Electricity: conductors and insulators – Boxes and housings – With electrical device
Reexamination Certificate
1999-08-11
2001-10-16
Reichard, Dean A. (Department: 2831)
Electricity: conductors and insulators
Boxes and housings
With electrical device
C174S063000, C220S003300, C220S003900
Reexamination Certificate
active
06303862
ABSTRACT:
FIELD OF THE INVENTION
The present invention relates to electrical boxes and methods of producing the same.
BACKGROUND OF THE INVENTION
Consumers, updated National Electrical Codes (NEC), and Underwriter Laboratories (UL) requirements all require that electrical boxes be made stronger than in the prior art.
OBJECTS AND SUMMARY OF THE INVENTION
An object of the invention is to overcome the drawbacks of known electrical boxes and mounting assemblies.
A further object of the invention includes making electrical boxes or mounting assemblies which use the standard punched-out, stamped electrical boxes in a more intelligent fashion.
Yet another object of the invention is to provide a standard industry size electrical box with a supplemental support for supporting a fixture, and that is located the proper distance from a second supplemental support, and meets National Electrical Code (NEC) standards.
Another object of the invention is to fully exploit the strength of fixture support studs, the top wall, and the side walls of electrical boxes.
Another object of the invention is to achieve a strengthened electrical box with a supplemental support within a standard so-called “4×4” box, while maintaining the near universal 3.5 inch (8.9 cm) spacing between the fixture supports so that the box is usable with standard light fixtures, ceiling fans, and the like.
It is likewise an object of the invention to provide supplemental metal inserts in and/or on the electrical boxes to enhance the carrying strength of the electrical boxes.
A further object of the invention is to provide studs in the electrical boxes that strengthen the electrical boxes.
Yet another object of the invention is to provide studs in the electrical boxes which cover the threads of standard screws so that no screw threads are present in the interior of such electrical boxes.
A still further object of the invention is to provide an electrical box having a supplemental support with a sufficiently smooth exterior for preventing wear to the plastic coating of plastic-coated electrical wire.
It is yet another object of the invention to provide electrical boxes in which added supports, such as studs, are added during the manufacturing process to eliminate problems in prior art electrical boxes, as well as to strengthen the inventive electrical boxes.
Another object of the invention is to provide a junction box having a supplemental support, yet which requires no screwing of fasteners nor welding during assembly thereof.
Yet another object of the invention is to provide an electrical box having components which are easily fabricated, added to the electrical box, and assembled in the final form by the operation of pressing or riveting, yet which do not loosen when subjected to static and/or dynamic loading.
Another object of the invention is to provide a junction box engineered and configured so that a single fixture support/junction box support combination fastener can carry both an electrical fixture and the junction box, as well as attach the junction box to a support.
A still further object of the invention is to provide a junction box in which the supplemental support for carrying static and dynamic loads automatically extends in the desired direction along the side walls of the junction box during assembly and/or in use thanks to the use of a dimpled hole in the top wall thereof and/or thanks to the auxiliary support being configured for engaging the dimpled hole when the auxiliary support is attached and located in its attached, final form ready for use.
A still further object of the invention is to provide a junction box capable of carrying static and/or dynamic loads that has an auxiliary support and that is assembled with fewer parts and with fewer steps than known devices.
It is a yet further object that all the above be carried out with an electrical box which carries the load of supported static and dynamic fixtures better than known electrical boxes.
Another object of the invention is to provide a junction box in which one or more fixture supports are located outside of the main cavity of the junction box, the main cavity being the cavity in which the wiring of the electrical fixture is connected to the wiring of the building.
A further object of the invention is provide a junction box having an outside perimeter sized for being located in a standard junction box opening in a wall, for example, and in which perimeter recesses are defined and sized for locating one or more electrical fixture supports, so that the electrical fixture support(s) are located outside of the main cavity of the junction box, yet within the outside perimeter of the junction box.
Another object of the invention is to provide a junction box in which the weight of the electrical fixture is carried by the top wall of the junction box.
Yet another object of the invention is to provide a junction box in which the weight of an electrical fixture is carried by the top wall of the junction box and by a strengthening element disposed on the top wall of the junction box.
Yet another object of the invention is to provide a junction box in which a fixture support is provided for carrying the weight of an electrical fixture, yet with the fixture support being disposed outside the main cavity of the junction box.
A further object of the invention is to provide a junction box having a fixture support which is disposed outside of the main cavity of the junction box and which cooperates with the top wall of the junction box and which carries the weight of an electrical fixture supported thereby, yet without providing openings in the top wall through which the fixture support extends.
In summary, the present invention is directed to a mounting assembly which includes a junction box having a top wall and a side wall. The side wall extends downwardly away from the top wall and defines a cavity therein. A supplemental fixture support is disposed in the cavity. A dimpled hole is provided in the top wall, and the supplemental fixture support extends into the dimpled hole for engaging at least a portion of the walls thereof. A threaded hole may be provided on the supplemental fixture support. The supplemental fixture support may be a rivet. A rough surface or fluting may be provided on a portion of said support for engaging the walls of the dimpled hole. Preferably, the supplemental fixture support has exposed portions which are sufficiently smooth for preventing wear to plastic-coated electrical wire which engages such exposed surfaces of the fixture support.
The present invention is likewise directed to a mounting assembly having a junction box having a top wall and a downwardly extending side wall defining a cavity therein. An auxiliary cavity is provided outside the cavity, and a fixture support is configured for securing a fixture fastener at least partially within the auxiliary cavity. The fixture support may likewise be disposed at least partially within the auxiliary cavity.
These objects and advantages as well as others will be readily apparent from a review of the following description and drawings.
The drawings show a variety of embodiments of the invention, as will be clear from reading the description below.
It is important to note that the use of relative terms such as “up” and “down”, and “left” and “right” is for convenience only and is not intended to be limiting. The term “main cavity” refers to the cavity within the junction box and in which the electrical fixture wiring is connected to the wiring of the building. The main cavity need not be the largest nor the central cavity.
REFERENCES:
patent: Re. 33147 (1990-01-01), Reiker
patent: Re. 34603 (1994-05-01), Caison et al.
patent: 950176 (1910-02-01), Hublinger
patent: 1004946 (1911-10-01), Wares
patent: 1040175 (1912-10-01), Earhart
patent: 1066706 (1913-07-01), Caine
patent: 1798838 (1931-03-01), Garvin
patent: 1805027 (1931-05-01), Adell
patent: 1824708 (1931-09-01), Davis et al.
patent: 1922432 (1933-08-01), Gould
patent: 2316389 (1943-04-01), Atkinson
patent: 2423757 (1947-07-01), Dedg
Estrada Angel R.
Reichard Dean A.
Reiker Enterprises of Northwest Florida Inc.
Schlesinger Arkwright & Garvey LLP
LandOfFree
Electrical box with main cavity and separate auxiliary... does not yet have a rating. At this time, there are no reviews or comments for this patent.
If you have personal experience with Electrical box with main cavity and separate auxiliary..., we encourage you to share that experience with our LandOfFree.com community. Your opinion is very important and Electrical box with main cavity and separate auxiliary... will most certainly appreciate the feedback.
Profile ID: LFUS-PAI-O-2577384