and a rear sidewall portion 58 extending rearward from the flange 54 . Fasteners 60 are inserted through the slots 40 in the peripheral flange 30 to secure the frame member 22 to the substrate 61 . A fastening arrangement 62 for securing the outlet box assembly 23 to the frame member 22 includes apertures 64 in the flange 54 and fasteners 66 for securing through the apertures 64 of the outlet box assembly 23 and into the apertures 36 in the panel 32 of the frame member 22 . A primary objective of the present invention is to provide a mounting assembly that will mount an electrical box and its closed cover below the surface of the wall. The present invention accomplishes that by providing a frame member 22 with a depth from the panel 32 to the front edge 48 , distance D 1 in FIG. 7 , that is greater than the distance D 2 between the back side of flange 54 and front side of the cover 26 of the outlet box assembly 23 with the cover 26 in a closed configuration. Thus the entire outlet box assembly 23 will be situated within the outer front edge 48 of the frame member 22 and therefore protected from damage by lawn equipment and similar hazards.

After the frame member 22 is secured to the substrate 61 and the outlet box assembly 23 is secured to the frame member 22 as shown in FIG. 8 , the flange 54 of the 15 ′ outlet box 24 is flush against the panel 32 of the frame member 22 . The hinged cover 26 of the outlet box assembly 23 , when it is in the closed configuration as shown in FIG. 8 , and the front sidewall portion 56 of the outlet box assembly 23 do not extend beyond the plane 68 (dashed line) defined by the planar front edge 48 of the frame member 22 .

As shown in FIG. 11 , the front sidewall portion 56 of the outlet box assembly 23 includes first U-shaped slots 70 extending inward from the front edge 57 and posts 72 extending outward from the front sidewall portion 56 . Knockouts 73 are provided in the rear sidewall portion 58 of the outlet box 24 .

As shown in FIG. 7 , the cover 26 includes a peripheral wall 74 with apertures 76 therein in ears 78 extending from the peripheral wall 74 . The cover 26 is hinged to the outlet box assembly 23 by the posts 72 extending through the apertures 76 in the cover 26 . The hinged cover 26 therefore is capable of rotating from a closed configuration as shown in FIG. 7 to an open configuration.

With reference to FIG. 12 , the peripheral wall 74 of the cover member 26 includes an edge 80 and second U-shaped slots 82 extending inward from the edge 80 into the peripheral wall 74 . The cover 26 , when placed in the closed configuration as shown in FIG. 13 , includes circular cord openings 84 formed by the first U-shaped slots 70 of the outlet box assembly 23 in alignment with the second U-shaped slots 82 of the cover 26 .

After the frame member 22 and outlet box assembly 23 are secured to the substrate 61 , as shown in FIG. 8 , stucco 86 is applied over the peripheral flange 30 of the frame member 22 . After the stucco 86 is applied, the outlet box 24 and cover 26 are recessed within the outer surface 88 of the wall. The openings 38 in the peripheral flange 30 of the frame member 22 promote adherence of the stucco 86 to the peripheral flange.

As shown in FIG. 6 , the sidewalls 28 of the frame member 22 are generally sloped inwards and extend at an angle θ with respect to the planar front edge 48 . As shown at the lower end of the figure, the inner surface 90 of first sidewall portion 46 and a major portion of the second sidewall portion 50 are sloped inward at a constant slope. A third sidewall portion 92 is orthogonal to the front edge 48 and orthogonal to the panel 32 .

Preferably the frame member 22 , the outlet box 24 , and the cover member 26 of the present invention are each molded in one-piece of plastic.

Referring to FIG. 14 there is shown a second embodiment of a frame member 100 according to the present invention. The second embodiment of the frame member 100 is for use on a structure that will be covered with siding rather than stucco. Similar to the first embodiment, the second embodiment of the frame member 100 includes sidewalls 28 , a panel 32 having apertures 36 therein, and a central opening 34 .

With reference to FIGS. 15 and 16 , the frame member 100 includes a front edge 102 on the sidewalls 28 , a second flange 104 extending outward from the front edge 102 , and an outer wall 106 extending rearward from the front edge 102 at a 90 degree angle from the second flange 104 and terminating in a rear edge 108 . A peripheral flange 109 including four arms 110 extend outward from the rear edge 108 of the outer wall 106 . The back side 112 of the arms 110 are planar with the rear end 44 of the sidewalls 28 . A channel 114 extends along the outer wall 106 between the arms 110 and the second flange 104 . The arms 110 each include a slot 116 therein.

Referring to FIG. 18 , the outlet box assembly 23 is shown in alignment with the central opening 34 and flush against the panel 32 of the second embodiment of the frame member 100 . The frame member 100 is secured to a substrate 61 with fasteners 60 as shown. The fastening arrangement 62 includes apertures 36 in the panel 32 of the frame member 100 , apertures 64 in the flange 54 of the outlet box assembly 23 and fasteners 66 for securing through the apertures 64 of the outlet box assembly 23 and into the apertures 36 in the panel 32 portion of the frame member 100 . By tightening of the fastening arrangement 62 , the flange 54 of the outlet box assembly 23 is secured flush against the panel 32 of the frame member 100 .

With reference to FIG. 18 , after the frame member 100 is secured to the substrate 61 and the outlet box assembly 23 is secured to the frame member 100 , siding 118 is installed around the channel 114 and butted up against the outer wall 106 . Caulk 120 can be added at the edge 122 of the second flange 104 and the siding 118 to seal the outlet box assembly against moisture penetration.

Having thus described the invention with reference to a preferred embodiment, it is to be understood that the invention is not so limited by the description herein but is defined as follows by the appended claims.