U.S. patent application number 09/873695 was filed with the patent office on 2002-02-21 for electrical outlet box.
Invention is credited to Reiker, Kenneth H..
Application Number | 20020020542 09/873695 |
Document ID | / |
Family ID | 26839178 |
Filed Date | 2002-02-21 |
United States Patent
Application |
20020020542 |
Kind Code |
A1 |
Reiker, Kenneth H. |
February 21, 2002 |
Electrical outlet box
Abstract
An electrical outlet box includes channels in a female member
for receiving in spaced apart relationship three conductors of an
uncut electrical cable. One or more sets of three receivers mounted
in a male member for electrically engaging each conductor
interconnects the conductors of the cable and defines an electrical
socket of a socket assembly of the electrical outlet box. A cover
is attachable to the male member for covering the space between the
socket assembly and the surrounding wall board aperture. Fittings
are included and formed as part of the electrical outlet box to
permit back to back attachment of a pair of electrical outlet boxes
and for side by side mounting in a ganged manner of two or more
electrical boxes. Routing of the cable in slots in the studs of a
wall is described along with a retainer for retaining the cable in
the slots.
Inventors: |
Reiker, Kenneth H.;
(Shalimar, FL) |
Correspondence
Address: |
Joel D. Myers, Esq.
Myers & Associates,
Intellectual Property Law, P.C.
1827 Powers Ferry Road Building 3, Suite 200
Atlanta
GA
30339
US
|
Family ID: |
26839178 |
Appl. No.: |
09/873695 |
Filed: |
June 4, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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09873695 |
Jun 4, 2001 |
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09602884 |
Jun 26, 2000 |
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6259023 |
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60141500 |
Jun 28, 1999 |
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60205708 |
May 19, 2000 |
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Current U.S.
Class: |
174/53 |
Current CPC
Class: |
H01R 4/2433 20130101;
H01R 9/2458 20130101; H02G 3/126 20130101; H01R 9/22 20130101 |
Class at
Publication: |
174/53 |
International
Class: |
H01H 009/02 |
Claims
What is claimed is:
1. An electrical outlet box, said electrical outlet box comprising
in combination: (a) female member including three channels, each
channel of said three channels receiving an uncut conductor of a
three conductor cable, and a flange extending laterally for
mounting said electrical out box; (b) a male member including at
least a set of three receivers for engaging the conductors of the
cable, each receiver of each said set of three receivers being
slotted to pierce any insulation about an engaged conductor of the
cable and to electrical interconnect with the engaged conductor of
the cable, said male member including a socket assembly for
receiving a conventional three prong electrical plug and
electrically engaging the prongs of the plug with one set of said
sets of three receivers; (c) attachment means for securing said
male member with said female member; (d) said male member including
at least a set of three cavities for housing said set of three
receivers to position and maintain said set of three receivers in
place upon securing said male member with said female member.
2. An electrical outlet box as set forth in claim 1 including a
cover attachable to said male member, said cover including a
plurality of studs for penetrably engaging corresponding apertures
in said male member to selectable degree of penetration.
3. An electrical outlet box as set forth in claim 2 wherein each
stud of said plurality of studs includes a plurality of bells for
selectively engaging said apertures.
4. An electrical outlet box as set forth in claim 1 including means
for mounting a pair of said electrical outlet boxes back to back,
said mounting means being disposed at the back of said female
member and including a plurality of posts at the back of said
female member and defining an inscribed circle and a further post
having a diameter not less than the diameter of the circle defined
by said plurality of posts whereby said post of one of said
electrical outlet boxes will mate with and be retained by said
plurality of posts of another of said electrical outlet boxes.
5. An electrical outlet box as set forth in claim 4 wherein the
back of each said female member includes a pair of said plurality
of posts and a pair of said further posts.
6. An electrical outlet box as set forth in claim 1 including at
least two of said outlet boxes and means for mounting said
electrical outlet boxes side to side, said mounting means including
a pair of spaced apart studs disposed proximate the lower edge of
one side of said female member of one of said outlet boxes and a
pair of indentations disposed proximate the lower edge of an
opposing side of said female member of another of said outlet
boxes, whereby said pair of studs of one electrical box of said
pair of electrical outlet boxes will mate with and engage said pair
of indentations of the other electrical outlet box of said
electrical outlet boxes.
7. An electrical outlet box as set forth in claim 6 wherein one of
said electrical outlet boxes includes a further indentation for
receiving said flange of the other electrical outlet box of said
electrical outlet boxes and retention means for retaining said
flange within said one of said electrical outlet boxes.
8. An electrical outlet box as set forth in claim 7 wherein said
female member includes a pair of ledges on opposed sides for
supporting the cable into and out of said female member and wherein
said male member includes a further pair of ledges mating with said
pair of ledges of said female member for retaining the cable
therebetween.
9. An electrical outlet box as set forth in claim 1 including a
pair of ledges extending from opposed sides of said female member
for supporting the cable and a further pair of ledges extending
from opposed sides of said male member for clamping the cable
between said pair of ledges and said further pair of ledges.
10. An electrical outlet box as set forth in claim 1 including an
open ended isolated compartment disposed in said female member and
a pair of knockouts for accommodating access to said component by
two or more conductors of the cable to be electrically connected
within said compartment.
11. An electrical outlet box as set forth in claim 10 including a
cover for covering the open end of said compartment and shield any
electrical connection therein.
12. An electrical outlet box as set forth in claim 1 wherein each
receiver of each said set of three receivers includes a clamp for
gripping and electrically engaging a further conductor.
13. An electrical outlet box as set forth in claim 12 wherein each
said clamp includes a channel for receiving the conductor and an
arm for urging electrical contact between said channel of said
clamps and the further conductor.
14. An electrical outlet box as set forth in claim 13 wherein said
arm includes an end bent toward said channel of said clamps for
engaging the further conductor.
15. An electrical outlet box as set forth in claim 1 wherein each
receiver of said set of three receivers includes at least one key
and each cavity of said set of three cavities includes a slot for
receiving said key of an inserted receiver of said set of three
receivers.
16. An electrical outlet box as set forth in claim 1 wherein each
slotted receiver of said set of three receivers includes a slot
defined by a pair of tabs for electrically engaging the respective
conductor of the cable.
17. An electrical outlet box as set forth in claim 16 including a
plate having a plurality of apertures, each of said apertures being
dimensioned to penetrably receive one pair of said tabs of each
receive of said set of three receivers and retention means for
retaining said plate adjacent said set of three cavities.
18. An electrical outlet box as set for the in claim 16 wherein
each receiver of said set of three receivers includes two spaced
apart pairs of said pair of tabs to define a pair of spaced apart
slots for engaging the respective conductor of the cable.
19. An electrical outlet box as set forth in claim 18 wherein each
receiver of said set of three receivers includes a pair of
resilient arms for gripping therebetween the prong of a plug
plugged into said socket assembly.
20. An electrical outlet box as set forth in claim 19 wherein each
receiver of said set of three receivers includes a third resilient
arm orthogonal to said pair of arms.
21. An electrical outlet box as set forth in claim 20 wherein each
cavity of said set of three cavities includes a pair of opposed
slots and wherein each third arm of each receiver of said set of
three receivers includes a pair of keys extending in opposed
directions for engaging said opposed slots of the respective cavity
of said set of three cavities.
22. An electrical outlet box as set forth in claim 18 including a
plate having three pairs of apertures, each said pair of apertures
being dimensioned to receive said spaced apart pair of said pair of
tabs to stabilize said set of three receivers upon engagement with
the respective ones of the conductors of the cable.
23. An electrical outlet box as set forth in claim 22 wherein said
male member, said female member, said socket assembly and said
plate are of dielectric material.
24. An electrical outlet box as set forth in claim 1 wherein said
male member, said female member and said attachment means are of
dielectric material.
25. An electrical outlet box as set forth in claim 1 wherein said
female member includes at least a pair of wall sections and said
attachment means comprises at least one slot formed in an edge of
each of said wall sections and an aperture disposed adjacent each
of said at least one slot and wherein said male member includes at
least a pair of male studs, each of said male studs engaging at
least one of said slots, each said male stud including a lip for a
snap fit with the corresponding one of said apertures.
26. An electrical outlet box as set forth in claim 25 wherein said
at least one slot comprises a first pair of slots disposed in one
of said wall sections spaced apart for a first distance and a
second pair of slots disposed in another of said wall sections
spaced apart for a second distance and wherein said at least pair
of male studs comprises a first pair of male studs spaced apart the
first distance for engaging said first pair of slots and a second
pair of male studs placed apart the second distance for engaging
said second pair of slots.
27. An electrical outlet box as set forth in claim 26 wherein the
first and second distances are not equal, whereby said male member
can be attached to said female member only in a predetermined
orientation therebetween.
28. An electrical outlet box as set forth in claim 1 wherein each
channel of said set of three channels is defined by pairs of
ridges, each ridge of aid pairs of ridges being at least partly
discontinuous to accommodate insertion of a part of a respective
receiver of aid set of three receivers intermediate the
discontinuous segments of respective ridges of said pairs of
ridges.
29. An electrical outlet box as set forth in claim 1 wherein each
channel of said set of three channels is defined by adjacent pairs
of ridges, each ridge of each of said pairs of ridges being at
least partly discontinuous to accommodate insertion of a part of a
respective receiver of said set of three receivers coincident with
the discontinuities of the respective ridge of said pairs of
ridges.
30. A method for mounting an electrical outlet box, said method
comprising the steps of: (a) attaching a female member of the
electrical outlet box to a wall stud, which female member includes
three channels; (b) laying an uncut cable through the female
member, including the steps of laying each conductor of the cable
into a separate one of the three channels; (c) mating a male member
of the electrical outlet box with the female member, which male
member includes at least a set of three receivers, said step of
mating including the steps of electrically engaging each conductor
of the cable with a corresponding receiver of the set of three
receivers defining a socket of the electrical outlet box; and (d)
securing said male member with said female member.
31. The method as set forth in claim 30 wherein the electrical
outlet box includes socket assembly comprising a pair of sockets,
each of the sockets including the set of three receivers and
wherein said step of mating includes the step of engaging each
conductor of the cable with a corresponding receiver of each of the
sets of receivers.
32. The method as set forth in claim 30 wherein said step of mating
comprises the step of piercing any insulation about the conductor
of the cable with each receiver of each of three sets of receivers
to make electrical contact with the conductor of the cable.
33. The method as set forth in claim 30 wherein the male and female
members are of electrically non-conducting material and including
the step of limiting flow of electrical power directly and solely
from the conductors of the cable to the receivers.
34. The method set forth in claim 30 wherein said step of securing
includes the steps of securing the male member to the female member
with a snap fit.
35. The method set forth in claim 30 wherein said step of securing
includes the step of inserting screws through the male member into
threaded engagement with the female member.
36. The method set forth in claim 34 wherein said step of securing
includes the step of inserting screws through the male member into
threaded engagement with the female member.
37. The method set forth in claim 30 including the step of affixing
a cover to the male member.
38. The method set forth in claim 37 wherein said step of affixing
includes the step of inserting studs extending from the cover into
corresponding apertures in the male member.
39. The method set forth in claim 38 wherein the studs include a
plurality of bells and wherein said step of inserting includes the
step of inserting a selected member of bells of each of said studs
into the corresponding aperture.
40. The method set forth in claim 30 wherein said step of mating
includes the step of mounting two electrical outlet boxes back to
back, said step of mounting including the step of engaging at least
one tube at the back of one female member of one of the electrical
outlet boxes intermediate at least a set of tubes at the back of an
adjacent female member of the other of the electrical outlet
boxes.
41. The method set forth in claim 40 including a pair of tubes
disposed at the back of the one female member of the one electrical
outlet box and a pair of sets of tubes at the back of the adjacent
female member of the other of the electrical outlet boxes and
wherein said step of mounting comprises the step of engaging each
tube of the pair of tubes of the one female member with one set of
tubes of the pair of sets of tubes of the other female member.
42. The method set forth in claim 40 wherein the back of each
female member of each of the electrical outlet boxes includes a
pair of tubes and a pair of sets of tubes and wherein said step of
mating comprises the step of engaging the pair of tubes and pair of
sets of tubes of one female member of the one electrical outlet box
with the pair of sets of tubes and pair of tubes, respectively, of
the other female member of the other electrical outlet box.
43. An electrical out box, said electrical out box comprising in
combination: (a) a female member, said female member including at
least one set of three channels for supporting the conductors of an
uncut three conductor cable extending through said female member;
(b) a male member for penetrably engaging said female member in a
fixed orientation relative to said female member, said male member
including a three hole socket for receiving the prongs of a three
prong electrical plug, said male member including three cavities
positionally corresponding with said three holes of said socket and
with of said at least one set of three channels; (c) a receiver
inserted into and supported by each of said cavities, each of said
receivers including a pair of opposed resilient arms for gripping a
respective prong of said plug plugged into said socket, a pair of
tabs defining a slot therebetween for engaging and making
electrical contact with a conductor of the cable disposed in one
channel of said set of three channels and corresponding with the
cavity supporting said receiver upon mating said male member with
said female member; and (d) attachment means for securing said male
member mated with said female member.
44. An electrical outlet box as set forth in claim 43 including at
least two electrical outlet boxes and interlock means disposed in
the bottom of said female member for interlocking the bottom of
said female member of one of said electrical outlet boxes with the
bottom of said female member of another of said electrical outlet
boxes.
45. An electrical outlet box as set forth in claim 43 including at
least two electrical outlet boxes and interlock means disposed on
opposed sides of said female member for interlocking one side of
one female member of one of said electrical outlet boxes with
another side of another female member of another of said electrical
outlet boxes.
46. An electrical outlet box as set forth in claim 43 including a
flange extending from said female member for attachment to a wall
stud to mount said electrical outlet box.
47. An electrical outlet box as set forth in claim 43 including a
ledge extending from each of opposed sides of said electrical
outlet box for supporting the cable at the ingress and egress of
the cable.
48. An electrical outlet box as set forth in claim 43 wherein each
receiver of said set of three receivers includes a clamp for
gripping and electrically connecting an end of a further
conductor.
49. An electrical outlet box as set forth in claim 43 wherein each
of said receivers includes two pairs of tabs defining two slots for
engaging and making electrical contact with the respective
conductor of the cable.
50. An electrical outlet box as set forth in claim 43 including an
apertured plate for penetrably receiving said pairs of tabs and
providing support for said set of three receivers.
51. An electrical outlet box as set forth in claim 43 wherein the
cable is routed through slots formed in a stud of a wall and
including a retainer for retaining the cable in a slot, each said
retainer comprising a hat retainer for insertion into the slot and
an element for contacting the stud to maintain said retainer in the
stud.
52. An electrical outlet box as set forth in claim 51 wherein said
element comprises a prong for penetrating the stud.
53. An electrical outlet box as set forth in claim 51 wherein said
element comprises a bend compressible against the respective slot.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation application of and
claims priority to non-provisional application entitled "Electrical
Outlet Box" filed Jun. 26, 2000, having assigned Ser. No.
09/602,884, wherein non-provisional application 09/602,884 claims
priority to a provisional application entitled "Electrical Outlet
Box", filed Jun. 28, 1999 and assigned Ser. No. 60/141,500, and to
a provisional application entitled "Electrical Receptacle With
Straight-Through Wiring", filed May 19, 2000 and assigned Ser. No.
60/205,708, which applications are incorporated herein by
reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to electrical outlets and,
more particularly, to an electrical outlet box for receiving and
electrically engaging an uncut three conductor electrical cable for
providing electrical power to sockets selectively engageable by
conventional electrical plugs.
[0004] 2. Description of Related Art
[0005] Conventional wall mounted electrical outlets include a box,
whether of metal or plastic, for receiving three conductor
electrical cables. The terminal end of each conductor is
mechanically fastened to corresponding electrical contacts of a
conventional socket assembly. One or more apertures in the box are
present to permit ingress of a cable and egress of another cable.
In the event of the latter, the ends of each conductor of such
cable must be attached to the corresponding electrical connections
of the outlet socket assembly. Alternatively, corresponding
conductors of each cable must be electrically and mechanically
secured to one another with a device known as a wire nut. A
pig-tail conductor is secured by each wire nut to each conductor to
provide electrical power to the corresponding electrical contact of
the socket assembly. When two sockets of each socket assembly are
present, as is conventional, further pig-tails must be used to
connect the sockets in parallel.
[0006] The amount of time and effort to cut and then insert the end
of each cable into the electrical box is time consuming. Additional
time and numerous separate operations must be carried out to effect
the appropriate electrical connections.
[0007] Each cable must be routed through the studs of a wall from
one location of an electrical box to another. This requires
drilling holes in each intervening stud and threading the cable
therethrough. Such work is time consuming and laborious.
[0008] Conventional electrical outlet boxes are secured to a wall
stud by nails or the like. A cutout is provided in the wall board
of the wall through which the electrical outlet box extends to
position the socket assembly essentially flush with the exterior
surface of the wall board. An apertured cover plate, penetrably
receiving the terminal end of each socket of the socket assembly,
is affixed to the electrical outlet box by screws. Often, due to
sloppy workmanship or inattention, the electrical outlet box is not
in proper alignment with the wall board. This results in a skewed
attachment of the cover plate since no provision for aligning the
cover plate with the wall board is provided. The result is
aesthetically displeasing.
[0009] Generally, the major expense attendant wiring a house, or
any building, is the cost of the labor involved as the parts,
including the cables, are inexpensive relative to the total cost.
By reducing the labor costs of skilled electricians through a
reduction in time spent, significant savings may be effected.
SUMMARY OF THE INVENTION
[0010] The female member of an electrical outlet box includes an
apertured flange for attachment by nails or screws to a stud. After
attachment, an uncut conductor cable is laid through the electrical
outlet box after the insulating sheath surrounding the three
conductors has been cut and removed to expose the three insulated
conductors. Each conductor is placed within a corresponding channel
to physically spread the conductors apart from one another. A male
member of the electrical outlet box is inserted into the female
member, which insertion causes receivers to penetrate the
insulation of each respective conductor and made an electrical
contact therewith. Each receiver corresponds with a prong of a
conventional grounded three prong plug to electrically connect the
plug with the corresponding electrical conductors upon insertion of
the plug into a socket. Thereby, all of the conventional steps of
cutting and attaching the electrical conductors extending into an
electrical outlet box are eliminated.
[0011] Each receiver may include one or more spring loaded tangs
for receiving and electrically connecting a further conductor of a
further cable. A positional cover plate is placed flush with the
surface of the wall board surrounding the electrical outlet box and
accommodates for any misalignment of the electrical outlet box
relative to the surface of the wall board. Male and female
attachments are provided in each electrical outlet box to permit
side by side and/or back to back mounting of a plurality of
electrical outlet boxes. Moreover, a single uncut cable is serially
routed through each electrical outlet box. To enhance routing of
cables through a wall, a slot may be cut in each stud to receive
the cable and eliminate threading of the cable through a hole. A
retainer engages the stud to maintain the cable in the slot.
[0012] It is therefore a primary object of the present invention to
provide an electrical outlet box which provides electrical power to
a conventional outlet without requiring cutting of any conductors
of an electrical cable supplying electrical power to the electrical
outlet box.
[0013] Another object of the present invention is to provide an
easy to install and electrically connect electrical outlet box.
[0014] Still another object of the present invention is to provide
a two part plastic electrical outlet box which upon assembly
automatically provides electrical connection between a socket and
an uncut electrical cable laid therein.
[0015] Yet another object of the present invention is to provide an
electrical outlet box of nonelectrically conductive material except
for receivers electrically connecting conductors of an uncut
electrical cable passing therethrough to provide electrical power
to a plug plugged into a socket.
[0016] A further object of the present invention is to provide an
inexpensive electrical outlet box installable by an electrician
with minimal instruction.
[0017] A yet further object of the present invention is to reduce
the costs of electrically wiring a wall of a building or other
facility.
[0018] A still further object of the present invention is to
provide a method for inexpensively wiring a building or other
facility.
[0019] These and other objects of the present invention will become
apparent to those skilled in the art as the description thereof
proceeds.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The present invention will be described with greater
specificity and clarity with reference to the following drawings,
in which:
[0021] FIG. 1 is an isometric view of the top and two sides of an
electrical outlet box;
[0022] FIG. 2 is a partial cut-out side view of the electrical
outlet box showing certain components;
[0023] FIG. 3 illustrates the electrical outlet box attached to a
stud of a conventional wall with a plurality of conductors
extending to and from the electrical box;
[0024] FIG. 4 is an isometric view of the bottom and two sides of
the female member of the electrical outlet box;
[0025] FIG. 5 is an isometric view of the interior and two sides of
the female member of the electrical outlet box;
[0026] FIG. 6 illustrates a cable laid within the female member of
the electrical outlet box;
[0027] FIG. 7 illustrates an isolated compartment within the female
member of the electrical outlet box for electrically connecting two
or more conductors;
[0028] FIG. 8 illustrates a cover for closing the compartment
illustrated in FIG. 7 to shield any electrical connection made
therein;
[0029] FIG. 9 is an isometric view of the interior of the male
member;
[0030] FIG. 10 is a view of the cavities disposed in the male
member for supporting the receivers;
[0031] FIG. 11 illustrates cover plates attached to the male member
for retaining the receivers within their respective cavities;
[0032] FIG. 12 illustrates a cover for attachment to the male
member of the electrical outlet box;
[0033] FIG. 13 illustrates the bottom of the cover;
[0034] FIG. 14 is a side view of the cover;
[0035] FIG. 15 is an isometric view of two sides of a receiver;
[0036] FIG. 16 is an isometric of two other sides of a
receiver;
[0037] FIG. 17 is a representative view of a conventional grounded
electrical plug engaging a set of three receivers mounted within
the male member of the electrical outlet box, and illustrates an
electrical conductor electrically attached to and extending from
each receiver;
[0038] FIG. 18 is a side view of the relationship of three
receivers mounted within a male member of the electrical outlet
box;
[0039] FIG. 19 illustrates a plurality of ganged electrical outlet
boxes and a common uncut electrical cable extending serially
through each;
[0040] FIG. 20 illustrates a plurality of ganged electrical outlet
boxes having further electrical outlet boxes connected thereto back
to back and a n uncut electrical cable extending serially through
each;
[0041] FIG. 21 illustrates a pair of electrical outlet boxes
interconnected back to back and an uncut electrical cable extending
serially therethrough;
[0042] FIG. 22 representatively illustrates a plurality of
electrical outlet boxes mounted to studs of a wall and
interconnected through a common uncut cable;
[0043] FIG. 23 illustrates an electrical outlet box attached to a
stud of a wall and a cable extending therefrom nested within and
secured to slots formed in each stud;
[0044] FIG. 24 illustrates a slot in a stud for retaining a cable
and a retainer attached thereto to secure the cable in place;
[0045] FIG. 25 illustrates a retainer of the type shown in FIG. 23;
and
[0046] FIG. 26 illustrates a variant retainer for use to retain a
cable within a slot.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0047] Referring to FIG. 1, there is shown an electrical outlet box
10 for providing electrical power to each of sockets 12, 14
disposed in socket assembly 16. The electrical outlet box includes
a female member 20 into which a male member 22 (see FIG. 2) is
attached and a cover 24 having an aperture 26 through which socket
assembly 16 protrudes. A flange 28 extends laterally from female
member 20 and includes apertures 29 for penetrably receiving nails,
screws, or the like to attach electrical outlet box 10 adjacent a
wall stud of a wall and serves in the manner of a mounting for the
electrical outlet box.
[0048] An overview of electrical outlet box 10 is provided in FIG.
2. An electrical cable 30 enters the electrical outlet box
intermediate the junction between female member 20 and male member
22 through an aperture defined by ledges 32, 34. Similarly, the
cable exits from the electrical outlet box intermediate the male
and female members through an aperture defined by ledges 36, 38.
Ledges 32, 36 are a part of female member 20 and ledges 34, 38 are
a part of male member 22. The portion of cable 30 interior of the
electrical box has been stripped of its external sheath to expose
the conventional three insulated conductors, of which one conductor
is ground. These three insulated conductors are collectively
identified by reference numeral 40. Each of three channels are
formed in female member 20 to receive in spaced apart relationship
one of conductors 40. Socket 12, formed in male member 22, includes
three receivers 42 of identical configuration and located by male
member 22 in such way that each receiver corresponds with one of
conductors 40. Receivers 42 of socket 14 are similarly located. On
joining the male member with the female member, each of receivers
42 penetrates the insulation about the respective conductor to make
electrical contact therewith. Thereby, each of sockets 12 and 14
are in electrical contact with the three conductors of cable 30 and
will provide electrical power to a conventional grounded three
prong plug plugged into either of sockets 12, 14. After male member
22 has been inserted into female member 20, it is retained in place
by a plurality of screws or bolts 44. From this description, it
will be apparent that cable 30 is not cut to provide electrical
power to either of sockets 12 or 14 and the cable is continuous
through the electrical outlet box.
[0049] FIG. 3 illustrates a typical mounting of electrical outlet
box 10. Female member 20 is placed adjacent a stud 50 found in a
typical wall construction to locate flange 28 adjacent a surface of
the stud. The female member is secured to the stud by bolts or
screws penetrating apertures 29 into threaded engagement with the
stud. Alternatively, nails or tacks may be used for this purpose or
other fastening devices may be used. After the female member has
been mounted on the stud, cable 30 is laid therein. Upon insertion
of male member 22, sockets 12 and 14 will be in electrical contact
with the corresponding conductors within the cable. Screws or bolts
44 (see FIG. 2) are inserted through apertures 46 and into the
threaded engagement with the female member to retain the male
member in place. As will be discussed in further detail below, the
conductors within additional cables 52, 54 may be attached to
corresponding receivers 42 of either of sockets 12, or 14 to
provide electrical power to other locations.
[0050] FIG. 4 illustrates a view of the bottom of female member 20.
The bottom is divided into essentially four sections. Section 60
includes two sets of four tubes 62 and 64. Section 66 includes a
single tube 68 having a diameter essentially corresponding with a
circle inscribed by the tubes of each set of tubes 62 and 64.
Section 70 also includes a tube 72 of a diameter equivalent to a
circle inscribed by either of set of tubes 62, 64. Upon placement
of two electrical boxes back to back, tubes 68, 72 of one female
member will nest within set of tubes 64, 62, respectively, of the
other female member. By having the fit between the respective tubes
a tight fit, the two electrical outlet boxes will be secured to or
interlocked with one another. Thus, these tubes and sets of tubes
form a mounting means or interlocking means for securing two female
members (electrical outlet boxes) back to back.
[0051] Section 74 is essentially a closed compartment that may be
covered by a cover shown in FIG. 8. A pair of knockouts 76, 78 are
disposed in wall 80. By removing the knockouts, conductors (as
shown in FIG. 7) are insertable through the resulting apertures and
may be electrically joined to one another within section 74. Thus,
section 74 provides a mechanically closed compartment to shield any
conductors electrically jointed therein and precludes the
possibility of an electrical hazard as a result of any exposed
conductors.
[0052] Slots 82, 84 along with indentations 86, 88 are formed in
side wall 90. These slots and indentations correspond with snap
studs 92, 94 (see also FIG. 5) to mechanically lock (interlock)
adjacent female members to one another to create a side by side
gang of electrical outlet boxes mechanically interconnected with
one another. That is, lip 96 of snap stud 92 of one female member
is placed adjacent the inner surface of wall 90 of another female
member. Lip 98 of snap stud 94 is similarly placed adjacent the
rear surface of wall 90 of the other female member. Upon such
joining, base 100 of snap stud 92 and base 102 of snap stud 94 will
rest within indentations 88, 86, respectively. A protrusion 104 at
the extremity of lip 96 and a protrusion 106 at the extremity of
lip 98 will become lodged in slots 82 and 84, respectively to lock
the interconnection therebetween. To accommodate such side by side
mounting of a pair of female members, an indentation in the wall
108 (which is opposed to wall 90), includes an indentation 110 to
accommodate and receive flange 28. Thereby, wall 90 of one female
member will be flush or adjacent wall 108 of a joined female
member. Thus, these elements form a mounting means or interlock
means for receiving two female members (electrical outlet boxes)
side to side.
[0053] Apertures 112, 114 are formed in indentations 116, 118 of
wall 90. Corresponding apertures 120, 122 are disposed in
indentations 124, 126 in wall 108 of the female member (see FIG.
5). These apertures are intended to permit insertion of bolts to
mechanically secure two or more female members adjacent one another
in ganged fashion. Each of apertures 112, 114, 120 and 122 may
include a spider shaped head which would flatten out in the event
of over tightening of a penetrating bolt and thereby prevent
cracking or damage to the wall of the corresponding
indentation.
[0054] The interior of female 20 is illustrated in FIG. 5. A pair
of ledges 36, 32 extend from opposed ends of the female member to
provide support for a cable extending through the female member. To
lock the cable in place on their respective ledges, each of the
ledges may include one or more laterally oriented ridges 130.
Furthermore, ledge 32 includes side walls 132, 134 and ledge 36
includes side walls 136, 138 to prevent lateral movement of a
cable. A central segmented channel 140 is disposed intermediate
ledges 32, 28 for receiving the insulated ground conductor of a
cable. Further segmented channels 142, 144 are disposed on opposed
sides of channel 140 for receiving the remaining two insulated
conductors of the cable. Necessarily, the sheath of the cable
surrounding the three conductors must be removed along the segment
of the cable generally corresponding to the interior length of
female member 20.
[0055] Four posts 146, 148, 150 and 152 extend upwardly from bottom
154 of the female member. Upon placement of the flange 28 from an
adjacent female member within indentation 110, apertures 29 of such
flange penetrably engage posts 150, 152 to lock the flange within
the female member and provide a robust attachment between the two
adjacent female members. FIG. 6 is similar to FIG. 5 except that
cable 30 has been inserted therein and electrical conductors 160,
162 and 164 have been lodged within segmented channels 140, 142 and
144, respectively. Similarly, the cable has been placed upon ledges
32, 36 within their respective side walls 132, 134 and 136,
138.
[0056] FIG. 7 specifically illustrates section 70 (see FIG. 4)
available for containing an electrical connection between
conductors 160, 162 inserted through knockouts 76, 78,
respectively. The ends of the conductors may be electrically
interconnected by use of wing nuts 164 or the like. To eliminate an
electrical hazard as a result of an exposed uninsulated conductor
within section 74, a cover 166, as shown in FIG. 8, may be used to
close section 74. The cover may include a depending skirt 168 for
insertion adjacent the interior upper edge of section 74. Top 170
of the cover may be flush with the top of the walls defining
section 74. Preferably, cover 166 is secured in place by a snap
fit, well known to those skilled in the art of making covers.
[0057] Male member 22 will be described with joint reference to
FIGS. 9, 10 and 11. Internal central section 180 defining two sets
of three cavities each is particularly shown in FIG. 10. These sets
of cavities are bounded by side walls 182, 184, 186 and 188.
Cavities 190, 192 and 194 correspond with socket 12 and cavities
196, 198 and 200 correspond with socket 14 (see FIG. 1). A flexibly
resilient receiver is lodged within each of cavities 190, 192, 194,
196, 198 and 200. Each of the cavities includes a pair of slots
204, 206 for receiving corresponding keys of a receiver. Each
receiver includes a slotted pair of tabs 208, 210 defining slots
212, 214, respectively. The edges of these tabs, including the
edges of slots 212, 214 may be tapered or beveled to provide a
cutting function for penetrating the insulation surrounding a
conductor engaged by the slots. As discussed above with respect to
FIGS. 5 and 6, the spaces of segmented channels 140, 142, 144
relate to slots 204, 206 of tabs 208, 210 of the corresponding
receiver to permit translation of each pair of receiver tabs
relative to a conductor to be gripped to permit engagement of the
slots of each receiver with the respective conductor. That is, upon
attachment of the male member to the female member, the receivers
will come into engagement with a corresponding one of the
conductors to create an electrical connection between each receiver
and its corresponding conductor whereby power is applied to each of
sockets 12 and 14. The tabs of the receivers extend into the
discontinuities of the respective ridges defining the channels (as
shown in FIGS. 5 and 6).
[0058] Male member 22 includes a cover element 220 essentially
conforming with the walls of female member 20. Each of male studs
222, 224, 226 and 228 depends from the edge of cover element 220
and includes a base section 230. A lip 232, including a protrusion
extending therefrom, terminates each male stud. Referring to FIG.
6, there are illustrated four slots 240, 242, 244 and 246 disposed
in the edges of opposed wall sections of the female member. These
slots are sized to receive base 230 of corresponding male studs
222, 224, 226 and 228. Apertures 250, 252, 254 and 256 are disposed
adjacent slots 240, 232, 244 and 246, respectively, for engagement
by in a snap fit configuration the corresponding with lip 232 of
each male stud. Thereby, male member 22 is initially attached to
female member 220 with a snap fit. The distance between pair of
slots 240, 242 is a first distance and the distance between pair of
slots 244, 246 is a second distance. To insure correct orientations
of the male member with the female member pair of male studs 222,
224 are the first distance apart and pair of male studs 226, 228
are the second distance apart. As mating of the male member with
the female member can only come about if the male studs are
coincident with the slots, the male member can be attached only one
way with the female member.
[0059] Apertures 260, 262, 264 and 266 in female member 22
correspond with posts 146, 148, 150 and 152, respectively, of male
member 20. After the initial snap fit attachment of the male member
with the female member, bolts or screws 44 (see FIG. 2) are
inserted through these apertures into threaded engagement with the
corresponding posts to prevent any inadvertent disengagement
between the male and female members.
[0060] Ledges 34, 38 of male member 22 are similar to ledges 32, 36
of female member 20 and serve essentially the same function. That
is, each of ledges 34, 38 includes one or more lateral ridges 130
for compressively engaging a part of the cable partially incased
between side walls 270, 272 of ledge 34 and side walls 274, 276 of
ledge 38. The side walls of ledges 34, 38 come into engagement with
the corresponding side walls of ledges 32, 36 to incase the cable
between corresponding pairs of ledges. Thereby, movement of the
cable into and out of or lateral of electrical outlet box 10 is
essentially precluded.
[0061] Referring specifically to FIG. 11, there is shown an
apertured plate 280 for penetrable engagement by the pairs of tabs
208, 210 of each of receivers 202 forming a part of socket 12. A
similar plate 282 provides penetrable engagement through slots for
each of tabs 208, 210 of receivers 202 forming a part of socket 14.
Each of plates 282, 283 is retained in place by means such as a
screw 284 in threaded engagement with corresponding apertures 286
of central section 180 (see FIG. 10). The purpose and function of
plates 280, 282 is to provide rigidity to the tabs of the
respective receivers to insure penetration of the insulation about
the respective conductor to be electrically engaged. That is, these
plates serve as retention means to preclude the tabs from bending
or becoming skewed during engagement of male member 22 with female
member 20 and preclude disengagement of the receivers from their
respective cavities.
[0062] FIGS. 12, 13 and 14 illustrate cover 24 (see FIG. 1). The
cover includes a central aperture 290 for penetrably receiving
socket assembly 16 of male member 22. During attachment of the
electrical outlet box to a wall stud (see FIG. 3), the wall stud
may be twisted or warped to preclude the exterior planar surface of
the socket assembly from being parallel with the surface of the
wall board to be attached to the stud. To accommodate such skewed
positioning of electrical outlet box 10 and to provide an
aesthetically and visually pleasing presentation, cover 24 can be
affixed or attached to the male member in a skewed relationship
therewith that conforms with the planar surface of the wall board.
Studs 292 extend from the undersurface of the cover and include a
plurality of deformable bells 294. Upon attachment of cover 290 to
male member 22, studs 292 are forced into corresponding ones of
apertures 296 formed in cover element 220 of male member 22 (see
FIGS. 3 and 9). Apertures 290 may have a spider shaped head or
other configuration of ridged or flexible flanges cooperating with
bells 294 to insure engagement and positionable rigidity
irrespective of the depth to which studs 292 are forced into the
apertures. Thereby, the cover may be skewed relative to the major
plane defined by the male member and yet the cover will be flush
with the surface of the wall board. By including one or more bevels
298 adjacent aperture 290, any planar alignment with socket
assembly 16 will not be readily visually perceivable. The perimeter
of the cover may be beveled, as indicated or of other configuration
dictated primarily by aesthetic considerations.
[0063] Referring directly to FIGS. 15, 16, 17 and 18, each receiver
202 (see FIG. 9) will be described in further detail. Each receiver
202 includes a pair of resilient arms 300, 302 in facing
relationship to grip one of blade prongs 304 or cylindrical prong
306 (ground) of conventional electrical plug 308. A further
resilient arm 310, orthogonally related to arms 300, 302, includes
a pair of opposed keys 312, 314. These keys slide into slots 204,
206 of the corresponding one of cavities 190, 192, 194 196, 198 and
200 (see FIG. 10). As discussed above, a pair of tabs 208, 210
include slots 212, 214. The depth of the slots must be sufficient
to engage a corresponding insulated conductor (see FIG. 6) and of
appropriate width to penetrate the insulation of the conductor and
make electrical contact with the conductor. To enhance such
penetration of the insulation and electrical engagement, the edges
of the slots may be beveled to a more or less sharp edge (see FIG.
18). Alternatively, if the material of tabs 208, 210 is
sufficiently thin a beveled or sharpened edge may not be
necessary.
[0064] To provide an electric power take off from within electrical
outlet box 10 without cutting or severing any conductor of cable
30, a resilient clamp 320 may be formed on one or both sides of
receiver 202. This clamp includes an arm 322. A channel or
depression 324 is disposed beneath the arm and in general alignment
therewith. To make an electrical connection, the uninsulated end of
an electrical conductor is placed within depression 324 under arm
322. As the arm is downwardly biased and resilient, it will tend to
grip the conductor and retain it in place. To enhance retention of
the conductor, end 326 of the arm may be bent downwardly, as shown.
A further clamp 328 may be disposed on the other side of receiver
202 to permit attachment of two independent conductors to each
receiver. As particularly shown in FIG. 17, each of receivers 202
includes a clamp 328 for engaging the terminal ends of respective
ones of conductors 340, 342 and 344.
[0065] FIG. 18 is primarily an illustration of the relative
positions of three receivers 202 forming the electrical
interconnections between the three conductors of a cable and a plug
308 to be plugged into one of sockets 12, 14. A beveled edge 350
may be formed in each of slots 212. As shown, such beveled edge may
extend further along the edge of the corresponding tab.
[0066] FIG. 19 illustrates an electrical outlet box 10 attached to
a stud 50 via flange 28. Such attachment may be by screws, nails,
or the like penetrating apertures 29 and into engagement with the
stud. Several additional electrical outlet boxes 10 are serially
ganged to the stud supported electrical outlet box through
engagement of snap studs 94 of one electrical outlet box engaging
slots 82 of the adjacent electrical outlet box and by flange 28 of
one box being inserted into an adjacent electrical outlet box and
retained in place by bolts or screws extending through apertures 46
and apertures 29 of the inserted flange and into threaded
engagement with the underlying posts. Additionally, bolts may
extend through two or more of the electrical outlet boxes by
penetrable engagement with respective ones of apertures 112,
114.
[0067] A single uncut length of cable 30 is serially located in
each of the electrical outlet boxes to define the serpentine path
illustrated. Where two or more socket assemblies are intended to
protrude at opposed sides of a wall, two sets of gang electrical
outlet boxes may be secured back to back as illustrated in FIG. 20.
Further details attended such back to back connection are discussed
with respective FIG. 4. Herein, a single uncut cable 30 extends
serially through each of the electrical outlet boxes.
[0068] At a location wherein an electrical outlet is desired on
opposed sides of a wall, the configuration illustrated in FIG. 21
may be employed. One of electrical outlet boxes 10 is secured to
stud 50 via flange 28, as described above. The other electrical
outlet box is attached to the anchored electrical outlet box by
engagement of tubes 68, 70 of one female member with sets of tubes
64, 62 of the other female member. Herein, a wall board 360 on one
side of stud 50 and the wall board 362 on the other side of the
stud are illustrated. It may be noted that the thickness of male
member 22 extending from respective female member 20 is essentially
equivalent to the thickness of the wall board. Socket assembly 16
extending from each male member extends beyond the plane of the
outer surface of the corresponding wall board. Cover 24 (not shown
herein) extends beyond the perimeter of male member 22 and hides
from view the junction between the male member and the side wall of
the aperture formed in the wall board. Cable 30 serially extends
through each of electrical outlet boxes and may define a loop 364
from one electrical outlet box to the other. The remaining ends of
the cable may be connected to a source of electrical power and a
further electrical outlet box or electrical fixture of some
sort.
[0069] FIG. 22 illustrates a plurality of electrical outlet boxes
supported by corresponding studs in an extended wall 370. This
figure also illustrates extension of a cable 372 from an electrical
outlet box 374 wherein such cable is attached to receivers 202
therein by engagement with the clamps of the respective receivers
(note FIGS. 15, 16 and 17). A switch box 376 may be employed to
control or regulate the power provided to all or some of the
electric outlet boxes illustrated. There is also illustrated in
this figure an electric ceiling fan 378 receiving electric power
through a cable 380 extending from electric outlet box 382.
[0070] Conventional practice in wiring a dwelling or other facility
involves boring holes through the wall studs and threading an
electrical cable therethrough. The threading of such cable,
particularly for an extended wall length, is laborious and somewhat
difficult due to kinking and coiling of the cable. These problems
can be eliminated by instead forming a slot 390 in a wall stud 50,
as illustrated FIGS. 23 and 24. Cable 30 is laid in such slot. This
avoids the necessity of threading an end of a possibly very long
cable through a plurality of wall studs. The cable is retained
within the slot by a retainer 392 shown in FIGS. 23, 24 and 25. The
retainer is formed as a hat section in cross-section. The hat
portion 394 is commensurate with the width of slot 390. The depth
of hat portion 394 is less than the depth of the slot to permit
cable 30 to lie in the part of the clot not occupied by hat portion
394, as shown particularly in FIG. 24. After cable 30 is laid in a
slot, the hat portion of the retainer is inserted into the slot and
the retainer is hammered in place. Such hammering will drive
pointed prongs 396 into the stud in the manner of nails to retain
retainer 392 in place. It may be noted that retainer 392 may be
formed from a single sheet of metallic material or other material.
A variant 400 of retainer 392 is shown in FIG. 26. This retainer
includes a rectangular cross-section element 402 having a height
commensurate with the height slot 390. To ensure a friction
engagement with the slot, opposed sides 404, 406 may include one of
beads 408, 310 for compressive engagement with the side walls of
slot 390. A cover plate 412 may be used to bear against the stud
but such cover plate is not mandatory. It may be noted that
retainer 400 is also retained permanently in place by the wall
board covering stud 50.
[0071] While the invention has been described with reference to
several particular embodiments thereof, those skilled in the art
will be able to make the various modifications to the described
embodiments of the invention without departing from the true spirit
and scope of the invention. It is intended that all combinations of
elements and steps which perform substantially the same function in
substantially the same way to achieve the same result are within
the scope of the invention.
* * * * *