Patent Application
20150197923
The present invention relates generally to plumbing outlet boxes, such as outlet boxes for connecting washers, ice makers, and other equipment to plumbing systems.
Conventional plumbing outlet boxes are typically used as housings for connections to plumbing systems. A plumbing outlet box may be provided, for example, for connecting a washing machine to pipes running within the walls of a building that are designed to carry water (e.g., hot and cold water supply and drain connections). As another example, a plumbing outlet box may be provided to connect an ice maker of a refrigerator to a water supply. Plumbing outlet boxes are generally installed in the walls of a house or other climate-controlled building. Often more than one plumbing outlet box is needed in the same area, each with the capability of connecting to different appliances having different configurations and requirements.
Accordingly, there is a need in the art for plumbing outlet boxes that can be configured to accommodate different types of connections and are easy to install, separately and in combination with other plumbing outlet boxes.
Plumbing outlet boxes, such as for connecting washing machines, ice makers, and other plumbed appliances to plumbing systems, are therefore provided that can be attached to each other without the use of separate connectors or mounting brackets. In this regard, a plumbing outlet box is provided that is configured for mounting within a wall. The plumbing outlet box may comprise a housing including a top wall, a bottom wall, first and second side walls, and an opening providing access into an interior of the housing. The plumbing outlet box may further include a first receiving feature extending outwardly from the first side wall; a second receiving feature extending outwardly from the second side wall; a first mounting tab extending outwardly from the first side wall;
and a second mounting tab extending outwardly from the second side wall. The first receiving feature may be located proximate the top wall, and the second receiving feature may be located proximate the bottom wall. The first mounting tab may be located proximate the bottom wall, and the second mounting tab may be located proximate the top wall. Each receiving feature may be configured to receive an engaging mounting tab of another plumbing outlet box, and each mounting tab may be configured to be received by an engaging receiving feature of another plumbing outlet box. The receiving features and the mounting tabs may be integral with the housing.
In some cases, each receiving feature may comprise a pair of lateral receiving arms and a main receiving arm disposed therebetween configured to opposingly engage the engaging mounting tab. The main receiving arm and a portion of each lateral receiving arm may define a receiving channel configured to receive the engaging mounting tab. Furthermore, each lateral receiving arm may define a ledge extending toward the other lateral receiving arm of the pair of lateral receiving arms, wherein a surface of the ledge proximate the main receiving arm is configured to support a corresponding surface of the engaging mounting tab.
In some embodiments, each of the lateral receiving arms and the main receiving arm may include an opening configured for receiving a fastener. Each mounting tab may include a slot configured for receiving a fastener. Additionally or alternatively, the main receiving arm may include a series of angled ridges configured to engage a series of complementary angled ridges on the engaging mounting tab.
In some cases, the top wall and the bottom wall of the housing may each include drain openings. At least one of the top wall or the bottom wall may also include a pair of laterally spaced openings configured to accommodate hot and cold water supply connections.
In other embodiments, a method of installing a plumbing outlet box assembly comprising at least two plumbing outlet boxes within a wall is provided. The method may include providing first and second plumbing outlet boxes, each having a housing that includes a top wall, a bottom wall, first and second side walls, and an opening providing access into an interior of the housing. A first receiving feature may extend outwardly from the first side wall; a second receiving feature may extend outwardly from the second side wall; a first mounting tab may extend outwardly from the first side wall; and a second mounting tab may extend outwardly from the second side wall. The first receiving feature may be located proximate the top wall and the second receiving feature may be located proximate the bottom wall. The first mounting tab may in turn be located proximate the bottom wall and the second mounting tab may be located proximate the top wall.
The method may include engaging the second plumbing outlet box housing to the first plumbing outlet box housing via engagement of one of the first or second mounting tabs of the second plumbing outlet box housing with a corresponding one of the first or second receiving features of the first plumbing outlet box housing and engagement of one of the first or second receiving features of the second plumbing outlet box housing with a corresponding one of the first or second mounting tabs of the first plumbing outlet box housing. The method may further include fastening at least one of the first plumbing outlet box housing or the second plumbing outlet box housing within the cutout.
In some cases, fastening at least one of the first or second plumbing outlet box housings within the cutout may comprise inserting a fastener through an opening on the respective receiving feature. Each receiving feature of the first and second plumbing outlet boxes may comprise a pair of lateral receiving arms and a main receiving arm disposed therebetween.
In some embodiments, fastening the first plumbing outlet box within the cutout may comprise inserting a fastener through an opening in the respective lateral receiving arms of the first plumbing outlet box and inserting a fastener through an opening in the main receiving arm of the first plumbing outlet box following engagement of the second plumbing outlet box housing to the first plumbing outlet box housing. Moreover, fastening the second plumbing outlet box within the cutout may comprise inserting a fastener through a slot in the mounting tab of the second plumbing outlet box and the opening in the corresponding main receiving arm of the first plumbing outlet box following engagement of the second plumbing outlet box housing to the first plumbing outlet box housing.
In still other embodiments, an assembly of plumbing outlet boxes is provided, where the assembly includes at least a first plumbing outlet box and a second plumbing outlet box. Each plumbing outlet box may be configured for mounting within a wall, and each may comprise a housing including a top wall, a bottom wall, first and second side walls, and an opening providing access into an interior of the housing. A first receiving feature may extend outwardly from the first side wall; a second receiving feature may extend outwardly from the second side wall; a first mounting tab may extend outwardly from the first side wall; and a second mounting tab may extend outwardly from the second side wall. The first receiving feature may be located proximate the top wall, and the second receiving feature may be located proximate the bottom wall. The first mounting tab may be located proximate the bottom wall, and the second mounting tab may be located proximate the top wall.
The second plumbing outlet box housing may be configured to be engaged with the first plumbing outlet box housing via engagement of one of the first or second mounting tabs of the second plumbing outlet box housing with a corresponding one of the first or second receiving features of the first plumbing outlet box housing and engagement of one of the first or second receiving features of the second plumbing outlet box housing with a corresponding one of the first or second mounting tabs of the first plumbing outlet box housing. Moreover, the first and second plumbing outlet box housings may be configured to be engaged to each other regardless of the relative orientation of the two plumbing outlet box housings. In some cases, the first and second plumbing outlet box housings may be similarly configured.
The second plumbing outlet box housing may be oriented 180° from the orientation of the first plumbing outlet box housing. Each receiving feature of the first and second plumbing outlet box housings may comprise a pair of lateral receiving arms and a main receiving arm disposed therebetween configured to opposingly engage a corresponding mounting tab of the other of the first or second plumbing outlet box housings. Furthermore, each of the lateral receiving arms and the main receiving arm of the first and second plumbing outlet box housings may include an opening configured for receiving a fastener, and each of the mounting tabs of the first and second plumbing outlet box housings may include a slot configured for receiving a fastener.
In still other embodiemnts, a faceplate is provided for mounting on a plumbing outlet box mounted within a cutout of a drywall panel. The faceplate may comprise a frame portion and a transverse extension extending inwardly from the frame portion toward an interior of the plumbing outlet box. The transverse extension may comprise at least one eyelet, and each eyelet may define a hole configured to receive a securing member therethrough.
Each eyelet may be configured to receive at least one cable tie therethrough for securing a drain hose in place. In some cases, the transverse extension may comprise a pair of eyelets.
Having thus described the invention in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:
Some embodiments of the present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all, embodiments of the invention are shown. Indeed, various embodiments of the invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like reference numerals refer to like elements throughout. Some components of the plumbing outlet box and associated systems are not shown in one or more of the figures for clarity and to facilitate explanation of embodiments of the present invention.
As used herein, the terms “bottom,” “top,” “upper,” “lower,” “interior,” “exterior,” and similar terms are used for ease of explanation and refer generally to the position of certain components of embodiments of the described invention in the installed configuration (e.g., in an operational configuration). It is understood that such terms are not used in any absolute sense, and, as such, a component described as a “bottom wall” may be on the same level (e.g., at the same distance from the ground) as another component described as a “side wall” in certain configurations of embodiments of the described invention, such as when the plumbing outlet boxes are laying on a flat surface prior to installation as opposed to held within a wall, as described below. Moreover, in some embodiments, the plumbing outlet boxes described herein may be configured to be installed in more than one orientation to accommodate different types of connections. For example, in one installation scenario, one end of the plumbing outlet box may be disposed such that it forms an “upper” or “top” wall of the housing (closer to the ceiling), whereas in another installation scenario that same end of the plumbing outlet box may be disposed such that it forms a “lower” or “bottom” wall of the housing (closer to the floor).
Moreover, although the examples used below refer primarily to plumbing outlet boxes for providing washing machines with access to a hot and cold water supply and/or to a drain, embodiments of the present invention may further be applicable to plumbing outlet boxes for other applications and in other contexts (e.g., for an ice maker, dishwasher, sink and toilet angle stop, etc.), as noted above.
Plumbing outlet boxes are typically installed within a wall of the building, such as a house, apartment building, office building, or other residence or dwelling, in a manner such that the box is accessible to a resident or caretaker (e.g., a plumber) when necessary (e.g., for installation, maintenance, or trouble shooting) and at the same time is not obtrusive to the resident's every day activities. In this regard, a hole is typically cut into the sheet rock of the building wall that is sized to provide access to the plumbing outlet box, and the box is installed within the appropriately sized hole. A faceplate may be applied to the front face of the plumbing outlet box to improve the aesthetics of the plumbing outlet box (e.g., by providing a finished look and hiding the internal components of the box).
The housing of a conventional plumbing outlet box is generally configured to hold certain supply connections (plumbing shut-offs, valves, pipes, and/or fittings). As noted above, depending on the particular purpose of the plumbing outlet box (e.g., for connecting hot and cold water and a drain to a washing machine versus providing water for an ice maker), the type and/or number of connections that must be accommodated by the plumbing outlet box can vary. For example, in one scenario, such as when the plumbing outlet box is used for a washing machine installation, the plumbing outlet box may need to be configured to connect to a hot water source, a cold water source, and a drain. Moreover, depending on the available connections, the hot and cold water sources may be disposed such that the connections must be made via a bottom wall of the housing next to a drain connection in one case, whereas in another case the hot and cold water connections must be made via a top wall of the housing, opposite the drain connection.
As another example, in a scenario in which the plumbing outlet box is used for an ice maker installation, the plumbing outlet box may require only a single opening for connecting to a source of water, such as via the bottom wall of the housing. In still other cases, multiple plumbing outlet boxes may be required. In such cases, for example, two plumbing outlet boxes may need to be positioned next to each other, such as on opposite sides of a stud in the wall. The strength of the installation (e.g., to keep the plumbing outlet boxes properly positioned and supporting the connections) may, in some cases, depend on the strength of the connection between each outlet box and the wall stud, instead of or in addition to the strength of the connection between the plumbing outlet boxes themselves.
Thus, in conventional installations, differently configured plumbing outlet boxes (e.g., plumbing outlet boxes having different sizes and/or that include a different number, size, type, and/or location of openings for making certain plumbing connections) may be required depending on the type of installation the plumbing outlet box is to be used for. Providing different options of plumbing outlet boxes may require increased tooling and manufacturing costs, as well as additional costs and headaches related to shipping and inventory. Moreover, installation of the plumbing outlet boxes may be complicated when the correct configuration of plumbing outlet box is not chosen, is not in stock, or is otherwise unavailable. Furthermore, in some conventional installations in which two or more outlet boxes are to be located next to each other, additional brackets, mounts, connectors, and other accessories may be required to complete the installation in a proper manner, which can also add to the costs, require additional up-front planning time, and make such installations more complicated to perform.
Accordingly, embodiments of the invention provide a plumbing outlet box that is configured for mounting within a wall, where the box has a universal configuration that can accommodate various types of connections for different installation scenarios. In particular, embodiments of the plumbing outlet box are configured with first and second mounting tabs and first and second receiving features extending from respective walls of the housing of the plumbing outlet box in such a manner that each receiving feature is able to receive and engage a mounting tab of an identically or similarly configured plumbing outlet box. At the same time, each mounting tab is able to be received by and engage a receiving feature of an identically or similarly configured plumbing outlet box. In this way, two plumbing outlet boxes may be engaged with each other without the use of separate fasteners, accessories, mounts, or brackets, and the plumbing outlet boxes may further be able to engage with each other regardless of the specific orientation of the plumbing outlet boxes, such that the plumbing outlet boxes may have different orientations to accommodate different connections, while still being able to engage one another.
Turning to
With continued reference to
Receiving features 50, 55 of one plumbing outlet box may be configured to receive and engage with mounting tabs 60, 65 of another plumbing outlet box, such that two plumbing outlet boxes may be attached to each other in a side-by-side manner (e.g., as shown in
As such, each receiving feature 50, 55 (shown in
As illustrated in
Thus, considering only the placement of the receiving features 50, 55 and the mounting tabs 60, 65 about the perimeter of the opening 40 (e.g., as shown in the simplified front plan view of
Turning now to
In this way, once the engaging mounting tab EMT is received by the receiving feature 50, the main receiving arm 53 (as a result of its tendency toward the neutral position of
Accordingly, in some embodiments, each lateral receiving arm 51, 52 may further define a ledge 58, 59 extending from the respective lateral receiving arm and toward the other lateral receiving arm of the pair of lateral receiving arms (e.g., toward the main receiving arm 53). A surface of each ledge 58, 59 proximate the main receiving arm 53 (best shown, for example, in
To allow for more secure engagement between the receiving features 50, 55 and the engaging mounting tabs EMT, in some embodiments, the main receiving arm 53 of each receiving feature 50, 55 may include a series of angled ridges 54 configured to engage a series of complementary angled ridges 64 on the engaging mounting tab EMT. A mounting tab 60 having a series of complementary angled ridges 64 on its first surface S is shown in a close-up view in
Turning again to
Moreover, as a result of the adjustability provided by the angled ridges 54, 64 and the slot 76 of the mounting tabs 60, 65, the joining of two plumbing outlet boxes 5 may be made in such a manner as to allow the plumbing outlet boxes to be mounted to various sizes of studs. For example, older homes may have wood studs that are 2-inches wide, whereas newer homes may have wood studs that are only 1⅝-inches wide. Still other homes may use metal studs that are only 1 ½-inches wide. By engaging the receiving features 50, 55 and mounting tabs 60, 65 to the appropriate degree of engagement (e.g., by engaging a greater or fewer number of the angled ridges 54, 64), such variations in the sizes of the studs may be accommodated.
In addition to fastening the plumbing outlet box housings using the openings 70, 72, 74 of the receiving features 50, 55 (
Turning now to
With reference to
In this regard, in some cases, the first and second plumbing outlet box housings 10, 10′ may be identical (e.g., have identical configurations). For the purposes of the description herein, the term “identical” does not preclude the existence of a certain imperfections and differences within an acceptable degree of manufacturing tolerance as understood in the art. Rather, the configuration of each plumbing outlet box 5, 5′ may be such that the size, number, position, function, etc. of the connections and openings for making such connections are the same.
Accordingly, a single configuration of a plumbing outlet box (such as the configuration of the plumbing outlet box 5 shown in
As noted above, due to the rotational symmetry of the placement of the receiving features and mounting tabs, the plumbing outlet box 5 may be orientated as shown in
In contrast, in
In some embodiments, a faceplate 100 (shown in
In the mounted position (e.g., when the plumbing outlet box is installed within the cutout of the drywall panel), the faceplate 100 may contact a portion of the interior surface of the drywall panel. Turning to
The transverse extension 120 of the faceplate 100 may, in turn, be configured to fit within and engage the housing 10 of the plumbing outlet box 5 (shown, e.g., in
Turning again to
With reference to
Accordingly, as described above, a method of installing a plumbing outlet box assembly comprising at least two plumbing outlet boxes within a wall is described that includes providing first and second plumbing outlet boxes. Each plumbing outlet box may have a housing that includes a top wall, a bottom wall, first and second side walls, and an opening providing access into an interior of the housing. As described above with respect to the figures, a first receiving feature may extend outwardly from the first side wall; a second receiving feature may extend outwardly from the second side wall; a first mounting tab may extend outwardly from the first side wall; and a second mounting tab may extend outwardly from the second side wall. The first receiving feature may be located proximate the top wall and the second receiving feature may be located proximate the bottom wall Likewise, the first mounting tab may be located proximate the bottom wall, and the second mounting tab may be located proximate the top wall.
In some embodiments, the second plumbing outlet box housing may be engaged to the first plumbing outlet box housing via engagement of one of the first or second mounting tabs of the second plumbing outlet box housing with a corresponding one of the first or second receiving features of the first plumbing outlet box housing and engagement of one of the first or second receiving features of the second plumbing outlet box housing with a corresponding one of the first or second mounting tabs of the first plumbing outlet box housing. The first plumbing outlet box housing may be fastened within the cutout, as described above, and the second plumbing outlet box housing may also be fastened within the cutout.
Moreover, the first plumbing outlet box and the second plumbing outlet box may be fastened within the cutout by inserting a fastener through an opening on the respective receiving feature, as described above. For example, each receiving feature of the first and second plumbing outlet boxes may comprise a pair of lateral receiving arms and a main receiving arm disposed therebetween. Fastening the first plumbing outlet box within the cutout may comprise inserting a fastener through an opening in the respective lateral receiving arms of the first plumbing outlet box and inserting a fastener through an opening in the main receiving arm of the first plumbing outlet box following engagement of the second plumbing outlet box housing to the first plumbing outlet box housing. Fastening the second plumbing outlet box within the cutout may comprise inserting a fastener through a slot in the mounting tab of the second plumbing outlet box and the opening in the corresponding main receiving arm of the first plumbing outlet box following engagement of the second plumbing outlet box housing to the first plumbing outlet box housing. In other embodiments, however, at least some of the fasteners may be applied to the first plumbing outlet box prior to engaging the second plumbing outlet box housing to the first plumbing outlet box housing.
In some cases, such as where a “universal” plumbing outlet box configuration is used, the first plumbing outlet box housing may be configured to be similar to the second plumbing outlet box housing, as described above.
As noted above, the structures and components depicted in the figures have been simplified for clarity and ease of explanation. As such, the shape of the housing, components of the housing or held within the housing interior (e.g., doors, fittings, connections, etc.) and/or external ductwork, connections, appliances, etc., although described above, may not be shown in the figures. Moreover, although particular configurations of the plumbing outlet box 5 and faceplate 100 are shown in
For example, although the foregoing examples and figures describe a configuration of a plumbing outlet box that includes a pair of laterally-spaced openings and one drain opening defined in one wall and another drain opening defined in an opposite wall of the housing, in other configurations no drain openings may be provided, the drain openings may be provided in only one wall, or more than one drain opening may be provided in one or both walls. Moreover, in some cases, no openings may be provided in the housing, a single opening may be provided in one or both walls of the housing, more than two openings may be provided in one or both walls of the housing, or other connection features other than openings and drains may be provided, as needed to satisfy user requirements and/or preferences.
Furthermore, although the embodiments provided in the examples and illustrated in the figures describe receiving features each including a pair of lateral receiving arms and a main receiving arm disposed therebetween that are configured to engage a slotted mounting tab (e.g., a ratcheted mounting tab as depicted), other types of engagement mechanisms may be used to engage the receiving features with the corresponding mounting tabs. As one example, instead of providing ratchets on the back surface of the main receiving arm, one or more pins (e.g., chamfered pins) may be provided that are configured to engage corresponding holes or concavities formed in the mounting tab. The pins and holes may be configured (e.g., sized and shaped) such that upon engagement of the receiving feature with a corresponding mounting tab, the pin(s) of the receiving feature fit within the corresponding hole(s) of the mounting tab, thereby maintaining the receiving feature and mounting tab in an engaged position. As other examples, the receiving feature may be structure to engage with a corresponding mounting tab via a friction fit, snap fit, or any other type of securing mechanism, as will be understood by one skilled in the art in light of this disclosure. Moreover, rather than having a pair of lateral receiving arms and a main receiving arm, in some embodiments each receiving feature may be structured to have any number of arms, such that in some embodiments no receiving channel may be defined.
In addition, many other modifications and other embodiments of the invention will come to mind to one skilled in the art to which this invention pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the invention is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation. Moreover, steps in the methods described above may occur in any order and are not limited to the order described above.
