Patent Application
20210408775
The present invention relates to electrical junction boxes, and specifically to gaskets and/or coverings for electrical junction boxes.
Electrical junction boxes or junction boxes are typically mounted to the framing of a home or building and contain two or more electrical circuit cables or electric wires (e.g. lead and neutral), and ground wires. Electrical junction boxes make splicing wires and connecting fixtures to devices possible. Junction boxes are typically comprised of metal or polymeric plastic, and range from 2 ½ inches to 3 ½ inches deep. The electrical junction boxes house electrical equipment and provide the necessary routing as well as protection for containing electrical components. Typical electrical junction boxes house electrical outlets or switches, and are sized dependent on the electrical component need.
The National Electric Code (NEC) is the regionally adopted standard for the safe and correct installation of electrical wiring and equipment within the United States. The NEC specifies requirements and sets standards for the installation of electrical wiring within homes and commercial buildings. Several NEC sections are relevant to the following discussion, including NEC 314.16 Wiring Methods Junction Box Fill, and NEC 314.29 All Boxes Shall be Accessible, and NEC 314 Boxes Shall be Installed at Each Conductor Splice Point, Outlet, Switch Point, Junction Point, or Pull Point.
In the late 1800's distributed electricity began to enter commercial buildings and homes. Along with it came the invention of electrical lighting and then alternating current. Then, in 1904 Harvey Hubbell was issued U.S. Pat. No. 774,250, for the first detachable electric wall plug. Hubbell's detachable wall plug revolutionized the way electrical wires were connected to accessories. Since then many adaptations and improvements have increased the safety, and reliability, and simplified the installation process of wall plugs through the use of electrical junction boxes. Electrical junction boxes are typically mounted to the framing of a building, and are installed prior to the drywall or other wall application. In doing so junction boxes are often misaligned or have gaps or other deformities that make faceplates essential to cover the blemishes. Further, the gaps in the wall structure result in reduced building performance and increased energy loss. Electrical junction box faceplates cannot cure all issues with junction box installation. There remains a long sought need to improve the installation, alignment, mounting, and safety of electrical junction boxes.
In one aspect, a trim cover kit for installing electrical junction boxes to framing of a wall is disclosed. In the kit an electrical junction box is operatively configured for installation in an opening of a wall structure and secured to the framing of the wall structure. In that opening, an electrical outlet with terminal screws may be installed. The kit further comprises a trim cover with an interior surface, an exterior surface, a distal border capable of covering the opening in the wall structure, and a proximal border with an opening for the electrical outlet. The trim cover further comprises interior flashing on the sides of the proximal border to secure the trim cover within the opening in the wall structure and to guard against contact with the terminal screws as well to provide one or more alignment fastener points for fastening the trim cover to the electrical junction box. Continuing, the trim cover further provides one or more retaining screw guides located on the proximal border for securing the trim cover to the opening in the wall structure. Lastly, the kit comprises a faceplate configured to fasten to the electrical outlet.
Many aspects of the present disclosure can be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale. Rather, emphasis is instead being placed upon clearly illustrating the principles of the disclosure. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views.
In the following detailed description, reference is made to the accompanying figures, which form a part hereof. In the figures, similar symbols typically identify similar components, unless context dictates otherwise. The illustrative embodiments described in the detailed description, figures, and claims are not meant to be limiting, but are examples of embodiments of the disclosure herein. Other embodiments may be utilized, and other changes may be made, without departing from the scope of the subject matter presented herein. It will be readily understood by those with skill in the art that the aspects of the present disclosure, as generally described herein, and illustrated in the figures, can be arranged, substituted, combined, separated, and designed in a wide variety of different configurations, all of which are explicitly contemplated herein.
Electrical junction boxes are designed to contain a variety of electrical outlets and switches. Today, the standard electrical outlets are being adapted to include combination outlets and receptacles that may include USB technology and or smart technology for powering devices. The smart technology may include WiFi and other features such as built in safety monitoring. Further, junction boxes may house outlets such as GFCI, AFCI, light switches, combination outlets, tamper resistant features, and many more improvements. As these new technologies change the size and dimensions afforded for electrical junction boxes contractors and builders must be prepared for designing and installing the circuitry. Inevitably the variables of sizing and fitting electrical junction boxes will create gaps within the wall space. Such gaps may cause energy loss to the building or provide for unsightly appearance such as an askew outlet or gap within the wall. Further, such gaps may expose the terminal screws or other elements such as bare wire and increase the risk of injury to the consumer. The disclosure herein remedies these ailments and provides a low-cost and effective solution for installation of electrical junction boxes.
We begin our review of the drawings with
Electrical outlets, as disclosed in
The framing 164 is typically comprised of wood or metal and is the foundation of the walls in most structures. The framing may also be comprised of a composite or a polymer. The framing provides rigidity and the ability to receive and hold the electrical junction box 150. Typically, a nail on the bottom and top will hold a junction box tight to the framing. In other embodiments the electrical junction box may be held in place by carriers, screws, adhesives, or other materials that form a tight and secure fit to the framing 164. The wiring for electrical boxes is typically done when the framing 164 is installed and prior to the installation of a wall structure. The problem is created when the wall structure is cut or fitted to the framing, wherein the installer makes imprecise cuts that allow for gaps and or deformations in the wall structure. Such deformations give rise to energy loss and unsightly appearance, amongst other things as discussed herein.
Referring now to
Turning to
The trim cover includes several foramens. Starting from the top of the trim cover, the top alignment fastener points 312 align with the wings which are standard features of electrical outlets—in particular the metal frame, wherein the alignment fastener points serve as fastener locations. The top retaining screw guide 315 is aligned with the guide screw of an electrical outlet and allows for correction of alignment. The outside edge of the trim cover 302 consists of the distal border, and directly opposite is the proximal border 308. The distal border 310 may consist of a slight slope such as a 18 degree slope or may be rounded, or in other example may have a hard edge—such as a 90 degree bend. The various distal border examples indicate that the border may be adapted to particular circumstance, for instance, a sloped border may allow for a more streamlined appearance with the wall, whereas a rounded border or 90-degree edge may show distinctiveness.
The next feature of the trim cover 302 is the proximal flashing 316 and 318. The proximal flashing 316 and 318 provide insulation as well as safety and security from the outlet terminal screws. The proximal flashing 316 and 318 may be made of the same material as the trim cover 302, or may be comprised of material that provides increased thermal insulation or electrical insulation from the terminal screws. The trim cover 302 may be comprised from a metal such as a galvanized steel or may be constructed from a polymer like polyvinyl chloride (PVC), or other materials such as wood, and cardboard. The material may be manufacture from a stamping process, or may be molded, or extruded through a die.
Continuing with
Referring now to
One such safety feature is to provide proximal flashing 416 and 418 that prevents user contact with the terminal screws 430. Another safety feature is to provide a gasket, such as a rubber compound, for the electrical junction box 450 so as to prevent debris or other material from accumulating and potentially posing a fire or an electrical shock hazard. An additional aspect of the proximal flashing 416 and 418 is providing a sealing or barrier for cold air flow from the wall opening, wherein the wall may not be insulated well, and may cause significant energy drain in the residential or commercial building. Lastly, the proximal flashing provides a weather barrier and may be used in combination with a rubber compound being applied to the proximal border and/or distal border or flashing to seal the electrical junction box 450 from water, snow, ice, and debris.
In the example embodiment of
An example installation process of a trim cover kit from the early stages of building is highlighted in the following steps:
An example of the installation process of a trim cover kit with respect to a previously-installed electrical junction box, electrical outlet, and faceplate is highlighted in the following steps:
Referring now to
In the example, the trim cover 502 is depicted with projected surfaces for the top and bottom alignment fasteners 512 and 514. In other examples the top and bottom alignment fasteners are foramens that allow additional fasteners to be applied. In other examples the top and bottom alignment fasteners may be removed and only the retaining screw guides may be used in securing the trim cover 502, the electrical outlet 532, and the electrical junction box 550.
In the example of
In the example embodiment the trim cover 602 is comprised of a sheet metal such as a galvanized steel metal. As discussed previously, in other embodiments the trim cover 602 is comprised of a polymeric material (PVC), or a rubber synthetic, or of a fibrous paper material such as a sturdy cardboard, or it may be comprised of wood. The material may have a paintable surface for occasions when the gap in the wall structure 662 is so large the faceplate (not depicted) will not cover the opening and the trim cover 602. Further, the interior surface of the trim cover 602 may have ridges or texture to enable a higher degree of friction against the wall structure 662 to prevent movement. Further the interior surface, including the distal and proximal borders may be coated in flame retardant material or may be dipped in a rubber compound or possess a further rubber compound sealant for securing and weatherproofing the trim cover 602. The exterior surface may have a tapered design at the edges or a bevel and may be designed to transition into the wall structure or with a more abrupt curve.
In the example of
Referring now to
Continuing with
Referring now to
It should be emphasized that the above-described embodiments of the present disclosure are merely some of the examples of implementations set forth for a clear understanding of the principles of the disclosure. Many variations and modifications may be made to the above-described embodiments without departing substantially from the scope and principles of the disclosure. All such modifications and variations are intended to be included herein within the scope of this disclosure and protected by the following claims.
This application claims the benefit and priority of U.S. Provisional Patent Application No. 63/102,748 filed on Jun. 29, 2020, entitled “TRIM COVER,” the contents of which is herein incorporated by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 63102748 | Jun 2020 | US |
