US20060105625A1 - Electrical receptacle and junction box free of wire-nuts - Google Patents

Electrical receptacle and junction box free of wire-nuts Download PDF

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Publication number
US20060105625A1
US20060105625A1 US10/990,035 US99003504A US2006105625A1 US 20060105625 A1 US20060105625 A1 US 20060105625A1 US 99003504 A US99003504 A US 99003504A US 2006105625 A1 US2006105625 A1 US 2006105625A1
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United States
Prior art keywords
box
electrical
molded
recited
aperture
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Abandoned
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US10/990,035
Inventor
James Scott
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Individual
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Individual
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Application filed by Individual filed Critical Individual
Priority to US10/990,035 priority Critical patent/US20060105625A1/en
Priority to PCT/US2005/041466 priority patent/WO2006055600A2/en
Priority to US11/274,981 priority patent/US7294017B2/en
Publication of US20060105625A1 publication Critical patent/US20060105625A1/en
Priority to US11/443,238 priority patent/US20060216988A1/en
Abandoned legal-status Critical Current

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    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02GINSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES
    • H02G3/00Installations of electric cables or lines or protective tubing therefor in or on buildings, equivalent structures or vehicles
    • H02G3/02Details
    • H02G3/08Distribution boxes; Connection or junction boxes
    • H02G3/081Bases, casings or covers
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R9/00Structural associations of a plurality of mutually-insulated electrical connecting elements, e.g. terminal strips or terminal blocks; Terminals or binding posts mounted upon a base or in a case; Bases therefor
    • H01R9/22Bases, e.g. strip, block, panel
    • H01R9/24Terminal blocks
    • H01R9/2491Terminal blocks structurally associated with plugs or sockets
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02GINSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES
    • H02G3/00Installations of electric cables or lines or protective tubing therefor in or on buildings, equivalent structures or vehicles
    • H02G3/02Details
    • H02G3/08Distribution boxes; Connection or junction boxes
    • H02G3/16Distribution boxes; Connection or junction boxes structurally associated with support for line-connecting terminals within the box
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/40Securing contact members in or to a base or case; Insulating of contact members
    • H01R13/405Securing in non-demountable manner, e.g. moulding, riveting

Definitions

  • the present invention relates generally to electrical receptacle connector boxes and, more particularly, to an electrical connector box having terminal connectors for allowing economical, safe, quick, and easy wiring of both electrical devices and electrical connectors without the use of wire-nuts.
  • wires carrying electricity are brought into the building from an outside source.
  • electrical conductors must be routed through the walls of the building to the many areas where power is desired and/or required. Once the electrical conductors are positioned within the structure, they must then be connected to either electrical devices or to continuing electrical conductor supply lines to ultimately supply electrical power for an end use, such as for light switches, plug outlets, and the like. Electrical conductors are usually connected to other electrical conductors or to electrical devices within a junction or receptacle box, respectively.
  • a junction box is essentially a container to house electrical conductor connections.
  • the actual electrical connections between a lead line and a wire emanating from an electrical device, such as a light-switch, may be first encased inside of a plastic “wire-nut” which is nothing more than a thimble-shaped and sized plastic cup designed to force the ends of wires together.
  • the wire-nuts with their protruding wires are then housed in an electrical connection box. If a wire-nut is not used to make the connection, electrical tape may be used, although this is considered an unsatisfactory solution as it is well-known that electrical tape loses its properties with time.
  • Wire-nuts while supposedly providing for an improvement over the use of electrical tape to secure electrical connections, provide little protection against wires that are connected within the nut becoming disconnected. This is a particular problem where several wire-nut encased wires are positioned within a junction or receptacle box and then must be hard-pressed into the box so that a switch and a switch plate cover is able to be secured over the opening of the box. Squeezing the wire-nut encased wires into the box in such a manner often results in broken connections.
  • wires that have been connected within a wire-nut become disconnected so frequently that some wire-nuts are now designed to be crimped. That is, once the wires to be connected are connected and placed inside of the wire-nut, the wire-nut is permanently crimped closed using a wire-nut crimper to ensure that the connected wires inside of the nut stay connected.
  • One of the negative repercussions of crimping wire-nuts is that if a repair or replacement is required after the wire-nut has been crimped, the wires must be cut free from the crimped wire-nut, as it is impossible to remove the wires from the wire-nut after the wire-nut has been crimped.
  • an electrical junction box configured to receive electrical conductors through openings in each of the end panels of the box.
  • Each electrical conductor is held in place by clamping means that are located adjacent to an opening.
  • the clamping means includes a contact shoe which is initially formed with the housing, but which is designed to be separated from the housing when the conductor is to be clamped. Breaking a tab that initially anchors the shoe to the housing enables the shoe to be brought into clamping engagement with the conductor at which time the shoe is secured to the housing. However, once the shoe is broken away from the housing to clamp the conductor to the box, it would be difficult to use the box again.
  • Another plug and switch receiving device that attempts to offer improved means for securing wires, comprises a complex, multi-part receptacle box that requires at a minimum two discrete pieces that must be attached to each other before the box can be attached to a structure so that a plug, switch, or similar device is able to be attached to a electrical conductor within the box.
  • Another example comprises a plug receptacle that must be first attached to a first front part of a receptacle box and then to a second inner part of the box using spring clips that are designed to extend through the first and second parts to reach a third part at which point connection is made between electrical device wires and a electrical conductor.
  • Such spring-type clips are prone to a loss of their springiness, to breakage, and/or rusting, if metal.
  • This type of custom made device is complicated and requires all of its parts to be specially made, which of course adds significantly to the cost of manufacture.
  • Such devices cannot accept off-the-shelf receptacles or switches as they do not come provided with the requisite prongs for fitting into the spring clips.
  • Another attempt teaches a specialized style of electrical receptacle outlet box that offers off-set mounting panels adjacent to either side of the box opening. Each mounting panel is angled away from the box opening to allow for easy access of the wiring terminals that are mounted on the interior side of these panels and to allow for conventional wiring to be pre-terminated within the outlet box. Each wiring terminal is shown having a single aperture to accept both wires and wire holding means, which could compromise the integrity of the wires that are positioned in the aperture. Additionally, the atypical shape of such boxes suggests that they would not likely be an acceptable candidate for use in commercial or home construction. Furthermore, these unusually shaped boxes would be much more complex to manufacture and thus are likely to more costly.
  • the present invention satisfies the urgent need in the art for a molded box-like container that provides for either an electrical wire connector or junction box that eliminates the need for the ubiquitous nut connectors of questionable safety that are presently relied on to connect conductor wires inside a junction box.
  • the molded box is of simple, streamlined, and economical construction.
  • the electrical receptacle box according to the principles of the present invention allows a user to rapidly and repeatedly pre-wire, wire, or re-wire conventional residential, commercial, or industrial wiring systems.
  • the present invention successfully alleviates the problems commonly suffered when wire-nuts or crimped wire-nuts are used to make wire connections in either electrical connector or junction boxes by providing for a box that is molded in one piece where the wiring terminals (also referred to as block connectors, block terminals, or terminal blocks) are molded into the box to become an integral part of the box.
  • These wiring terminals comprise small, mainly hollow, box-like interior extensions positioned within a junction box of any desired size or shape.
  • the number of wiring terminals in a box is determined by the number of connections required. The low cost of these boxes, however, would allow multiple wiring terminals to be a part of each box, so that various box models would not be required.
  • each wiring terminal Within the body of each wiring terminal is a space that is accessible by a first and a second aperture.
  • the wires from the electrical conductor and the electrical device are placed into one aperture and secured by the tightening of a screw, or the like, that is placed into the second aperture. Tightening of the screw prevents the wires from inadvertently becoming disconnected, yet loosening of the securing means allows the connected wires to be disconnected, if necessary, and reconnected, if desired.
  • the fixed position of the wiring terminals ensures that once the connected wires are fixedly secured and protected by the securing means, the wire connection need not be disturbed and thus is safe from having the connection broken, unlike connections that are made within moveable wire-nuts.
  • the screw or other securing means is easily loosened and the wires removed without any need to cut the wires or to prevent further use of the device.
  • the tightening means is usually a ubiquitous means, such as a screw, which means is easily replaced at minimal cost in case the original tightening means is misplaced or damaged.
  • the present invention provides more room in the box for switches, receptacles, or both.
  • the box would have multiple wiring or block terminals. All block terminals are molded into the box when they are manufactured and would be made of a known, or yet to be known, conducting material, such as copper or aluminum. Set screws, or other means for securing the connecting wires, are provided with each box.
  • no extra parts are needed for the installation or of the junction box as described herein, preventing the need for last minute trips to the hardware store because a required piece of hardware is missing.
  • the junction box may be molded in one piece from a variety of non-conductive materials, such as plastic, it can be mass-produced at low cost making the device attractively affordable to all. If desired, however, the box may be made from a variety of other materials, such as fiber glass or ceramic, and even such conductive materials, such as steel, aluminum, or the like, may be used provided that any conductive material would insulated. Additionally, the molding process is amenable to the easy addition of an anchoring device to the box, such as a series of eye holes to be added to the molded junction box during production without incurring significant additional cost, while simultaneously increasing the versatility of the device.
  • an anchoring device such as a series of eye holes to be added to the molded junction box during production without incurring significant additional cost, while simultaneously increasing the versatility of the device.
  • the box can be made through any standard molding technique, a wide range of shapes and sizes, depending on the desired use, may be contemplated while within the scope of the invention.
  • the size, and perhaps the shape, of a box used for the installation of a light switch would be different than that of a box to be used as a junction box for five electrical conduits.
  • a molded electrical receptacle box comprising:
  • the back panel, the side panels, and the end panels are adapted to form accessible internal volume
  • the end panels have at least one opening that is configured to receive at least one electrical conductor therethrough for positioning in the accessible internal volume of the molded electrical connection box, and where an open front face, which is opposite to the back panel, is configured to receive an electrical device, and
  • connection box where at least one wiring terminal block is integrally molded onto the connection box providing for reversible electrical connection between the conductor and an electrical device.
  • the molded electrical receptacle box further comprises wherein the wiring terminal is designed as a block terminal, which terminal may be made of a conducting material that may or may not be faced with a non-conducting material.
  • the molded electrical receptacle box provides for an electrical conductor to be secured into at least one of the block terminals by a securing means, which may be a set screw or the like.
  • the electrical device that is received into the open front face may be any type of electrical device such as a plug receptacle or a switch, for example.
  • the molded electrical receptacle box further comprises wherein the block terminal has an at least first aperture opening to an at least second aperture, wherein at least one electrical conductor and at least one wire from an electrical device are positioned into at least one second aperture wherein electrical connection is made between said electrical conductor and electrical device and wherein said electrical connection is secured by a securing means that is positioned into said at least first aperture.
  • the molded electrical receptacle box may be molded by any known molding means and, therefore, may be manufactured from a plastic, metal, or other material.
  • the molded electrical connection box may be molded with means for mounting the box to a support.
  • Another molded electrical box comprises:
  • back panel, the side panels, and the end panels are adapted for forming accessible internal box volume
  • end panels have at least one opening configured to receive at least one electrical conductor therethrough for positioning in the accessible internal volume of the box
  • connection box where at least one wiring terminal is integrally molded onto the connection box, wherein the wiring terminals provide for reversible electrical connection between electrical conductors, in the manner that is discussed above.
  • the molded electrical junction box wherein the wiring terminal may be a block terminal, wherein the block terminal may be made of a conducting material that may, or may not be, faced with a non-conducting material.
  • FIG. 1 is a perspective top view of the junction box according to principles of the present invention.
  • FIG. 2 is a perspective bottom view of the junction box as shown in FIG. 1 .
  • FIG. 3 is a partial perspective sectional view of an inner side panel of the junction box taken along line 3 - 3 ′ of FIG. 1 .
  • FIG. 4 is a partial perspective sectional view of the opposite inner side panel of the junction box taken along line 44 ′ of FIG. 1 .
  • Integral refers to a whole made up of parts, wherein the parts are formed united as one unit and are all of one and the same single piece.
  • Molded refers to any process wherein an object is produced as one solid piece, either by casting, forming, injection into a mold, or any other acceptable means that provides for a integral construction.
  • Electrical Device refers to any device that either uses or implements electricity, which includes, but is not limited to, plug receptacles, switch plates, and the like.
  • Block or Wiring Terminal refers to a means for connecting electrical wires and may be referred to as terminal blocks, connectors, connecting blocks, wire connectors and the like.
  • the block terminals comprises a small, relative to the electrical connector box of which it is a part, container having at least two apertures that are internally connected to one another for receiving connecting wires and securing those wires through the use of securing means, such as screws.
  • the block terminal(s) which may be of curvilinear as well as block form, provide for rapid, safe, and secure connection of electrical wires and, if desired, provides for the connection(s) to be unsecured without damaging the wires, the securing means, or the block terminal.
  • Electrical Conductor refers to any wire or cable that carries an electrical current.
  • FIG. 1 presents a perspective top view of the molded electrical connection box 10 , which box is to be understood to be an exemplary embodiment of this invention.
  • Box 10 demonstrates how the above mentioned disadvantages have been overcome.
  • the disclosed invention is disposed to embodiments in various sizes, shapes, and forms. Therefore, the embodiments described herein are provided with the understanding that the present disclosure is intended as illustrative and is not intended to limit the invention to the embodiments described herein.
  • FIG. 1 illustrates a molded electrical connection box 10 according to the teachings of the present invention.
  • Box 10 consists of two end panels each having an exterior surface 22 a and an interior surface 26 b , two side panels each having an exterior surface 20 a and interior surface 24 b , and bottom panel with exterior surface 28 a , wherein the end panels, side panels, and bottom panel are arranged to provide an inner volume that is to be used for the connection and storage of electrical and ground wires.
  • Mounting flanges 12 a - 12 d may extend from the bottom 28 a and may be used to secure box 10 to a support feature, such as wall framing.
  • Apertures 13 a - 13 d placed through mounting flanges 12 a - 12 d allow for an attachment means (not shown), such as conventional screws, nails, bolts, or the like, to extend through the apertures to provide for mounting of box 10 on a support feature.
  • FIG. 2 which provides a perspective view of the bottom of box 10 , illustrates one example of mounting flanges 12 a - 12 d integrally formed as an extension of bottom surface 28 a of box 10 , although, as mentioned above, the position, size, and style of the flanges or other mounting means may be changed, as required.
  • Extending through opposing sides of box 10 are cable openings and supports 14 a and 14 b providing for cable access to the interior of connector box 10 and for support of said cable so that the cable may be positioned in the inner volume of box 10 to make electrical connection to another electrical element within box 10 .
  • the examples illustrated in FIGS. 1 and 2 show cable openings 14 a and 14 b positioned through the end panels identified by their outer surface 22 a and their inner surface 26 b , respectively. Opening supports 14 a and 14 b are shown as being contiguous with the panels through which they extend, and additionally, may provide for another means of anchoring box 10 securely in place.
  • pylons 30 a - 30 d integrally formed as an internal part of molded electrical connector box 10 and functionally designed to provide for the reversible attachment of any standard receptacle, switch, or cover plate securely to the box. This attachment is accomplished by placing the desired cover (not shown) over the open front face of the box and by inserting any standard connection means, such as screws, through screw holes typically provided on such covers and into pylons 30 a - 30 d , which are designed to accept and securely hold such connection means.
  • any standard connection means such as screws
  • pylons 32 a and 32 b are functionally designed to provide in connector box 10 means for mounting an electrical device securely in the box 10 , which, of course, is accomplished before a cover is placed over the box and the device secured to the box.
  • pylons 30 a - 30 d are designed to utilize any standard mounting means, including, but not limited to screws.
  • Pylons 30 a - 30 d and 32 a and 32 b are each supported and connected to the interior of end or side panels by a flange identified by reference number 32 , as illustrated in FIGS. 3 and 4 .
  • FIG. 3 provides a partial perspective sectional view taken along line 3 - 3 ′ of FIG. 1 illustrating inner surface 24 b of one side panel of the junction box. Also illustrated are connector blocks 40 and 42 shown as being integral parts of box 10 . It is contemplated that the block terminals are made of a conducting material, such as a metal, but can be of any desired material. If the block terminals are made of a conducting material, they may or may not be coated with a non-conducting material.
  • FIG. 4 provides a partial perspective sectional view taken along line 4 - 4 ′ of FIG. 1 of the inner surface of the side panel of the junction box that is diametrically opposite to the inner surface shown in FIG. 3 .
  • the entirety of box 10 including the internal components is molded of one piece, either from a plastic material, or from some other non-conducting material that would be suitable for a molding process. While any particular type of wiring terminal can be used in this instance, the exemplified preferred embodiment comprises block terminals, which, as mentioned, are integrally molded into box 10 during the molding process.
  • Block terminals 42 and 44 in FIG. 3 and FIG. 4 respectively provide a housing in which electrical current carrying wires are connected to another electrical conductor or to an electrical device (not shown).
  • Block terminals 42 and 44 should comprise at least two apertures, one for positioning therein the wires to be connected, which is illustrated as aperture 52 and a second aperture providing means for securely fastening the connected wires, which is illustrated as those apertures into which fastening means 50 is inserted.
  • block terminal 40 as illustrated in both FIGS. 1 and 3 , provides for grounding purposes.
  • block terminal 40 comprises at least two apertures, aperture 52 for the positioning of those wires that will provide a ground, and a second aperture providing means for fastening, which as illustrated is that aperture into which fastening means 50 is inserted.
  • the box To use the electrical connection box according to the principles of the present invention, one simply attaches the box to a support, which may be accomplished by using mounting means, such as mounting flanges 12 a - 12 d .
  • mounting means such as mounting flanges 12 a - 12 d .
  • at least one electrical conductor is inserted into the box via an opening, such as exemplified by cable openings 14 a & 14 b that provide for cable support and cable access to the interior of box 10 .
  • the at least one electrical conductor is electrically connected to either another electrical conductor if the box is a junction box or to the wires emanating from an electrical device if the box is a receptacle box.
  • the wires to be connected are inserted into a first aperture of a terminal block and secured therein by the secure placement of a securing means, such as a screw, into a second aperture of the terminal block, wherein the two apertures are connected so that the securing means may make secure contact with the wires.
  • a securing means such as a screw
  • the conducting wires and ground are secured in the block terminals, if there is an electrical device it is now secured to the box via securing means inserted through apertures routinely provided in the device for just such a purpose and the apertures of pylons 32 a and 32 b .
  • a cover plate is placed over the box and secured in the usual manner.
  • the present invention satisfies the urgent need in the art for a molded box-like container that provides for either a electrical device or junction connector box that eliminates the need for the ubiquitous nut connectors of questionable safety that are presently relied on to connect conductor wires inside a junction box.
  • the molded box as described is of simple, streamlined, molded, economical construction and, according to the principles of the present invention, provides for rapid and repeated pre-wiring, wiring, or re-wiring of conventional residential, commercial, or industrial wiring systems.

Abstract

A molded electrical connection box eliminates the need for wire-nuts. Wiring terminals, molded into the box, provide for reversible electrical connection between a conductor wire and another conductor wire or between a conductor wire and the wire of an electrical device. The box has least one end panel having an opening through which at least one electrical conductor may be inserted into the box. The open front face receives an electrical device, such as a plug receptacle or a switch plate. At least one wiring terminal block is integrally molded onto said connection box. The wiring block comprises two apertures, one for the insertion of the wires to be connected and one for wire securing means, such as a set screw. The box may be made of any moldable material, such as plastic or the like and the wiring terminal may be made of a conducting material.

Description

    CROSS-REFERENCE TO RELATED APPLICATIONS
  • Not Applicable
  • STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
  • Not Applicable
  • REFERENCE TO SEQUENCE LISTING, A TABLE OR A COMPUTER PROGRAM LISTING COMPACT DISK APPENDIX
  • Not Applicable
  • BACKGROUND OF THE INVENTION
  • The present invention relates generally to electrical receptacle connector boxes and, more particularly, to an electrical connector box having terminal connectors for allowing economical, safe, quick, and easy wiring of both electrical devices and electrical connectors without the use of wire-nuts.
  • The background information discussed below is presented to better illustrate the novelty of the present invention. This background information is not admitted prior art.
  • In order to provide for electrical power inside a building, wires carrying electricity are brought into the building from an outside source. Generally, this means connecting an electrical power supply line (also referred to as a wire, a lead wire, or an electrical conductor) to a main box just inside or outside the building. Once inside, electrical conductors must be routed through the walls of the building to the many areas where power is desired and/or required. Once the electrical conductors are positioned within the structure, they must then be connected to either electrical devices or to continuing electrical conductor supply lines to ultimately supply electrical power for an end use, such as for light switches, plug outlets, and the like. Electrical conductors are usually connected to other electrical conductors or to electrical devices within a junction or receptacle box, respectively. A junction box is essentially a container to house electrical conductor connections. The actual electrical connections between a lead line and a wire emanating from an electrical device, such as a light-switch, may be first encased inside of a plastic “wire-nut” which is nothing more than a thimble-shaped and sized plastic cup designed to force the ends of wires together. The wire-nuts with their protruding wires are then housed in an electrical connection box. If a wire-nut is not used to make the connection, electrical tape may be used, although this is considered an unsatisfactory solution as it is well-known that electrical tape loses its properties with time.
  • Wire-nuts, while supposedly providing for an improvement over the use of electrical tape to secure electrical connections, provide little protection against wires that are connected within the nut becoming disconnected. This is a particular problem where several wire-nut encased wires are positioned within a junction or receptacle box and then must be hard-pressed into the box so that a switch and a switch plate cover is able to be secured over the opening of the box. Squeezing the wire-nut encased wires into the box in such a manner often results in broken connections.
  • In fact, wires that have been connected within a wire-nut become disconnected so frequently that some wire-nuts are now designed to be crimped. That is, once the wires to be connected are connected and placed inside of the wire-nut, the wire-nut is permanently crimped closed using a wire-nut crimper to ensure that the connected wires inside of the nut stay connected. One of the negative repercussions of crimping wire-nuts, however, is that if a repair or replacement is required after the wire-nut has been crimped, the wires must be cut free from the crimped wire-nut, as it is impossible to remove the wires from the wire-nut after the wire-nut has been crimped. Cutting the wires, however, results in shortened wires which may complicate or eliminate the possibility of any reconnection. This of course, will then require a whole new switch plate with new wires or the wires will have to be spliced which can pose additional safety concerns. And, of course, incomplete crimping may cause the same problems as uncrimped wire-nuts cause that is, a loose connection.
  • Attempts have been made to provide for securing an electrical receptacle within an outlet box in electronic communication with wiring systems. One example offers an electrical junction box configured to receive electrical conductors through openings in each of the end panels of the box. Each electrical conductor is held in place by clamping means that are located adjacent to an opening. The clamping means, however, includes a contact shoe which is initially formed with the housing, but which is designed to be separated from the housing when the conductor is to be clamped. Breaking a tab that initially anchors the shoe to the housing enables the shoe to be brought into clamping engagement with the conductor at which time the shoe is secured to the housing. However, once the shoe is broken away from the housing to clamp the conductor to the box, it would be difficult to use the box again. If a receptacle or wires need to be replaced or relocated, the box also would have to be replaced. Moreover, such devices do not offer means to connect wires to each other. They are designed only to hold a wire cable secure within the box. These devices require many design features that are structurally complex, suggesting that its manufacturing cost is likely to be relatively high, and thus, unlikely to be universally affordable. It certainly would be desirable to have an affordable, uncomplicated outlet box that provided for the simple, easy, and rapid attachment and detachment of wires as many times as required, without the need to replace the box or any parts of the box.
  • Another plug and switch receiving device that attempts to offer improved means for securing wires, comprises a complex, multi-part receptacle box that requires at a minimum two discrete pieces that must be attached to each other before the box can be attached to a structure so that a plug, switch, or similar device is able to be attached to a electrical conductor within the box. Another example comprises a plug receptacle that must be first attached to a first front part of a receptacle box and then to a second inner part of the box using spring clips that are designed to extend through the first and second parts to reach a third part at which point connection is made between electrical device wires and a electrical conductor. Such spring-type clips, however, are prone to a loss of their springiness, to breakage, and/or rusting, if metal. This type of custom made device is complicated and requires all of its parts to be specially made, which of course adds significantly to the cost of manufacture. Such devices cannot accept off-the-shelf receptacles or switches as they do not come provided with the requisite prongs for fitting into the spring clips.
  • Another attempt teaches a specialized style of electrical receptacle outlet box that offers off-set mounting panels adjacent to either side of the box opening. Each mounting panel is angled away from the box opening to allow for easy access of the wiring terminals that are mounted on the interior side of these panels and to allow for conventional wiring to be pre-terminated within the outlet box. Each wiring terminal is shown having a single aperture to accept both wires and wire holding means, which could compromise the integrity of the wires that are positioned in the aperture. Additionally, the atypical shape of such boxes suggests that they would not likely be an acceptable candidate for use in commercial or home construction. Furthermore, these unusually shaped boxes would be much more complex to manufacture and thus are likely to more costly.
  • Accordingly, it would be a significant improvement in the art to provide for an economical, easy to use, electrical receptacle box of simple design that would allow a user to rapidly and repeatedly, if required, pre-wire or wire conventional residential, commercial, or industrial buildings, especially prior to enclosing such wiring systems behind drywall or other interior wall finish without using wire-nuts, such that the remaining wiring of standard electrical receptacles is easily and safely completed.
  • SUMMARY
  • The present invention satisfies the urgent need in the art for a molded box-like container that provides for either an electrical wire connector or junction box that eliminates the need for the ubiquitous nut connectors of questionable safety that are presently relied on to connect conductor wires inside a junction box. The molded box is of simple, streamlined, and economical construction. The electrical receptacle box according to the principles of the present invention allows a user to rapidly and repeatedly pre-wire, wire, or re-wire conventional residential, commercial, or industrial wiring systems.
  • The present invention successfully alleviates the problems commonly suffered when wire-nuts or crimped wire-nuts are used to make wire connections in either electrical connector or junction boxes by providing for a box that is molded in one piece where the wiring terminals (also referred to as block connectors, block terminals, or terminal blocks) are molded into the box to become an integral part of the box. These wiring terminals comprise small, mainly hollow, box-like interior extensions positioned within a junction box of any desired size or shape. The number of wiring terminals in a box is determined by the number of connections required. The low cost of these boxes, however, would allow multiple wiring terminals to be a part of each box, so that various box models would not be required. Within the body of each wiring terminal is a space that is accessible by a first and a second aperture. The wires from the electrical conductor and the electrical device are placed into one aperture and secured by the tightening of a screw, or the like, that is placed into the second aperture. Tightening of the screw prevents the wires from inadvertently becoming disconnected, yet loosening of the securing means allows the connected wires to be disconnected, if necessary, and reconnected, if desired. The fixed position of the wiring terminals ensures that once the connected wires are fixedly secured and protected by the securing means, the wire connection need not be disturbed and thus is safe from having the connection broken, unlike connections that are made within moveable wire-nuts. However, when there is a need to disconnect the connected wires, the screw or other securing means is easily loosened and the wires removed without any need to cut the wires or to prevent further use of the device. Moreover, the tightening means is usually a ubiquitous means, such as a screw, which means is easily replaced at minimal cost in case the original tightening means is misplaced or damaged.
  • In addition to providing for easier, more rapid, more secure, and safer connections within an electrical junction box, as well as eliminating the need for wire-nuts, or for any other type of wire connector, such as electrical tape (which it is well-known is not a recommended choice), the present invention provides more room in the box for switches, receptacles, or both. For example, in the case of boxes designed to accept multiple switches or receptacles, the box would have multiple wiring or block terminals. All block terminals are molded into the box when they are manufactured and would be made of a known, or yet to be known, conducting material, such as copper or aluminum. Set screws, or other means for securing the connecting wires, are provided with each box. Moreover, no extra parts are needed for the installation or of the junction box as described herein, preventing the need for last minute trips to the hardware store because a required piece of hardware is missing.
  • Because the junction box may be molded in one piece from a variety of non-conductive materials, such as plastic, it can be mass-produced at low cost making the device attractively affordable to all. If desired, however, the box may be made from a variety of other materials, such as fiber glass or ceramic, and even such conductive materials, such as steel, aluminum, or the like, may be used provided that any conductive material would insulated. Additionally, the molding process is amenable to the easy addition of an anchoring device to the box, such as a series of eye holes to be added to the molded junction box during production without incurring significant additional cost, while simultaneously increasing the versatility of the device. Also, as the box can be made through any standard molding technique, a wide range of shapes and sizes, depending on the desired use, may be contemplated while within the scope of the invention. For example, the size, and perhaps the shape, of a box used for the installation of a light switch would be different than that of a box to be used as a junction box for five electrical conduits.
  • All of these advances and advantages are made available by providing for a molded electrical receptacle box, comprising:
  • a back panel;
  • a first side panel and a second side panel;
  • a first end panel and a second end panel;
  • where the back panel, the side panels, and the end panels are adapted to form accessible internal volume, where the end panels have at least one opening that is configured to receive at least one electrical conductor therethrough for positioning in the accessible internal volume of the molded electrical connection box, and where an open front face, which is opposite to the back panel, is configured to receive an electrical device, and
  • where at least one wiring terminal block is integrally molded onto the connection box providing for reversible electrical connection between the conductor and an electrical device.
  • Moreover, the molded electrical receptacle box, further comprises wherein the wiring terminal is designed as a block terminal, which terminal may be made of a conducting material that may or may not be faced with a non-conducting material.
  • The molded electrical receptacle box provides for an electrical conductor to be secured into at least one of the block terminals by a securing means, which may be a set screw or the like.
  • The electrical device that is received into the open front face may be any type of electrical device such as a plug receptacle or a switch, for example.
  • The molded electrical receptacle box further comprises wherein the block terminal has an at least first aperture opening to an at least second aperture, wherein at least one electrical conductor and at least one wire from an electrical device are positioned into at least one second aperture wherein electrical connection is made between said electrical conductor and electrical device and wherein said electrical connection is secured by a securing means that is positioned into said at least first aperture.
  • The molded electrical receptacle box may be molded by any known molding means and, therefore, may be manufactured from a plastic, metal, or other material. The molded electrical connection box may be molded with means for mounting the box to a support.
  • Another molded electrical box, comprises:
  • a back face panel;
  • a first side panel and a second side panel;
  • a first end panel and a second end panel;
  • where the back panel, the side panels, and the end panels are adapted for forming accessible internal box volume,
  • and where the end panels have at least one opening configured to receive at least one electrical conductor therethrough for positioning in the accessible internal volume of the box,
  • where at least one wiring terminal is integrally molded onto the connection box, wherein the wiring terminals provide for reversible electrical connection between electrical conductors, in the manner that is discussed above.
  • The molded electrical junction box wherein the wiring terminal may be a block terminal, wherein the block terminal may be made of a conducting material that may, or may not be, faced with a non-conducting material.
  • Still other benefits and advantages of this invention will become apparent to those skilled in the art upon reading and understanding the following detailed specification and related drawings.
  • BRIEF DESCRIPTION OF THE DRAWINGS
  • In order that these and other objects, features, and advantages of the present invention may be more fully comprehended, the invention will now be described, by way of example, with reference to the accompanying drawings, wherein like reference characters indicate like parts throughout the several figures, and in which:
  • FIG. 1 is a perspective top view of the junction box according to principles of the present invention.
  • FIG. 2 is a perspective bottom view of the junction box as shown in FIG. 1.
  • FIG. 3 is a partial perspective sectional view of an inner side panel of the junction box taken along line 3-3′ of FIG. 1.
  • FIG. 4 is a partial perspective sectional view of the opposite inner side panel of the junction box taken along line 44′ of FIG. 1.
  • Definitions
  • Integral, as used herein, refers to a whole made up of parts, wherein the parts are formed united as one unit and are all of one and the same single piece.
  • Molded, as used herein, refers to any process wherein an object is produced as one solid piece, either by casting, forming, injection into a mold, or any other acceptable means that provides for a integral construction.
  • Electrical Device, as used herein, refers to any device that either uses or implements electricity, which includes, but is not limited to, plug receptacles, switch plates, and the like.
  • Block or Wiring Terminal, as used herein, refers to a means for connecting electrical wires and may be referred to as terminal blocks, connectors, connecting blocks, wire connectors and the like. The block terminals comprises a small, relative to the electrical connector box of which it is a part, container having at least two apertures that are internally connected to one another for receiving connecting wires and securing those wires through the use of securing means, such as screws. Following the principles of the present invention, the block terminal(s), which may be of curvilinear as well as block form, provide for rapid, safe, and secure connection of electrical wires and, if desired, provides for the connection(s) to be unsecured without damaging the wires, the securing means, or the block terminal.
  • Electrical Conductor, as used herein, refers to any wire or cable that carries an electrical current.
  • A LIST OF THE REFERENCE NUMBERS AND RELATED PARTS OF THE INVENTION
    • 10 A molded electrical junction or receptacle connector box according to the teachings of the present invention.
    • 12 a-12 d Means, such as mounting flanges, for securing box 10 to a support feature.
    • 13 a-13 d Apertures through which attachment means (not shown), such as convention screws, nails, bolts, or the like, may extend to mount box 10 on a support feature.
    • 14 a & 14 b Cable openings providing cable support and cable access to interior of box 10.
    • 20 a An exterior side panel of box 10.
    • 22 a An exterior end panel of box 10.
    • 24 b An interior side panel of box 10.
    • 26 b An interior end panel of box 10.
    • 28 a An exterior bottom panel of box 10.
    • 30 a-30 d Plug and switch plate mounting means.
    • 32 Connection flanges attaching and supporting 30 a-30 d, 32 a, and 32 b to interior end panels of box 10.
    • 32 a & 32 b Plug and switch receptacle mounting means.
    • 40 Block or wiring terminal in which wires with ground wires are fastened.
    • 42 & 44 Block or wiring terminal in which electrical wires are fastened.
    • 50 Fastening means for securing wires, a set screw, for example.
    • 52 Aperture in which wires are positioned for fastening.
  • It should be understood that the drawings are not necessarily to scale. In certain instances, details which are not necessary for an understanding of the present invention or which render other details difficult to perceive may have been omitted. It should be understood, of course, that the invention is not limited to the particular embodiments illustrated herein, but encompasses many embodiments as are discussed throughout the specification.
  • DETAILED DESCRIPTION
  • Referring now particularly to the drawings, FIG. 1 presents a perspective top view of the molded electrical connection box 10, which box is to be understood to be an exemplary embodiment of this invention. Box 10 demonstrates how the above mentioned disadvantages have been overcome. However, it should be noted that the disclosed invention is disposed to embodiments in various sizes, shapes, and forms. Therefore, the embodiments described herein are provided with the understanding that the present disclosure is intended as illustrative and is not intended to limit the invention to the embodiments described herein.
  • More particularly, FIG. 1 illustrates a molded electrical connection box 10 according to the teachings of the present invention. Box 10 consists of two end panels each having an exterior surface 22 a and an interior surface 26 b, two side panels each having an exterior surface 20 a and interior surface 24 b, and bottom panel with exterior surface 28 a, wherein the end panels, side panels, and bottom panel are arranged to provide an inner volume that is to be used for the connection and storage of electrical and ground wires. Mounting flanges 12 a-12 d may extend from the bottom 28 a and may be used to secure box 10 to a support feature, such as wall framing. It should be understood that the exact position of mounting flanges or other mounting means on the electrical conductor box may vary depending on need and such changes are within the scope of the present invention. Apertures 13 a-13 d, placed through mounting flanges 12 a-12 d allow for an attachment means (not shown), such as conventional screws, nails, bolts, or the like, to extend through the apertures to provide for mounting of box 10 on a support feature.
  • FIG. 2, which provides a perspective view of the bottom of box 10, illustrates one example of mounting flanges 12 a-12 d integrally formed as an extension of bottom surface 28 a of box 10, although, as mentioned above, the position, size, and style of the flanges or other mounting means may be changed, as required.
  • Extending through opposing sides of box 10 are cable openings and supports 14 a and 14 b providing for cable access to the interior of connector box 10 and for support of said cable so that the cable may be positioned in the inner volume of box 10 to make electrical connection to another electrical element within box 10. The examples illustrated in FIGS. 1 and 2 show cable openings 14 a and 14 b positioned through the end panels identified by their outer surface 22 a and their inner surface 26 b, respectively. Opening supports 14 a and 14 b are shown as being contiguous with the panels through which they extend, and additionally, may provide for another means of anchoring box 10 securely in place.
  • Also illustrated in FIG. 1, are pylons 30 a-30 d integrally formed as an internal part of molded electrical connector box 10 and functionally designed to provide for the reversible attachment of any standard receptacle, switch, or cover plate securely to the box. This attachment is accomplished by placing the desired cover (not shown) over the open front face of the box and by inserting any standard connection means, such as screws, through screw holes typically provided on such covers and into pylons 30 a-30 d, which are designed to accept and securely hold such connection means. Additionally, pylons 32 a and 32 b, also integrally formed as an internal part of molded electrical connector box 10, are functionally designed to provide in connector box 10 means for mounting an electrical device securely in the box 10, which, of course, is accomplished before a cover is placed over the box and the device secured to the box. Much like pylons 30 a-30 d, pylons 32 a and 32 b are designed to utilize any standard mounting means, including, but not limited to screws. Pylons 30 a-30 d and 32 a and 32 b are each supported and connected to the interior of end or side panels by a flange identified by reference number 32, as illustrated in FIGS. 3 and 4.
  • FIG. 3 provides a partial perspective sectional view taken along line 3-3′ of FIG. 1 illustrating inner surface 24 b of one side panel of the junction box. Also illustrated are connector blocks 40 and 42 shown as being integral parts of box 10. It is contemplated that the block terminals are made of a conducting material, such as a metal, but can be of any desired material. If the block terminals are made of a conducting material, they may or may not be coated with a non-conducting material.
  • FIG. 4 provides a partial perspective sectional view taken along line 4-4′ of FIG. 1 of the inner surface of the side panel of the junction box that is diametrically opposite to the inner surface shown in FIG. 3. The entirety of box 10, including the internal components is molded of one piece, either from a plastic material, or from some other non-conducting material that would be suitable for a molding process. While any particular type of wiring terminal can be used in this instance, the exemplified preferred embodiment comprises block terminals, which, as mentioned, are integrally molded into box 10 during the molding process.
  • Two types of block terminals in the electrical box 10 are shown in FIGS. 3 and 4. Block terminals 42 and 44 in FIG. 3 and FIG. 4, respectively provide a housing in which electrical current carrying wires are connected to another electrical conductor or to an electrical device (not shown). Block terminals 42 and 44, should comprise at least two apertures, one for positioning therein the wires to be connected, which is illustrated as aperture 52 and a second aperture providing means for securely fastening the connected wires, which is illustrated as those apertures into which fastening means 50 is inserted. Comparatively, block terminal 40, as illustrated in both FIGS. 1 and 3, provides for grounding purposes. Like block terminals 42 and 44, block terminal 40 comprises at least two apertures, aperture 52 for the positioning of those wires that will provide a ground, and a second aperture providing means for fastening, which as illustrated is that aperture into which fastening means 50 is inserted.
  • To use the electrical connection box according to the principles of the present invention, one simply attaches the box to a support, which may be accomplished by using mounting means, such as mounting flanges 12 a-12 d. Once the box is attached to a desired support, at least one electrical conductor is inserted into the box via an opening, such as exemplified by cable openings 14 a & 14 b that provide for cable support and cable access to the interior of box 10. At this point the at least one electrical conductor is electrically connected to either another electrical conductor if the box is a junction box or to the wires emanating from an electrical device if the box is a receptacle box. The wires to be connected are inserted into a first aperture of a terminal block and secured therein by the secure placement of a securing means, such as a screw, into a second aperture of the terminal block, wherein the two apertures are connected so that the securing means may make secure contact with the wires. Thus, in this way a safe, secure connection is made between desired wires rapidly and economically. Once the conducting wires and ground are secured in the block terminals, if there is an electrical device it is now secured to the box via securing means inserted through apertures routinely provided in the device for just such a purpose and the apertures of pylons 32 a and 32 b. At this time a cover plate is placed over the box and secured in the usual manner.
  • If for any reason the connections made as described above are required to be disconnected, one simply reverses the process as follows. After taking the safety step of shutting off the electrical power, remove the cover plate, which removal is usually accomplished by simply unscrewing the screw-type cover plate securing means, detach the electrical device from the box, which detaching is usually accomplished by simply unscrewing the screw-type electrical device securing means from the apertures of pylons 32 a and 32 b, remove all fastening means 50 from their related apertures and remove the connected wires from aperture 52. At this point any connection made between a set of wires may be disconnected. This is accomplished without destroying any part of the electrical connector box so that the processes of connecting wires and disconnecting wires may be made without the use of wire-nuts and as often as required using the same box.
  • Thus, it has been shown that the present invention satisfies the urgent need in the art for a molded box-like container that provides for either a electrical device or junction connector box that eliminates the need for the ubiquitous nut connectors of questionable safety that are presently relied on to connect conductor wires inside a junction box. The molded box as described is of simple, streamlined, molded, economical construction and, according to the principles of the present invention, provides for rapid and repeated pre-wiring, wiring, or re-wiring of conventional residential, commercial, or industrial wiring systems.
  • The foregoing description, for purposes of explanation, used specific and defined nomenclature to provide a thorough understanding of the invention. However, it will be apparent to one skilled in the art that the specific details presented are not required in order to practice the invention and are not intended to be exhaustive or to limit the invention to the precise forms disclosed. Those skilled in the art will recognize that many changes may be made to the features, embodiments, and methods of making the embodiments of the invention described herein without departing from the spirit and scope of the invention. The invention is limited only by the claims.

Claims (20)

1. A molded electrical receptacle connection box, comprising:
a. a back panel;
b. a first side panel and a second side panel;
c. a first end panel and a second end panel;
said back panel, said side panels, and said end panels adapted for forming accessible internal box volume,
said end panels having at least one opening therein, said opening configured for receiving at least one electrical conductor therethrough for positioning in the accessible internal volume of said box,
d. an open front opposite to said back panel, said open front configured for receiving and connecting an electrical device, and
e. at least one wiring terminal integrally molded onto said connection box, said wiring terminal providing for reversible electrical connection between the conductor and the electrical device.
2. The molded electrical connection box, as recited in claim 1, further comprising wherein said at least one wiring terminal is made of a conducting material.
3. The molded electrical connection box, as recited in claim 1, further comprising wherein said wiring terminal further comprises a block terminal.
4. The molded electrical connection box, as recited in claim 3, further comprising wherein said block terminal has at least a first aperture opening to at least a second aperture.
5. The molded electrical connection box, as recited in claim 4, further comprising wherein said at least one electrical conductor is positioned into said at least second aperture and secured therein by a securing means positioned into said at least first aperture.
6. The molded electrical connection box, as recited in claim 5, further comprising wherein at least one wire of said electrical device is positioned into said at least second aperture and secured therein by said securing means positioned into said at least first aperture providing for electrical connection between said electrical conductor and said electrical device.
7. The molded electrical connection box, as recited in claim 1, further comprising wherein said electrical device is a switch plate.
8. The molded electrical connection box, as recited in claim 1, further comprising wherein said electrical device is a plug receptacle.
9. The molded electrical connection box, as recited in claim 1, wherein said molded box is molded from a plastic material.
10. A molded electrical junction box, comprising:
a. aback panel;
b. a first side panel and a second side panel;
c. a first end panel and a second end panel;
said back panel, said side panels, and said end panels adapted for forming accessible internal box volume,
said end panels having at least two openings therein, said openings configured for each receiving at least one electrical conductor therethrough for positioning in the accessible internal volume of said box, and
d. at least one wiring terminal integrally molded onto said connection box,
said wiring terminal providing for reversible electrical connection between said electrical conductors.
11. The molded electrical junction box, as recited in claim 10, wherein the said terminal is made of a conducting material.
12. The molded electrical junction box, as recited in claim 11, wherein said wiring terminal further comprises a block terminal.
13. The molded electrical connection box, as recited in claim 12, further comprising wherein said block terminal has at least a first aperture opening to at least a second aperture.
14. The molded electrical connection box, as recited in claim 13, further comprising wherein at least one wire of said at least one electrical conductor is positioned into said at least second aperture and secured therein by said securing means positioned into said at least first aperture.
15. The molded electrical connection box, as recited in claim 14, further comprising wherein at least one wire of another of said at least one electrical conductor is positioned into said at least second aperture and secured therein by said securing means positioned into said at least first aperture providing for electrical connection between said electrical conductors.
16. The molded electrical junction box, as recited in claim 15, further comprising wherein said securing means is a set screw.
17. The molded electrical junction box, as recited in claim 10, further comprising wherein said molded junction box is molded from a plastic material.
18. A molded electrical connector box, comprising:
a. a back panel;
b. a first side panel and a second side panel;
c. a first end panel and a second end panel, and
d. at least one wiring terminal integrally molded onto said electrical box,
said back panel, said side panels, and said end panels adapted for forming accessible internal box volume,
said end panels having at least one opening therein, said opening configured for receiving at least one electrical conductor therethrough for positioning in the accessible internal volume of said box, and
said at least one wiring terminal providing for reversible electrical connection between said at least one electrical conductor and another electrical component.
19. The molded electrical box, as recited in claim 18, further comprising wherein said electrical component is a second electrical conductor.
20. The molded electrical box, as recited in claim 18, further comprising wherein said electrical component is an electrical device.
US10/990,035 2004-11-16 2004-11-16 Electrical receptacle and junction box free of wire-nuts Abandoned US20060105625A1 (en)

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US10/990,035 US20060105625A1 (en) 2004-11-16 2004-11-16 Electrical receptacle and junction box free of wire-nuts
PCT/US2005/041466 WO2006055600A2 (en) 2004-11-16 2005-11-15 Electrical receptacle and junction box free of wire-nuts
US11/274,981 US7294017B2 (en) 2004-11-16 2005-11-15 Electrical receptacle and junction box free of wire-nuts
US11/443,238 US20060216988A1 (en) 2004-11-16 2006-05-30 Electrical receptacle and junction box free of wire-nuts

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US20060105626A1 (en) 2006-05-18
US7294017B2 (en) 2007-11-13
WO2006055600A3 (en) 2006-12-21
WO2006055600A2 (en) 2006-05-26

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