US20060079125A1 - Connection box assembly method - Google Patents
Connection box assembly method Download PDFInfo
- Publication number
- US20060079125A1 US20060079125A1 US11/286,033 US28603305A US2006079125A1 US 20060079125 A1 US20060079125 A1 US 20060079125A1 US 28603305 A US28603305 A US 28603305A US 2006079125 A1 US2006079125 A1 US 2006079125A1
- Authority
- US
- United States
- Prior art keywords
- anchor
- connection box
- fixture
- selecting
- assembly
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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Classifications
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
- H01R13/46—Bases; Cases
- H01R13/502—Bases; Cases composed of different pieces
- H01R13/506—Bases; Cases composed of different pieces assembled by snap action of the parts
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
- H01R13/73—Means for mounting coupling parts to apparatus or structures, e.g. to a wall
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02G—INSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES
- H02G3/00—Installations of electric cables or lines or protective tubing therefor in or on buildings, equivalent structures or vehicles
- H02G3/02—Details
- H02G3/08—Distribution boxes; Connection or junction boxes
- H02G3/086—Assembled boxes
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02G—INSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES
- H02G3/00—Installations of electric cables or lines or protective tubing therefor in or on buildings, equivalent structures or vehicles
- H02G3/02—Details
- H02G3/08—Distribution boxes; Connection or junction boxes
- H02G3/14—Fastening of cover or lid to box
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02G—INSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES
- H02G3/00—Installations of electric cables or lines or protective tubing therefor in or on buildings, equivalent structures or vehicles
- H02G3/02—Details
- H02G3/08—Distribution boxes; Connection or junction boxes
- H02G3/18—Distribution boxes; Connection or junction boxes providing line outlets
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R25/00—Coupling parts adapted for simultaneous co-operation with two or more identical counterparts, e.g. for distributing energy to two or more circuits
- H01R25/006—Coupling parts adapted for simultaneous co-operation with two or more identical counterparts, e.g. for distributing energy to two or more circuits the coupling part being secured to apparatus or structure, e.g. duplex wall receptacle
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49117—Conductor or circuit manufacturing
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49117—Conductor or circuit manufacturing
- Y10T29/49124—On flat or curved insulated base, e.g., printed circuit, etc.
- Y10T29/49147—Assembling terminal to base
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49117—Conductor or circuit manufacturing
- Y10T29/49174—Assembling terminal to elongated conductor
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49117—Conductor or circuit manufacturing
- Y10T29/49204—Contact or terminal manufacturing
- Y10T29/49208—Contact or terminal manufacturing by assembling plural parts
Definitions
- This invention relates to fixture anchoring and, more particularly, to novel systems and methods for facilitating connection box assembly.
- Power tools may simplify the installation process by providing the motion (e.g. rotation) necessary to advance or install a fastener.
- the power tool must, however, be held and positioned in a manner similar to a manual tool.
- the use of power tools may not significantly lessen the demands on the installer.
- An electrical connection box assembly is one example of a time consuming fastener installation. Once an electrical fixture has been wired, the fixture is typically secured inside a connection box. Securement of the electrical fixture to the connection box often involves the installation of multiple screws. These screws are generally over an inch long and are relatively finely threaded. The length of the screws may be selected to accommodate various connection box placements and wall paneling thicknesses. To complete a conventional electrical connection box assembly, a face plate is secured to the fixture by another screw. Similar problems may be encountered in the installation of connections boxes used for a wide variety of devices and systems, including without limitation telephone, stereo, computer network, information systems, cable television system, and security systems fixtures.
- connection box screws require an installer concurrently to hold a fixture, maintain screw alignment, and provide rotation to the screw. Often it is difficult to initiate engagement between the screw and the receiving hole. Such difficulty typically arises because the receiving hole may be obscured by the wall paneling or recessed into the wall. Once the screw is in engagement with the receiving hole, the time consuming and often laborious task of advancing the finely threaded screw remains.
- Face plate screws and other securement devices may be unsightly as well as time consuming and laborious to install. Screws used to secure face plates to connection boxes and fixtures are typically painted and are, therefore, exposed to chipping, tarnishing, wear, and oxidation. In certain applications, it may be desirable to use a snap-on face plate to provide fast securement without the use of screws to provide securement.
- Fixture installation may consume a large portion of an electrician's time budget for any given project. If the amount of time needed to install electrical fixtures were reduced, both the installer and the financier (e.g. home owner, developer, or the like) may realize large economic rewards.
- the financier e.g. home owner, developer, or the like
- Typical screwless face plates require additional components to enable securement to the electrical fixture. These additional components increase manufacturing cost as well as installation time.
- connection box assembly would greatly reduce the time, skill level, and effort required to assemble and complete connection box installation (e.g. electrical fixture installation or the like).
- connection box apparatus and method that may be installed without screw rotation.
- An embodiment in accordance with the present invention may provide an apparatus for securing a fixture to a connection box.
- an anchor In a factory manufacturing process an anchor may be secured to a fixture.
- the anchor In one embodiment, the anchor is secured to the fixture by a releasable fastener.
- the anchor may have an engagement mechanism formed therewith.
- a connection box may be provided to house lines or wires originiating from a signal source to terminate therein.
- the lines may provide a connection for the fixture.
- a receiver may be associated with the connection box.
- the receiver may have an engagement mechanism formed to receive and retain the engagement mechanism of the anchor.
- the anchor and receiver may be intermediaries in the securement of the fixture to the connection box.
- Face plates are often secured to fixtures to cover and hide the wiring and access holes therebehind. Face plates in accordance with the present invention may have engagement prongs. These prongs may be inserted through apertures in a corresponding fixture to maintain the face plate aligned securely thereagainst.
- an installer may first connect a fixture to the lines or wires housed in a connection box.
- a face plate may be installed by simply pressing the engagement prongs through the apropriate apertures in the fixture.
- the fixture may be secured to the connection box by inserting one or more of the attached anchors into corresponding receivers associated with the connection box.
- the anchors may be inserted a selected distance into the receivers until the face plate is properly positioned. Insertion of an anchor into a receiver may be accomplished without the aid of tools.
- the method of engagement between the engagement mechanism of the receiver and that of the anchor may be selected to provide a fast, clean securement.
- the engagement mechanism of the receiver may be a barb configured to engage a series of teeth provided as part of the engagement mechanism of the anchor.
- the engagement mechanism of the anchor may be a barb configured to engage a series of teeth provided as part of the engagement mechanism of the receiver.
- the engagement between the anchor and receiver may provide a single or multiple locking positions.
- a fixture may be secured to a connection box in a comparatively short amount of time.
- Embodiments in accordance with the present invention may be particularly advantageous when it is desirable to preserve the ability to remove the fixture from the connection box. For example, an electrician or computer network technician may need to remove a fixture to gain access to the lines or wiring tucked therebehind. In such a situation, the face plate may be “popped” off and the fasteners holding the fixture to the anchors may be released, thus freeing the fixture. Each anchor may maintain engagement with its corresponding receiver. After the revisions are complete the fixture may once again be secured to the anchors by the installation of the fastener previously released.
- FIG. 1 is an-exploded perspective view of a connection box assembly in accordance with the present invention
- FIG. 2 is a perspective view of one embodiment of an anchor in accordance with the present invention.
- FIG. 3 is a perspective view of an alternative embodiment of an anchor in accordance with the present invention.
- FIG. 4 is a perspective view of another alternative embodiment of an anchor in accordance with the present invention.
- FIG. 5 is a top cross-sectional view of an engagement between an anchor and receiver in accordance with the present invention.
- FIG. 6 is a front cross-sectional view of the engagement of FIG. 5 ;
- FIG. 7 is a partial perspective view of an alternative embodiment of an anchor in accordance with the present invention.
- FIG. 8 is a top cross-sectional view of an alternative engagement between an anchor and receiver in accordance with the present invention.
- FIG. 9 is a top cross-sectional view of another alternative engagement between an anchor and receiver in accordance with the present invention.
- FIG. 10 is a partial cutaway, perspective view of an application of a quick assembling connection box in accordance with the present invention.
- FIG. 11 is a perspective view of a receiver in accordance with the present invention formed as part of a metal connection box
- FIG. 12 is an exploded perspective view of an alternative embodiment of a face plate and fixture assembly in accordance with the present invention.
- FIG. 13 is a perspective view of a complete assembly prepared for installation in accordance with the present invention.
- FIG. 14 is a partial perspective view of a face plate and fixture assembly in accordance with the present invention.
- FIG. 15 is a side cross-sectional view of a screwless face plate assembly using an adapter in accordance with the present invention.
- FIG. 16 is a side cross-sectional view of an engagement prong in accordance with the present invention.
- FIG. 17 is a perspective view of an engagement prong in accordance with the present invention.
- FIG. 18 is a perspective view of a fixture with a flange modified in accordance with the present invention.
- FIG. 19 is a perspective view of an alternative embodiment of a screwless face plate in accordance with the present invention to engage the fixture of FIG. 18 ;
- FIG. 20 is a side cross-sectional view of an engagement between the fixture of FIG. 18 and the screwless face plate of FIG. 19 ;
- FIG. 21 is a partial perspective view of alternative engagement between a screwless face plate and an fixture in accordance with the present invention.
- FIG. 22 is a cutaway, partial perspective view of alternative engagement between a screwless face plate and a fixture in accordance with the present invention.
- FIG. 23 is a perspective view of a fixture with an adapter in accordance with the present invention.
- FIG. 24 is a side cross-sectional view of a fixture with an adapter in accordance with the present invention.
- connection box assemblies of the present invention could be arranged and designed in a wide variety of different configurations.
- the description herein is not intended to limit the scope of the invention, but is merely representative of certain presently preferred embodiments of devices and systems in accordance with the invention.
- Those of ordinary skill in the art will, of course, appreciate that various modifications to the details herein may easily be made without departing from the essential characteristics of the invention, as described. Thus, the following information is intended only by way of example, and simply illustrates certain presently preferred embodiments consistent with the invention.
- Coordinate axes 11 may be defined by longitudinal 11 a, lateral 11 b, and transverse directions 11 c substantially orthogonal to one another.
- a connection box assembly 10 in accordance with the present invention may provide an apparatus for securing a fixture 12 to a connection box 14 .
- an anchor 16 may be secured to the fixture 12 .
- the connection box 14 to which the fixture 12 is to be secured may have a receiver 18 associated therewith for admitting and retaining the anchor 16 .
- the anchor 16 and receiver 18 may be intermediaries in the securement of the fixture 12 to the connection box 14 .
- a face plate 20 may be provided to cover and hide the wiring and access holes therebehind.
- a fixture 12 maybe any suitable piece for which securement is desired.
- a fixture 12 may be a power receptacle, power switch, light fixture, telephone jack, network jack, cable connector, stereo system connector, information system connector, or any other unit 12 for which permanent or removable securement to a connection box 14 may be desired.
- the connection box 14 may be any box to which a fixture 12 may be secured.
- a connection box 14 may be constructed of any suitable material. Suitable materials may include without limitation metals, polymers, composites, and the like. Additionally, a connection box 14 , in accordance with the present invention, may be of any suitable size.
- connection box 14 may be a single gang, double gang, triple gang, quadruple gang, quintuple gang, or the like.
- the concepts presented herein are illustrated as a single gang box, however, the principles and concepts may easily be expanded to multiple-gang connection boxes.
- Embodiments in accordance with the present invention may be particularly well suited to assemblies that may be assembled in the field (i.e. not in a factory). Such field assemblies need not be limited to connection box assemblies 10 . Embodiments in accordance with the present invention may provide convenience and ease of assembly in the field where less than perfect conditions are often encountered.
- An anchor 16 in accordance with the present invention may be constructed, formed, machined, extruded, molded, cast, or otherwise made from any suitable material. Suitable materials may include without limitation metals, polymers, composites, or the like. For example, in certain embodiments, an anchor 16 may be formed of a polymer in a molding process.
- An anchor 16 may be secured to a fixture 12 in any suitable manner.
- an anchor 16 may be secured to a fixture 12 by a fastener 22 such as a bolt, rivet, screw, engagement prong, engagement hook, or the like.
- a fastener 22 such as a bolt, rivet, screw, engagement prong, engagement hook, or the like.
- an anchor 16 may be glued or otherwise bonded to a fixture 12 .
- an anchor 16 may be formed as an integral part of the fixture 12 .
- Each form of attachment between the anchor 16 and the fixture 12 may have particular advantages.
- an installer may need to remove a fixture 12 to gain access to something (e.g. wiring) tucked therebehind.
- screws 22 may provide an ideal attachment between the anchor 16 and the fixture 12 .
- the screws 22 may be removed, thus freeing the fixture 12 .
- the anchors 16 may maintain engagement with the connection box 14 . After the revisions are complete the fixture 12 may once again be secured to the anchors 16 by the insertion of the screws 22 previously removed.
- an anchor 16 in accordance with the present invention may be applied to all or a subset of the securement locations.
- power receptacles 12 and switches 12 are typically secured to connection boxes 14 by two screws spaced from each other in a longitudinal direction 11 a.
- An anchor 16 a, 16 b may be applied to fasteners 22 a, 22 b respectively.
- a connection box 14 may have multiple receivers 18 a, 18 b to engage both anchors 16 a, 16 b, respectively.
- the method of engagement between a receiver 18 and an anchor 14 may be selected to provide a fast, clean securement.
- the fixture 12 may be secured to the connection box 14 in a minimum amount of time.
- installers e.g. electricians, network technicians, cable television installers, and the like
- a fastener 22 e.g. screw 22
- the installation of the fastener 22 may be performed in ideal conditions with proper alignment and fast tool speeds. In the field, when an installer installs the fixture 12 , the time consuming screw installation no longer needs to be performed.
- An anchor 16 may simply be inserted into a receiver 18 .
- connection box 14 anchors 16 a, 16 b, receivers 1 8 a, 1 8 b, and face plate 20 , as illustrated in FIG. 1 may be arranged and designed in a wide variety of different configurations that fall within the scope of the present invention.
- the description hereinabove is not intended to limit the scope of the possible embodiments, but is merely representative of certain presently preferred embodiments of devices and systems in accordance with the invention. The information is intended only by way of example.
- an anchor 16 in accordance with the present invention may have an engagement mechanism 24 configured to provide a mechanical grip with a receiver 18 . If an anchor 16 is to be secured to a fixture 12 by a bolt 22 or screw 22 , a threaded aperture 26 may be formed therein. The threaded aperture 26 may extend completely or only partially through the anchor 16 in a transverse direction 11 c.
- a length 28 of the engagement mechanism 24 may be selected to provide a desired number of engagement locations 30 .
- each engagement location 30 is a tooth 30 .
- the engagement length 28 and the number of engagement locations 30 may be selected to permit insertion of the anchor 16 a desired distance into the receiver 18 .
- an anchor 14 in accordance with the present invention may include a spacer 32 .
- the length 34 of the spacer 32 may be selected to provide additional control over the spacing of the fixture 12 in relation to the connection box 14 .
- one end 36 of the anchor 16 maybe formed to promote easy insertion into the receiver 18 .
- an end 36 may be pointed, rounded, tapered, or otherwise formed.
- An anchor 16 in accordance with the present invention may have any suitable cross-section.
- the cross-section may be rectangular, circular, triangular, oval, an unconventional shape, or the like.
- the cross-sectional shape of an anchor 16 may be selected to resist rotation about a transverse axis 11 c once installed inside a receiver 18 .
- an anchor 16 having a generally circular cross-section may have a key-way formed therein to correspond to a key formed or located in the receiver 18 .
- the shape and configuration of a receiver 18 may be selected to match and complement the particular shape of a selected anchor 16 .
- the receiver 18 may be formed to have a generally rectangular shape.
- the receiver 18 may admit the anchor 16 and hold the anchor 16 securely without motion (e.g rotation about a transverse axis 11 c ) therebetween.
- an anchor 16 may have multiple sliding surfaces 38 to promote ease of insertion and proper alignment.
- a recessed groove 40 may be formed in one or more surfaces 38 of the anchor 16 to provide a location for disposition of an engagement mechanism 24 .
- Such an engagement mechanism 24 may be recessed to reduce the risk of interfering with proper insertion of the anchor 16 into the receiver 18 .
- an anchor 16 may have a generally circular cross-section.
- the anchor may include a single flat 42 or may include a plurality of flats 42 that provide a location for disposition of an engagement mechanism 24 .
- the flats 42 may also provide a location for a corresponding receiver 18 to engage the anchor 16 to resist rotation about a transverse axis 11 c.
- FIG. 4 also illustrates an alternative embodiment of a fastener 22 in accordance with the present invention.
- Opposing engagement hooks 22 may be shaped to promote insertion into a corresponding aperture in a fixture 12 .
- the engagement hooks 22 may be formed to engage an aperture of any suitable shape (e.g. circular, oval, triangular, or the like).
- the illustrated engagement hooks 22 have been formed in a shape to fit a square aperture.
- a square aperture may provide a mechanism to resist rotation of the anchor 16 about a transverse axis 11 c with respect to a corresponding fixture 12 .
- Engagement hooks 22 in accordance with the present invention may flex to allow an anchor 16 to be separated from the fixture 12 to which the anchor 16 is attached. Once separated, the anchor 16 and fixture 12 may be reattached by reinserting the engagement hooks 22 of the anchor 16 through the corresponding aperture in the fixture 12 .
- anchors 16 as illustrated in FIGS. 2-4 , could be arranged and designed in a wide variety of different configurations that fall within the scope of the present invention.
- the description hereinabove is not intended to limit the scope of the possible embodiments, but is merely representative of certain presently preferred embodiments of devices and systems in accordance with the invention.
- the information is intended only by way of example and not by way of limitation.
- an anchor 16 in accordance with the present invention may have multiple sliding surfaces 38 .
- the sliding surfaces 38 may maintain proper alignment of the anchor 16 with respect to the receiver 18 .
- a receiver 18 in accordance with the present invention may include an engagement mechanism 39 .
- This engagement mechanism 39 may be configured to engage the engagement mechanism 24 of an anchor 16 .
- an engagement mechanism 39 may comprise hooks 44 or barbs 44 . These barbs 44 may extend from the receiver 18 with a shape selected to engage the teeth 30 of the anchor 16 .
- the engagement of the hooks 44 and teeth 30 may be selected to provide unidirectional motion so that an anchor 16 may be easily inserted yet resist removal in a transverse direction 11 c.
- the number of teeth 30 and the incremental distance 46 therebetween may be selected to provide a continuum of possible locking positions between the anchor 16 and the receiver 18 .
- an anchor 16 may include a single hook 44 .
- an anchor 16 may include multiple hooks 44 .
- a flexible region 48 may permit a hook 44 to flex as it “clicks” or passes over the teeth 30 of a receiver 18 .
- the number of teeth 30 and the incremental distance 46 therebetween may be selected to provide a continuum of possible locking positions between the anchor 16 and the receiver 18 .
- the engagement between an anchor 16 and a receiver 18 may not be incremental, rather a single locking position may be defined.
- the anchor 16 may be inserted into the receiver 18 until a lock 50 is activated.
- a lock 50 may consist of a hook 44 secured on the distal end of a flexible region 48 .
- a stop 52 may provide a register to correctly position the anchor 16 with respect to the receiver 18 .
- a hook 44 may engage an engagement location 30 of the receiver 18 .
- the length 28 (see FIG. 2 ) of the engagement mechanism 24 may be selected to best match the particular application to which the engagement mechanism 24 may be applied.
- the installation of a light fixture 12 may be simplified by employing a comparatively long anchor 16 having a similarly long engagement mechanism 24 .
- two long anchors 16 may be secured to the fixture 12 .
- the anchors 16 may be introduced into the corresponding receivers 18 a distance sufficient to engage the engagement mechanisms 39 thereof.
- the anchors 16 may then hold the fixture 12 in place while the installer proceeds to connect the necessary wires 54 .
- the fixture 12 may be pushed in a transverse direction 11 c until a proper position is achieved.
- the installer need not hold the fixture 12 while connecting wires 54 and tightening terminal screws 56 .
- a receiver 18 may be associated with a connection box 14 in any suitable manner.
- the receiver 18 may be formed as an integral part of the connection box 14 . This forming may be part of a molding process. That is, the receiver 18 may be molded as part of the connection box 14 in its original forming process.
- FIG. 11 illustrates an embodiment in which the receiver 18 is formed by stamping selected shapes from a metal connection box 14 and then bending the cut portions in a selected direction to form a guide 57 and an engagement mechanism 39 .
- a receiver 18 may be formed (e.g. molded, extruded, cast, machined, stamped, or the like) and then joined to the connection box 14 . Such a joining may be accomplished by bolting, screwing, welding, gluing, bonding, or the like.
- connection boxes 14 are typically installed and wired before the installation of the wall paneling (e.g., ceiling paneling and the like).
- Fixtures 12 and face plates 20 are typically installed after the installation of the wall paneling.
- the installation of wall paneling often involves the application of dry wall compound. It is very common for clumps of dry wall compound to be inadvertently introduced inside a previously installed connection box 14 .
- Receivers 18 in accordance with the present invention may be formed in a manner to greatly limit the adverse effects of misplaced dry wall compound.
- the receiver may be formed to have an open back exit 59 .
- anchor 16 may be inserted into the receiver 18 and any clump of dry wall compound may simply be pushed out the back 59 of the receiver 18 .
- the back 59 may be open to the exterior of the connection box 14 .
- the back 59 may also be configured to open to the interior of the connection box 14 . In such a configuration, a dry wall compound clump will be pushed to the interior of the connection box 14 where it can do no harm.
- Embodiments in accordance with the present invention may be applied to any unit 12 for which permanent or removable securement to a connection box 14 is desired.
- Data terminals such as phone jacks, network jacks, cable connections, and the like may not have a fixture 12 associated therewith.
- These applications may deliver a transmission line to a jack 60 or connector 60 mounted directly in a face plate 20 .
- the face plate 20 provides the structure and support for the jack 60 , and indeed may provide many of the same functions as a fixture 12 .
- these face plates have been secured directly to a corresponding connection box by multiple screws. Installation of such screws presents difficulties similar to those encountered in the installation of fixtures 12 .
- FIG. 12 illustrates one embodiment of a jack connection box assembly 10 in accordance with the present invention.
- Interface members 62 a, 62 b may provide an interface between a face plate 20 and anchors 16 a, 16 b.
- the interface members 62 may include an aperture 64 to accommodate securement of an anchor 16 .
- Additional apertures 66 may provide locations for the face plate 20 to engage the interface members 62 .
- extensions 68 or “dog ears” 68 may be incorporated to hold each interface member 62 flush with the wall paneling.
- the interface members 62 may be formed in any suitable shape for providing adequate engagement between an anchor 16 and a face plate 20 .
- the interface members 62 are generally flat pieces having multiple apertures 64 , 66 and extensions 68 .
- the interface members 62 may be constructed of any suitable material.
- interface members 62 may be formed by stamping sheet metal.
- interface members 62 may be molded from a polymer, a composite, or the like.
- a face plate 20 is typically secured thereto to hide the under workings from view.
- Conventional face plates 20 are often secured by at least one screw. Screws and other securement devices may be unsightly. Screws used to secure face plates 20 to receptacles and switches are typically painted and are, therefore, exposed to chipping, tarnishing, wear, oxidation, and the like. In such applications, it may be desirable to provide a snap-on assembly to provide fast securement of a face plate 20 without the use of screws.
- FIGS. 13-15 illustrate one embodiment of a screwless face plate 20 in accordance with the present invention.
- a face plate 20 may include engagement prongs 70 .
- the engagement prongs 70 may engage a fixture 12 and maintain the face plate 20 aligned and secured thereto.
- a complete fixture 12 assembly may be quickly and easily wired and then secured to a corresponding connection box 14 .
- Selected fixtures 12 in accordance with the present invention may include flanges 72 .
- Flanges 72 a, 72 b may extend away from a main body 74 of a fixture 12 in a longitudinal direction 1 I a.
- the flanges 72 may include an aperture 64 to accommodate the securement of an anchor 16 .
- Additional apertures 66 may provide locations for the engagement prongs 70 of the face plate 20 to engage the flanges 72 .
- extensions 68 or “dog ears” 68 may be selected to hold the fixture 12 flush with the wall paneling.
- Engagement prongs 70 in accordance with the present invention may be formed to have multiple hooks 76 a, 76 b, 76 c, 76 d.
- the hooks 76 may be secured to the face plate 20 by flexible necks 78 a, 78 b, 78 c, 78 d, respectively.
- a flex clearance 80 may be provided between the hooks 76 so that as the prong 70 is inserted through an aperture 66 , the hooks 76 may deflect toward each other, thus, effectively reducing the diameter of the prong 70 .
- the hooks 76 may return to their neutral position and engage the edges of the aperture 66 .
- the hooks 76 may be shaped to release at a desired removal loading, thus, once the face plate 20 is removed, the face plate 20 may be used again.
- the hooks 76 may be provided with an inside taper 82 .
- the inside taper 82 may allow each hook 76 to gradually flex and bend towards the flex clearance 80 as the face plate 20 is pulled away from the fixture 12 so that the effective diameter of the engagement prong 70 may be reduced and the prong 70 may be removed from the aperture 66 .
- a face plate 20 in accordance with the present invention may be removed by applying sufficient force to fail the hooks 66 .
- a screwless face plate 20 in accordance with the present invention may be formed of any suitable material. This material may be selected based on several characteristics including cost, aesthetics, dielectric constant, thermal capacity, strength, toughness, flexibility, formability, and the like.
- Engagement prongs 70 in accordance with the present invention may have any suitable configuration.
- the number of prongs 70 may range from one to several and be selected to provide a balanced securement between a face plate 20 and a fixture 12 .
- the number of hooks 76 making up each prong 70 may also range from one to several depending on a desired engagement strength, ease of manufacture, ease of installation, ease of removal, and the like.
- the engagement strength may be balanced with a desired release loading.
- the general shape or contour of the prongs 70 may also be selected to provide a desired engagement strength, ease of manufacture, ease of installation, ease of removal, and the like.
- alternative embodiments in accordance with the present invention may employ alternative methods for securing a screwless face plate 20 to a fixture 12 .
- a flange 72 a of a fixture 12 may have an engagement lip 84 formed therein.
- a extension 86 may be formed in association with a corresponding face plate 20 .
- the engagement lip 84 may be configured to fit behind the extension 86 to hold the upper portion of the face plate 20 to the flange 72 a.
- An aperture 66 may be formed in a flange 72 b of the fixture 12 .
- a corresponding engagement prong 70 may be formed in association with the face plate 20 .
- the prong 70 illustrated in FIGS. 18-19 is an example of a single hook, rectangular prong 70 .
- the aperture 66 may be shaped to correspond to the design of the prong 70 .
- the lip 84 /extension 86 and aperture 66 /prong 70 combinations may cooperate to secure the face plate 20 to the fixture 12 .
- Such an embodiment may be installed by first inserting the lip 84 behind the extension 86 and then rotating the face plate 20 down against the fixture 12 until the prong(s) 70 may be inserted into the corresponding aperture(s) 66 .
- the prong 70 engagement may provide a tie to resist the tendency of the lip 84 to disengage from the extension 86 .
- An engagement lip 84 in accordance with the present invention may be divided into multiple engagement lips 84 .
- an upper flange 72 a may be formed into two lips 84 a, 84 b.
- the lips 84 a, 84 b may be separated by a notch 88 .
- a stop 90 may be formed as part of a corresponding extension 86 . The stop 90 may fit into the notch 88 to prevent lateral motion between the upper flange 72 a and the face plate 20 .
- ends 92 may form an enclosure 94 in combination with an extension 86 and corresponding face plate 20 .
- the ends 92 may function to laterally retain the lip 84 of a flange 72 a, when assembled.
- a face plate 20 in accordance with the present invention may have an access notch 96 .
- an access notch 96 may simply provide a hold to permit the application of force to “pop” a face plate 20 from a corresponding fixture 12 .
- the access notch 96 may provide access behind the face plate 20 to a slender tool. The slender tool may then be used to assist in the release of an engagement prong 70 .
- an alternative embodiment of an engagement between a screwless face plate 20 and a fixture 12 may involve the engagement of an edge 98 of the flanges 72 of the fixture 12 .
- One or more of the engagement prongs 70 of the face plate 20 may be configured to engage an edge 98 .
- the prongs 70 may be formed to have a hook 76 and a flexible neck 78 .
- a flange 72 may include a formation 100 to resist motion in a longitudinal direction 11 a of a face plate 70 with respect thereto. Such a formation 100 may be formed by bending, cutting and bending, notching, or similarly modifying the edge 98 to resist sliding of a prong 70 therealong in a longitudinal direction 11 a.
- an alternative embodiment of an engagement between a screwless face plate 20 and a fixture 12 may involve an engagement between a face plate 20 and an interface 104 of a fixture 12 .
- the interface 104 of a fixture 12 extends a selected distance 106 to provide a flush joint with a face plate 20 . That is, the interface 104 extends to provide a facing 108 that may be substantially coplanar with a surface 110 of the face plate 20 , thereby improving aesthetic appeal.
- the area of the facing 108 may be selected to correspond to a selected interface 104 .
- Power outlet plugs 104 provide a relatively large surface area.
- switches 104 typically have a toggle central unit and a thin border providing minimal surrounding facing 108 .
- the extension distance 106 of the electrical interface 104 provides the surface (substantially perpendicular to the facing 108 ) of an edge 102 .
- An edge 112 of an aperture 114 (the aperture 114 may admit the interface 104 through the face plate 20 ) may be configured to engage the edge 102 of the interface 104 .
- This engagement may be of any suitable form.
- the engagement may involve any suitable combination of tabs, recesses, hooks, shoulders, and the like.
- the engagement between the edges 102 , 112 may involve tabs 116 formed on the face plate 20 and recesses 118 formed in the interface 104 .
- the shape, number, and location of these corresponding pairs may be selected to provide a desired engagement strength, magnitude, and balance.
- Engagement strength refers to the amount of force required to apply and secure the face plate 20 to the fixture 12 or, alternatively, the force required to separate the face plate 20 from the fixture 12 .
- the engagement strength- may be selected to provide fast “snap-on” assembly without risking inadvertent removal of the face plate 20 and possible electrical shock resulting therefrom.
- an adapter 120 may be provided to convert or retrofit a conventional fixture 12 to receive a screwless face plate 20 .
- an adapter 120 in accordance with the present invention may include an aperture 122 corresponding to aperture 64 of a flange 72 .
- a fastener 22 used to secure an anchor 16 to a fixture 12 may also pass through the aperture 122 to hold an adapter 120 in place against the flange 72 .
- the adapter 120 may extend to provide apertures 68 for admitting the prongs 70 of a corresponding face plate 20 . In this manner, a snap-on, screwless face plate 20 may be retrofitted to typical power receptacles and switches.
- An adapter 120 in accordance with the present invention may be formed of any suitable material.
- the adapter 120 may be formed by stamping sheet metal.
- the adapter 120 may be a molded polymer or composite.
- An embodiment in accordance with the present invention may provide an apparatus for securing a fixture to a connection box.
- an anchor In a factory manufacturing process an anchor may be secured to a fixture. The anchor may have an engagement mechanism formed therewith.
- a connection box may be provided to house wires proceeding from a source to terminate therein.
- a receiver may be associated with the connection box. The receiver may have an engagement mechanism formed to receive and retain the engagement mechanism of the anchor.
- the anchor and receiver may be intermediaries in the securement of the fixture to the connection box.
- Face plates in accordance with the present invention may have engagement prongs.
- prongs may be inserted through apertures in a corresponding fixture to maintain the face plate aligned securely thereagainst.
- a face plate may be installed by simply pressing the engagement prongs through the appropriate apertures in the fixture.
- the resulting assembly may be secured to the connection box by inserting one or more of the attached anchors into corresponding receivers associated with the connection box.
- the anchor may be inserted a depth into the receiver selected to properly position the face plate. Insertion of an anchor into a receiver may be accomplished without the aid of tools.
Abstract
Description
- This application is a continuation of U.S. patent application Ser. No. 10/435,716 filed May 8, 2003 and entitled QUICK ASSEMBLING ELECTRICAL CONNECTION BOX APPARATUS AND METHOD, which is a continuation of U.S. Pat. No. 6,609,927 issued Aug. 26, 2003, which claims the benefit of U.S. Provisional Patent Application Ser. No. 60/297,823 filed Jun. 12, 2001 and U.S. Provisional Patent Application Ser. No. 60/273,803 filed on Mar. 6, 2001.
- 1. The Field of the Invention
- This invention relates to fixture anchoring and, more particularly, to novel systems and methods for facilitating connection box assembly.
- 2. The Background Art
- Manually installing screws or other fasteners is often time consuming. Additionally, in certain installations, the installer must employ his or her hands to hold several components as well as rotate a tool transferring rotation to a screw or other type of fastener. Maintaining all of the components in proper alignment is often difficult and requires skill. In any case, the complexity slows the installation process.
- Power tools may simplify the installation process by providing the motion (e.g. rotation) necessary to advance or install a fastener. The power tool must, however, be held and positioned in a manner similar to a manual tool. Thus, the use of power tools may not significantly lessen the demands on the installer.
- An electrical connection box assembly is one example of a time consuming fastener installation. Once an electrical fixture has been wired, the fixture is typically secured inside a connection box. Securement of the electrical fixture to the connection box often involves the installation of multiple screws. These screws are generally over an inch long and are relatively finely threaded. The length of the screws may be selected to accommodate various connection box placements and wall paneling thicknesses. To complete a conventional electrical connection box assembly, a face plate is secured to the fixture by another screw. Similar problems may be encountered in the installation of connections boxes used for a wide variety of devices and systems, including without limitation telephone, stereo, computer network, information systems, cable television system, and security systems fixtures.
- The installation of the connection box screws requires an installer concurrently to hold a fixture, maintain screw alignment, and provide rotation to the screw. Often it is difficult to initiate engagement between the screw and the receiving hole. Such difficulty typically arises because the receiving hole may be obscured by the wall paneling or recessed into the wall. Once the screw is in engagement with the receiving hole, the time consuming and often laborious task of advancing the finely threaded screw remains.
- Face plate screws and other securement devices may be unsightly as well as time consuming and laborious to install. Screws used to secure face plates to connection boxes and fixtures are typically painted and are, therefore, exposed to chipping, tarnishing, wear, and oxidation. In certain applications, it may be desirable to use a snap-on face plate to provide fast securement without the use of screws to provide securement.
- Fixture installation may consume a large portion of an electrician's time budget for any given project. If the amount of time needed to install electrical fixtures were reduced, both the installer and the financier (e.g. home owner, developer, or the like) may realize large economic rewards.
- Attempts have been made to provide quick assembling connection boxes and fixture assemblies. Quick assembling devices typically involve at least some rotation of the fixture screws and, therefore, require the use of tools for installation. Often these devices are limited in how well they are able to engage the threads of the fixture screws. Thus, such devices may not provide a reliable and solid securement between the fixture and connection box.
- Typical screwless face plates require additional components to enable securement to the electrical fixture. These additional components increase manufacturing cost as well as installation time.
- What is needed is an anchor that provides a strong and reliable securement between a fixture and associated connection box. Such an anchor would also provide for quick and simple installation thereof. Additionally, a screwless face plate that requires no additional components to accomplish a reliable securement would be an advancement in the art. Such a connection box assembly would greatly reduce the time, skill level, and effort required to assemble and complete connection box installation (e.g. electrical fixture installation or the like).
- In view of the foregoing, it is a primary object of the present invention to provide an apparatus and method requiring minimal time, effort, and skill to install.
- It is a further object of the invention to provide a connection box apparatus and method that may be installed without screw rotation.
- Consistent with the foregoing objects, and in accordance with the invention as embodied and broadly described herein, a method and apparatus are disclosed. An embodiment in accordance with the present invention may provide an apparatus for securing a fixture to a connection box. In a factory manufacturing process an anchor may be secured to a fixture. In one embodiment, the anchor is secured to the fixture by a releasable fastener. The anchor may have an engagement mechanism formed therewith.
- A connection box may be provided to house lines or wires originiating from a signal source to terminate therein. The lines may provide a connection for the fixture. A receiver may be associated with the connection box. The receiver may have an engagement mechanism formed to receive and retain the engagement mechanism of the anchor. Thus, the anchor and receiver may be intermediaries in the securement of the fixture to the connection box.
- In certain applications, screws and other securement devices may be unsightly. In these applications it may be desirable to provide a snap-on face plate to provide fast securement without the use of screws. Face plates are often secured to fixtures to cover and hide the wiring and access holes therebehind. Face plates in accordance with the present invention may have engagement prongs. These prongs may be inserted through apertures in a corresponding fixture to maintain the face plate aligned securely thereagainst.
- In selected embodiments in accordance with the present invention, an installer may first connect a fixture to the lines or wires housed in a connection box. A face plate may be installed by simply pressing the engagement prongs through the apropriate apertures in the fixture. Once a fixture has been connected to the lines and a face plate applied, the fixture may be secured to the connection box by inserting one or more of the attached anchors into corresponding receivers associated with the connection box. The anchors may be inserted a selected distance into the receivers until the face plate is properly positioned. Insertion of an anchor into a receiver may be accomplished without the aid of tools.
- The method of engagement between the engagement mechanism of the receiver and that of the anchor may be selected to provide a fast, clean securement. In selected embodiments, the engagement mechanism of the receiver may be a barb configured to engage a series of teeth provided as part of the engagement mechanism of the anchor. In other embodiments, the engagement mechanism of the anchor may be a barb configured to engage a series of teeth provided as part of the engagement mechanism of the receiver. The engagement between the anchor and receiver may provide a single or multiple locking positions.
- By applying embodiments in accordance with the present invention, a fixture may be secured to a connection box in a comparatively short amount of time. Embodiments in accordance with the present invention may be particularly advantageous when it is desirable to preserve the ability to remove the fixture from the connection box. For example, an electrician or computer network technician may need to remove a fixture to gain access to the lines or wiring tucked therebehind. In such a situation, the face plate may be “popped” off and the fasteners holding the fixture to the anchors may be released, thus freeing the fixture. Each anchor may maintain engagement with its corresponding receiver. After the revisions are complete the fixture may once again be secured to the anchors by the installation of the fastener previously released.
- The foregoing and other objects and features of the present invention will become more fully apparent from the following description, taken in conjunction with the accompanying drawings. Understanding that these drawings depict only typical embodiments of the invention and are, therefore, not to be considered limiting of its scope, the invention will be described with additional specificity and detail through use of the accompanying drawings in which:
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FIG. 1 is an-exploded perspective view of a connection box assembly in accordance with the present invention; -
FIG. 2 is a perspective view of one embodiment of an anchor in accordance with the present invention; -
FIG. 3 is a perspective view of an alternative embodiment of an anchor in accordance with the present invention; -
FIG. 4 is a perspective view of another alternative embodiment of an anchor in accordance with the present invention; -
FIG. 5 is a top cross-sectional view of an engagement between an anchor and receiver in accordance with the present invention; -
FIG. 6 is a front cross-sectional view of the engagement ofFIG. 5 ; -
FIG. 7 is a partial perspective view of an alternative embodiment of an anchor in accordance with the present invention; -
FIG. 8 is a top cross-sectional view of an alternative engagement between an anchor and receiver in accordance with the present invention; -
FIG. 9 is a top cross-sectional view of another alternative engagement between an anchor and receiver in accordance with the present invention; -
FIG. 10 is a partial cutaway, perspective view of an application of a quick assembling connection box in accordance with the present invention; -
FIG. 11 is a perspective view of a receiver in accordance with the present invention formed as part of a metal connection box; -
FIG. 12 is an exploded perspective view of an alternative embodiment of a face plate and fixture assembly in accordance with the present invention; -
FIG. 13 is a perspective view of a complete assembly prepared for installation in accordance with the present invention; -
FIG. 14 is a partial perspective view of a face plate and fixture assembly in accordance with the present invention; -
FIG. 15 is a side cross-sectional view of a screwless face plate assembly using an adapter in accordance with the present invention; -
FIG. 16 is a side cross-sectional view of an engagement prong in accordance with the present invention; -
FIG. 17 is a perspective view of an engagement prong in accordance with the present invention; -
FIG. 18 is a perspective view of a fixture with a flange modified in accordance with the present invention; -
FIG. 19 is a perspective view of an alternative embodiment of a screwless face plate in accordance with the present invention to engage the fixture ofFIG. 18 ; -
FIG. 20 is a side cross-sectional view of an engagement between the fixture ofFIG. 18 and the screwless face plate ofFIG. 19 ; -
FIG. 21 is a partial perspective view of alternative engagement between a screwless face plate and an fixture in accordance with the present invention; -
FIG. 22 is a cutaway, partial perspective view of alternative engagement between a screwless face plate and a fixture in accordance with the present invention; -
FIG. 23 is a perspective view of a fixture with an adapter in accordance with the present invention; and -
FIG. 24 is a side cross-sectional view of a fixture with an adapter in accordance with the present invention. - It will be readily understood that the connection box assemblies of the present invention, as generally described and illustrated in the Figures herein, could be arranged and designed in a wide variety of different configurations. Thus, the description herein is not intended to limit the scope of the invention, but is merely representative of certain presently preferred embodiments of devices and systems in accordance with the invention. Those of ordinary skill in the art will, of course, appreciate that various modifications to the details herein may easily be made without departing from the essential characteristics of the invention, as described. Thus, the following information is intended only by way of example, and simply illustrates certain presently preferred embodiments consistent with the invention.
- Referring to
FIG. 1 , in discussing the Figures, it may be advantageous to establish a reliable coordinate system to aid in the description of several of the embodiments in accordance with the present invention. Coordinate axes 11 may be defined by longitudinal 11 a, lateral 11 b, andtransverse directions 11 c substantially orthogonal to one another. - A
connection box assembly 10 in accordance with the present invention may provide an apparatus for securing afixture 12 to aconnection box 14. In a factory manufacturing process, ananchor 16 may be secured to thefixture 12. Theconnection box 14 to which thefixture 12 is to be secured may have areceiver 18 associated therewith for admitting and retaining theanchor 16. Thus, theanchor 16 andreceiver 18 may be intermediaries in the securement of thefixture 12 to theconnection box 14. Aface plate 20 may be provided to cover and hide the wiring and access holes therebehind. - A
fixture 12 maybe any suitable piece for which securement is desired. For example, afixture 12 may be a power receptacle, power switch, light fixture, telephone jack, network jack, cable connector, stereo system connector, information system connector, or anyother unit 12 for which permanent or removable securement to aconnection box 14 may be desired. In a similar manner, theconnection box 14 may be any box to which afixture 12 may be secured. Aconnection box 14 may be constructed of any suitable material. Suitable materials may include without limitation metals, polymers, composites, and the like. Additionally, aconnection box 14, in accordance with the present invention, may be of any suitable size. For example, aconnection box 14 may be a single gang, double gang, triple gang, quadruple gang, quintuple gang, or the like. The concepts presented herein are illustrated as a single gang box, however, the principles and concepts may easily be expanded to multiple-gang connection boxes. - Embodiments in accordance with the present invention may be particularly well suited to assemblies that may be assembled in the field (i.e. not in a factory). Such field assemblies need not be limited to
connection box assemblies 10. Embodiments in accordance with the present invention may provide convenience and ease of assembly in the field where less than perfect conditions are often encountered. - An
anchor 16 in accordance with the present invention may be constructed, formed, machined, extruded, molded, cast, or otherwise made from any suitable material. Suitable materials may include without limitation metals, polymers, composites, or the like. For example, in certain embodiments, ananchor 16 may be formed of a polymer in a molding process. - An
anchor 16 may be secured to afixture 12 in any suitable manner. In certain embodiments, ananchor 16 may be secured to afixture 12 by afastener 22 such as a bolt, rivet, screw, engagement prong, engagement hook, or the like. In other embodiments, ananchor 16 may be glued or otherwise bonded to afixture 12. Additionally, ananchor 16 may be formed as an integral part of thefixture 12. - Each form of attachment between the
anchor 16 and thefixture 12 may have particular advantages. In certain applications, such as the installation ofpower receptacles 12, switches 12,computer network outlets 12,cable television outlets 12, and the like an installer may need to remove afixture 12 to gain access to something (e.g. wiring) tucked therebehind. In such a situation, screws 22 may provide an ideal attachment between theanchor 16 and thefixture 12. Thescrews 22 may be removed, thus freeing thefixture 12. Theanchors 16 may maintain engagement with theconnection box 14. After the revisions are complete thefixture 12 may once again be secured to theanchors 16 by the insertion of thescrews 22 previously removed. - In selected applications, multiple points of securement between a
fixture 12 and aconnection box 14 may exist. In such situations, ananchor 16 in accordance with the present invention may be applied to all or a subset of the securement locations. For example,power receptacles 12 and switches 12 are typically secured toconnection boxes 14 by two screws spaced from each other in alongitudinal direction 11 a. Ananchor fasteners connection box 14 may havemultiple receivers anchors - The method of engagement between a
receiver 18 and ananchor 14 may be selected to provide a fast, clean securement. By so doing, thefixture 12 may be secured to theconnection box 14 in a minimum amount of time. For example, installers (e.g. electricians, network technicians, cable television installers, and the like) spend a large portion of their installationtime screwing fixtures 12 toconnection boxes 14. In certain embodiments in accordance with the present invention, a fastener 22 (e.g. screw 22) may be introduced to secure ananchor 16 to the appropriate locations on afixture 12 by a manufacturing machine. Thus, the installation of thefastener 22 may be performed in ideal conditions with proper alignment and fast tool speeds. In the field, when an installer installs thefixture 12, the time consuming screw installation no longer needs to be performed. Ananchor 16 may simply be inserted into areceiver 18. - The embodiments of the
fixture 12,connection box 14, anchors 16a, 16b, receivers 1 8a, 1 8b, and faceplate 20, as illustrated inFIG. 1 may be arranged and designed in a wide variety of different configurations that fall within the scope of the present invention. Thus, the description hereinabove is not intended to limit the scope of the possible embodiments, but is merely representative of certain presently preferred embodiments of devices and systems in accordance with the invention. The information is intended only by way of example. - Referring to
FIG. 2 , ananchor 16 in accordance with the present invention may have anengagement mechanism 24 configured to provide a mechanical grip with areceiver 18. If ananchor 16 is to be secured to afixture 12 by abolt 22 orscrew 22, a threadedaperture 26 may be formed therein. The threadedaperture 26 may extend completely or only partially through theanchor 16 in atransverse direction 11 c. - A
length 28 of theengagement mechanism 24 may be selected to provide a desired number ofengagement locations 30. In selected embodiments, eachengagement location 30 is atooth 30. Additionally, theengagement length 28 and the number ofengagement locations 30 may be selected to permit insertion of theanchor 16 a desired distance into thereceiver 18. Thus, providing a desired alignment of thefixture 12 with respect to theconnection box 14. - In selected embodiments, an
anchor 14 in accordance with the present invention may include aspacer 32. The length 34 of thespacer 32 may be selected to provide additional control over the spacing of thefixture 12 in relation to theconnection box 14. - In certain embodiments, one
end 36 of theanchor 16 maybe formed to promote easy insertion into thereceiver 18. For example, anend 36 may be pointed, rounded, tapered, or otherwise formed. - An
anchor 16 in accordance with the present invention may have any suitable cross-section. For example, the cross-section may be rectangular, circular, triangular, oval, an unconventional shape, or the like. The cross-sectional shape of ananchor 16 may be selected to resist rotation about atransverse axis 11 c once installed inside areceiver 18. For example, ananchor 16 having a generally circular cross-section may have a key-way formed therein to correspond to a key formed or located in thereceiver 18. - The shape and configuration of a
receiver 18 may be selected to match and complement the particular shape of a selectedanchor 16. For example, if ananchor 16 having a rectangular cross section is desired, thereceiver 18 may be formed to have a generally rectangular shape. Thus, thereceiver 18 may admit theanchor 16 and hold theanchor 16 securely without motion (e.g rotation about atransverse axis 11 c) therebetween. - Referring to
FIG. 3 , in certain embodiments, ananchor 16 may have multiple sliding surfaces 38 to promote ease of insertion and proper alignment. A recessedgroove 40 may be formed in one or more surfaces 38 of theanchor 16 to provide a location for disposition of anengagement mechanism 24. Such anengagement mechanism 24 may be recessed to reduce the risk of interfering with proper insertion of theanchor 16 into thereceiver 18. - Referring to
FIG. 4 , ananchor 16 may have a generally circular cross-section. In such an embodiment, the anchor may include a single flat 42 or may include a plurality offlats 42 that provide a location for disposition of anengagement mechanism 24. Theflats 42 may also provide a location for a correspondingreceiver 18 to engage theanchor 16 to resist rotation about atransverse axis 11 c. -
FIG. 4 also illustrates an alternative embodiment of afastener 22 in accordance with the present invention. Opposing engagement hooks 22 may be shaped to promote insertion into a corresponding aperture in afixture 12. The engagement hooks 22 may be formed to engage an aperture of any suitable shape (e.g. circular, oval, triangular, or the like). The illustrated engagement hooks 22 have been formed in a shape to fit a square aperture. A square aperture may provide a mechanism to resist rotation of theanchor 16 about atransverse axis 11 c with respect to acorresponding fixture 12. Engagement hooks 22 in accordance with the present invention may flex to allow ananchor 16 to be separated from thefixture 12 to which theanchor 16 is attached. Once separated, theanchor 16 andfixture 12 may be reattached by reinserting the engagement hooks 22 of theanchor 16 through the corresponding aperture in thefixture 12. - The embodiments of
anchors 16, as illustrated inFIGS. 2-4 , could be arranged and designed in a wide variety of different configurations that fall within the scope of the present invention. Thus, the description hereinabove is not intended to limit the scope of the possible embodiments, but is merely representative of certain presently preferred embodiments of devices and systems in accordance with the invention. The information is intended only by way of example and not by way of limitation. - Referring to
FIGS. 5-6 while continuing to refer generally toFIGS. 1-4 , as discussed hereinabove, ananchor 16 in accordance with the present invention may have multiple sliding surfaces 38. The sliding surfaces 38 may maintain proper alignment of theanchor 16 with respect to thereceiver 18. - In selected embodiments, a
receiver 18 in accordance with the present invention may include anengagement mechanism 39. Thisengagement mechanism 39 may be configured to engage theengagement mechanism 24 of ananchor 16. In selected embodiments, anengagement mechanism 39 may comprisehooks 44 orbarbs 44. Thesebarbs 44 may extend from thereceiver 18 with a shape selected to engage theteeth 30 of theanchor 16. The engagement of thehooks 44 andteeth 30 may be selected to provide unidirectional motion so that ananchor 16 may be easily inserted yet resist removal in atransverse direction 11 c. The number ofteeth 30 and theincremental distance 46 therebetween may be selected to provide a continuum of possible locking positions between theanchor 16 and thereceiver 18. - Referring to
FIGS. 7-8 while continuing to refer generally toFIGS. 1-6 , in an alternative embodiment, ananchor 16 may include asingle hook 44. In selected embodiments, ananchor 16 may includemultiple hooks 44. Aflexible region 48 may permit ahook 44 to flex as it “clicks” or passes over theteeth 30 of areceiver 18. As discussed hereinabove and as best shown inFIG. 8 , the number ofteeth 30 and theincremental distance 46 therebetween may be selected to provide a continuum of possible locking positions between theanchor 16 and thereceiver 18. - Referring to
FIG. 9 , in selected embodiments, the engagement between ananchor 16 and areceiver 18 may not be incremental, rather a single locking position may be defined. In such an embodiment, theanchor 16 may be inserted into thereceiver 18 until alock 50 is activated. In selected embodiments, alock 50 may consist of ahook 44 secured on the distal end of aflexible region 48. A stop 52 may provide a register to correctly position theanchor 16 with respect to thereceiver 18. When theanchor 16 is inserted to the stop 52, ahook 44 may engage anengagement location 30 of thereceiver 18. - Referring to Figure. 10, the length 28 (see
FIG. 2 ) of theengagement mechanism 24 may be selected to best match the particular application to which theengagement mechanism 24 may be applied. For example, the installation of alight fixture 12 may be simplified by employing a comparativelylong anchor 16 having a similarlylong engagement mechanism 24. In such an application, twolong anchors 16 may be secured to thefixture 12. Theanchors 16 may be introduced into the correspondingreceivers 18 a distance sufficient to engage theengagement mechanisms 39 thereof. Theanchors 16 may then hold thefixture 12 in place while the installer proceeds to connect thenecessary wires 54. Upon completion of the connecting of thewires 54, thefixture 12 may be pushed in atransverse direction 11 c until a proper position is achieved. Thus, the installer need not hold thefixture 12 while connectingwires 54 and tightening terminal screws 56. - Referring to
FIG. 11 , areceiver 18 may be associated with aconnection box 14 in any suitable manner. In selected embodiments, thereceiver 18 may be formed as an integral part of theconnection box 14. This forming may be part of a molding process. That is, thereceiver 18 may be molded as part of theconnection box 14 in its original forming process.FIG. 11 illustrates an embodiment in which thereceiver 18 is formed by stamping selected shapes from ametal connection box 14 and then bending the cut portions in a selected direction to form aguide 57 and anengagement mechanism 39. In an alternative embodiment, areceiver 18 may be formed (e.g. molded, extruded, cast, machined, stamped, or the like) and then joined to theconnection box 14. Such a joining may be accomplished by bolting, screwing, welding, gluing, bonding, or the like. - Referring to
FIG. 12 ,connection boxes 14 are typically installed and wired before the installation of the wall paneling (e.g., ceiling paneling and the like).Fixtures 12 andface plates 20 are typically installed after the installation of the wall paneling. The installation of wall paneling often involves the application of dry wall compound. It is very common for clumps of dry wall compound to be inadvertently introduced inside a previously installedconnection box 14.Receivers 18 in accordance with the present invention may be formed in a manner to greatly limit the adverse effects of misplaced dry wall compound. - For example, if dry wall compound were placed in the
receiver entrance 58, the receiver may be formed to have anopen back exit 59. Thus,anchor 16 may be inserted into thereceiver 18 and any clump of dry wall compound may simply be pushed out the back 59 of thereceiver 18. The back 59 may be open to the exterior of theconnection box 14. The back 59 may also be configured to open to the interior of theconnection box 14. In such a configuration, a dry wall compound clump will be pushed to the interior of theconnection box 14 where it can do no harm. - Embodiments in accordance with the present invention may be applied to any
unit 12 for which permanent or removable securement to aconnection box 14 is desired. Data terminals such as phone jacks, network jacks, cable connections, and the like may not have afixture 12 associated therewith. These applications may deliver a transmission line to ajack 60 orconnector 60 mounted directly in aface plate 20. Theface plate 20 provides the structure and support for thejack 60, and indeed may provide many of the same functions as afixture 12. Typically these face plates have been secured directly to a corresponding connection box by multiple screws. Installation of such screws presents difficulties similar to those encountered in the installation offixtures 12. -
FIG. 12 illustrates one embodiment of a jackconnection box assembly 10 in accordance with the present invention.Interface members face plate 20 and anchors 16 a, 16 b. In selected embodiments, the interface members 62 may include anaperture 64 to accommodate securement of ananchor 16.Additional apertures 66 may provide locations for theface plate 20 to engage the interface members 62. In certain embodiments,extensions 68 or “dog ears” 68 may be incorporated to hold each interface member 62 flush with the wall paneling. - The interface members 62 may be formed in any suitable shape for providing adequate engagement between an
anchor 16 and aface plate 20. In one embodiment, the interface members 62 are generally flat pieces havingmultiple apertures extensions 68. The interface members 62 may be constructed of any suitable material. In selected embodiments, interface members 62 may be formed by stamping sheet metal. In alternative embodiments, interface members 62 may be molded from a polymer, a composite, or the like. - Referring to
FIGS. 13-15 , as discussed hereinabove, after the installation of afixture 12, aface plate 20 is typically secured thereto to hide the under workings from view.Conventional face plates 20 are often secured by at least one screw. Screws and other securement devices may be unsightly. Screws used to secureface plates 20 to receptacles and switches are typically painted and are, therefore, exposed to chipping, tarnishing, wear, oxidation, and the like. In such applications, it may be desirable to provide a snap-on assembly to provide fast securement of aface plate 20 without the use of screws. -
FIGS. 13-15 illustrate one embodiment of ascrewless face plate 20 in accordance with the present invention. In selected embodiments, aface plate 20 may include engagement prongs 70. The engagement prongs 70 may engage afixture 12 and maintain theface plate 20 aligned and secured thereto. Thus, once aface plate 20 has been attached, acomplete fixture 12 assembly may be quickly and easily wired and then secured to acorresponding connection box 14. -
Selected fixtures 12 in accordance with the present invention may includeflanges 72.Flanges main body 74 of afixture 12 in a longitudinal direction 1I a. In selected embodiments, theflanges 72 may include anaperture 64 to accommodate the securement of ananchor 16.Additional apertures 66 may provide locations for the engagement prongs 70 of theface plate 20 to engage theflanges 72. In certain embodiments,extensions 68 or “dog ears” 68 may be selected to hold thefixture 12 flush with the wall paneling. - Engagement prongs 70 in accordance with the present invention may be formed to have
multiple hooks hooks 76 may be secured to theface plate 20 by flexible necks 78 a, 78 b, 78 c, 78 d, respectively. Aflex clearance 80 may be provided between thehooks 76 so that as theprong 70 is inserted through anaperture 66, thehooks 76 may deflect toward each other, thus, effectively reducing the diameter of theprong 70. Once theprong 70 has passed through theaperture 66, thehooks 76 may return to their neutral position and engage the edges of theaperture 66. - Referring to
FIGS. 16 and 17 , in selected embodiments, thehooks 76 may be shaped to release at a desired removal loading, thus, once theface plate 20 is removed, theface plate 20 may be used again. For example, thehooks 76 may be provided with aninside taper 82. Theinside taper 82 may allow eachhook 76 to gradually flex and bend towards theflex clearance 80 as theface plate 20 is pulled away from thefixture 12 so that the effective diameter of theengagement prong 70 may be reduced and theprong 70 may be removed from theaperture 66. In an alternative embodiment, aface plate 20 in accordance with the present invention may be removed by applying sufficient force to fail thehooks 66. - A
screwless face plate 20 in accordance with the present invention may be formed of any suitable material. This material may be selected based on several characteristics including cost, aesthetics, dielectric constant, thermal capacity, strength, toughness, flexibility, formability, and the like. - Engagement prongs 70 in accordance with the present invention may have any suitable configuration. The number of
prongs 70 may range from one to several and be selected to provide a balanced securement between aface plate 20 and afixture 12. The number ofhooks 76 making up eachprong 70 may also range from one to several depending on a desired engagement strength, ease of manufacture, ease of installation, ease of removal, and the like. In certain embodiments, the engagement strength may be balanced with a desired release loading. The general shape or contour of theprongs 70 may also be selected to provide a desired engagement strength, ease of manufacture, ease of installation, ease of removal, and the like. - Referring to
FIGS. 18-20 , alternative embodiments in accordance with the present invention may employ alternative methods for securing ascrewless face plate 20 to afixture 12. In one alternative embodiment, aflange 72 a of afixture 12 may have anengagement lip 84 formed therein. Aextension 86 may be formed in association with acorresponding face plate 20. Theengagement lip 84 may be configured to fit behind theextension 86 to hold the upper portion of theface plate 20 to theflange 72 a. - An
aperture 66 may be formed in aflange 72 b of thefixture 12. Acorresponding engagement prong 70 may be formed in association with theface plate 20. Theprong 70 illustrated inFIGS. 18-19 is an example of a single hook,rectangular prong 70. Theaperture 66 may be shaped to correspond to the design of theprong 70. In selected embodiments, thelip 84/extension 86 andaperture 66/prong 70 combinations may cooperate to secure theface plate 20 to thefixture 12. Such an embodiment may be installed by first inserting thelip 84 behind theextension 86 and then rotating theface plate 20 down against thefixture 12 until the prong(s) 70 may be inserted into the corresponding aperture(s) 66. Theprong 70 engagement may provide a tie to resist the tendency of thelip 84 to disengage from theextension 86. - An
engagement lip 84 in accordance with the present invention may be divided intomultiple engagement lips 84. In selected embodiments, anupper flange 72 a may be formed into twolips lips notch 88. Astop 90 may be formed as part of acorresponding extension 86. Thestop 90 may fit into thenotch 88 to prevent lateral motion between theupper flange 72 a and theface plate 20. - In certain embodiments, ends 92 may form an
enclosure 94 in combination with anextension 86 andcorresponding face plate 20. The ends 92 may function to laterally retain thelip 84 of aflange 72 a, when assembled. - In selected embodiments, a
face plate 20 in accordance with the present invention may have anaccess notch 96. In certain embodiments, anaccess notch 96 may simply provide a hold to permit the application of force to “pop” aface plate 20 from acorresponding fixture 12. In alternative embodiments, theaccess notch 96 may provide access behind theface plate 20 to a slender tool. The slender tool may then be used to assist in the release of anengagement prong 70. - Referring to
FIG. 21 , an alternative embodiment of an engagement between ascrewless face plate 20 and afixture 12 may involve the engagement of anedge 98 of theflanges 72 of thefixture 12. One or more of the engagement prongs 70 of theface plate 20 may be configured to engage anedge 98. In selected embodiments, theprongs 70 may be formed to have ahook 76 and aflexible neck 78. In certain embodiments, aflange 72 may include aformation 100 to resist motion in alongitudinal direction 11 a of aface plate 70 with respect thereto. Such aformation 100 may be formed by bending, cutting and bending, notching, or similarly modifying theedge 98 to resist sliding of aprong 70 therealong in alongitudinal direction 11 a. - Referring to
FIG. 22 , an alternative embodiment of an engagement between ascrewless face plate 20 and afixture 12 may involve an engagement between aface plate 20 and aninterface 104 of afixture 12. Typically, theinterface 104 of afixture 12 extends a selecteddistance 106 to provide a flush joint with aface plate 20. That is, theinterface 104 extends to provide a facing 108 that may be substantially coplanar with asurface 110 of theface plate 20, thereby improving aesthetic appeal. The area of the facing 108 may be selected to correspond to a selectedinterface 104. Power outlet plugs 104 provide a relatively large surface area. In contrast, switches 104 typically have a toggle central unit and a thin border providing minimal surrounding facing 108. - The
extension distance 106 of theelectrical interface 104 provides the surface (substantially perpendicular to the facing 108) of anedge 102. Anedge 112 of an aperture 114 (theaperture 114 may admit theinterface 104 through the face plate 20) may be configured to engage theedge 102 of theinterface 104. This engagement may be of any suitable form. For example, the engagement may involve any suitable combination of tabs, recesses, hooks, shoulders, and the like. - In selected embodiments, the engagement between the
edges tabs 116 formed on theface plate 20 and recesses 118 formed in theinterface 104. The shape, number, and location of these corresponding pairs may be selected to provide a desired engagement strength, magnitude, and balance. Engagement strength refers to the amount of force required to apply and secure theface plate 20 to thefixture 12 or, alternatively, the force required to separate theface plate 20 from thefixture 12. The engagement strength-may be selected to provide fast “snap-on” assembly without risking inadvertent removal of theface plate 20 and possible electrical shock resulting therefrom. - Referring to
FIGS. 23 and 24 , anadapter 120 may be provided to convert or retrofit aconventional fixture 12 to receive ascrewless face plate 20. In selected embodiments, anadapter 120 in accordance with the present invention may include anaperture 122 corresponding toaperture 64 of aflange 72. Afastener 22 used to secure ananchor 16 to afixture 12 may also pass through theaperture 122 to hold anadapter 120 in place against theflange 72. Theadapter 120 may extend to provideapertures 68 for admitting theprongs 70 of acorresponding face plate 20. In this manner, a snap-on,screwless face plate 20 may be retrofitted to typical power receptacles and switches. - An
adapter 120 in accordance with the present invention may be formed of any suitable material. In selected embodiments, theadapter 120 may be formed by stamping sheet metal. In an alternative embodiment, theadapter 120 may be a molded polymer or composite. - From the above discussion, it will be appreciated that the present invention provides an apparatus and method for fast and simple connection box assembly without screw rotation and the time associated therewith. An embodiment in accordance with the present invention may provide an apparatus for securing a fixture to a connection box. In a factory manufacturing process an anchor may be secured to a fixture. The anchor may have an engagement mechanism formed therewith. A connection box may be provided to house wires proceeding from a source to terminate therein. A receiver may be associated with the connection box. The receiver may have an engagement mechanism formed to receive and retain the engagement mechanism of the anchor. Thus, the anchor and receiver may be intermediaries in the securement of the fixture to the connection box. Face plates in accordance with the present invention may have engagement prongs. These prongs may be inserted through apertures in a corresponding fixture to maintain the face plate aligned securely thereagainst. A face plate may be installed by simply pressing the engagement prongs through the appropriate apertures in the fixture. Once a fixture has been wired and a face plate applied thereto, the resulting assembly may be secured to the connection box by inserting one or more of the attached anchors into corresponding receivers associated with the connection box. The anchor may be inserted a depth into the receiver selected to properly position the face plate. Insertion of an anchor into a receiver may be accomplished without the aid of tools.
- The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative, and not restrictive. The scope of the invention is, therefore, indicated by the appended claims, rather than by the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope.
- What is claimed and desired to be secured by United States Letters Patent is:
Claims (20)
Priority Applications (3)
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US12/727,091 US8109785B2 (en) | 2001-03-06 | 2010-03-18 | Connection box assembly method |
US13/366,674 US20120132456A1 (en) | 2001-03-06 | 2012-02-06 | Connection box assembly method |
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US09/974,306 US6609927B2 (en) | 2001-03-06 | 2001-10-10 | Quick assembling electrical connection box apparatus and method |
US10/435,716 US7118413B2 (en) | 2001-10-10 | 2003-05-08 | Quick assembling electrical connection box apparatus and method |
US11/286,033 US20060079125A1 (en) | 2001-03-06 | 2005-11-23 | Connection box assembly method |
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US11/286,033 Abandoned US20060079125A1 (en) | 2001-03-06 | 2005-11-23 | Connection box assembly method |
US11/286,090 Expired - Fee Related US7395598B2 (en) | 2001-03-06 | 2005-11-23 | Face plate securement method |
US11/542,746 Expired - Fee Related US7494371B2 (en) | 2001-03-06 | 2006-10-04 | Pronged, screwless face plate |
US12/727,091 Expired - Fee Related US8109785B2 (en) | 2001-03-06 | 2010-03-18 | Connection box assembly method |
US13/366,674 Abandoned US20120132456A1 (en) | 2001-03-06 | 2012-02-06 | Connection box assembly method |
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US10/435,716 Expired - Fee Related US7118413B2 (en) | 2001-03-06 | 2003-05-08 | Quick assembling electrical connection box apparatus and method |
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US11/286,090 Expired - Fee Related US7395598B2 (en) | 2001-03-06 | 2005-11-23 | Face plate securement method |
US11/542,746 Expired - Fee Related US7494371B2 (en) | 2001-03-06 | 2006-10-04 | Pronged, screwless face plate |
US12/727,091 Expired - Fee Related US8109785B2 (en) | 2001-03-06 | 2010-03-18 | Connection box assembly method |
US13/366,674 Abandoned US20120132456A1 (en) | 2001-03-06 | 2012-02-06 | Connection box assembly method |
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Also Published As
Publication number | Publication date |
---|---|
US20040018779A1 (en) | 2004-01-29 |
US20100270053A1 (en) | 2010-10-28 |
US20060079126A1 (en) | 2006-04-13 |
US20070066133A1 (en) | 2007-03-22 |
US7494371B2 (en) | 2009-02-24 |
US8109785B2 (en) | 2012-02-07 |
US7118413B2 (en) | 2006-10-10 |
US20120132456A1 (en) | 2012-05-31 |
US7395598B2 (en) | 2008-07-08 |
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