US 4,297,525 AGrant
Electrical Outlet Box and Pawl Mounting Device
Issue Date:1981-10-27
•14 Claims
•2 Drawing Sheets
Abstract
An electrical outlet box having wall areas recessed inwardly from the outermost periphery of the box wall structure, the recessed areas housing pawl mounting devices and electrical power cable entry ports. Each pawl mounting device includes a single stop flange on the outer surface of the box wall structure. The pawl arm includes a hub into which a threaded mounting screw is fastened and extends tangentially of the hub. The pawl arm terminates on one side of the hub in a right-angled stop flange and terminates on the opposite side of the hub in a small tab member. A guide channel adjacent the box stop flange slidably receives the pawl hub to guide the pawl in back and forth linear travel while the rear tab moves freely within a slotted channel formed between the box stop flange and the guide channel. The pawl arm and rear tab are alternatively urged against the box stop flange upon rotating the pawl in opposite directions causing the pawl to travel linearly in both a forward and backward direction.
Metadata
Assignee
- Slater Electric Inc.
Inventor
- Wade R. Bowden, Jr.
Application Information
Application Number:US 022992&
Filing Date:1979-03-22
Priority Date:1979-03-22
Art Unit:213
Classifications
IPC:
H02G 308
Field of Search:
17422024853;583.2-3.9427.1
Patent Drawings (2 sheets)
Description
Background and Objects of the Invention
1. Field of the Invention
The present invention relates generally to electrical outlet boxes and the like and relates more particularly to certain new and useful improvements in the configuration of such boxes, in provisions for mounting such boxes in a suitable wall opening, and in combinations of the foregoing features.
It will be understood that although the present invention is described with particular reference to electrical outlet boxes which are adapted to house the termination (i.e., electrical connection) between an electrical power cable and an electrical fixture such as an electrical outlet receptacle or an electrical switch, the present invention can be adapted, where desired, for use in other housing for electrical distribution appliances, such as electrical junction boxes, flush type boxes, etc. Accordingly, when used herein, the term "electrical outlet box" is intended to embrace such additional structures.
The usual electrical outlet box is constructed in a generally box-like configuration with a generally continuous sidewall member depending from a back (or bottom) wall, and formed with one or more cable entry ports (hereinafter sometimes referred to as "knockout windows") in the side wall member, which are adapted to permit access to the interior of the box for electrical power cables. One or more electrical power cables are inserted into the box, each through a cable port opening, for connection to (or termination with) the electrical fixture to be mounted in the box. Moreover, in order to prevent debris from entering the box through cable ports that are not utilized, and to minimize fire spread in the event that the electrical appliance housed in the box malfunctions, the typical cable entry ports in electrical outlet boxes are substantially or completely closed by knockout panels which are removably attached to the box wall structure across each port opening.
It will also be understood that although the present invention is described with respect to a rectangularly-shaped electrical outlet box, the invention is equally applicable to other conventionally shaped boxes, including round boxes.
2. Description of the Prior Art
Heretofore, it has been conventional in electrical outlet boxes for the outermost periphery of the box wall structure to be comprised of substantially straight walls or, in the case of a round box, for the wall structure to be located at a substantially constant radial distance from the center of the box. These conventional structures are disadvantageous in certain usages since they cause the electrical power cable and certain box mounting devices to protrude laterally from the outermost periphery of the wall structure, thereby obstructing entry and mounting of the box in a wall opening.
The desirability of the use of a lug or pawl member displaceable by rotation of a threaded screw for clamping an appliance within an opening in a wall structure has been previously recognized.
For example, U.S. Pat. No. 3,090,587 discloses an appliance casing having a flange extending laterally outwardly beyond the periphery of the casing body and a clamping lug threadably mounted within a frame adjacent the perimeter of the casing. Rotation of the threaded screw operates to displace the arm of the clamping lug from a retracted position adjacent the perimeter of the casing body to an extended position which is adapted to engage the adjacent wall structure. Thus, with the lug in the retracted position, the appliance casing may be readily inserted through the wall opening until the casing flange engages the wall surface; thereafter, rotation of the threaded screw displaces the lug arm outwardly until it engages the lug mounting frame, whereupon continued rotation causes the lug to travel linearly along the shaft of the threaded screw until the lug engages the back surface of the wall, thereby clamping the appliance in place.
U.S. Pat. No. 2,401,948 shows a structure similar to U.S. Pat. No. 3,090,587 applied to a device similar to an electrical outlet box, in which the clamping lug is restrained from rotation in only a single direction of rotative movement.
It heretofore has also been recognized in U.S. Pat. No. 3,966,152 that, as applied to the mounting of an electrical receptacle in a suitably sized wall opening, the aforedescribed lug or pawl mounting device are disadvantageous in that the rotational movement of the lug or pawl arm is restrained in only one direction of linear movement. U.S. Pat. No. 3,966,152 discloses the provision of either (i) a pair of parallel planar pawl stops of differing lengths, or (ii) a single planar pawl stop engageable by a hook extending from the pawl member, in order to restrain rotational movement of the pawl arm in both clockwise or counterclockwise directions at a point where the pawl arm is adjacent the back surface of the wall structure in which the receptacle is mounted.
However, although the aforesaid structures of U.S. Pat. No. 3,966,152 restrain rotational movement of the pawl arm in both clockwise and counterclockwise directions, and hence in both forward and reverse directions of linear travel, they each suffer from disadvantages in their manufacture and/or use. Thus, the hooked structure is awkward to fabricate and is subject to breakage; where two planar stop walls are employed, one of the stop walls has a relatively long and narrow unsupported cantilevered portion which is also subject to breakage.
Objects of the Invention
It is therefore an object of this invention to provide a new and improved electrical outlet box.
Another object of this invention is to provide a new and improved electrical outlet box which is formed in a novel and improved configuration.
Another object of this invention is to provide a new and improved electrical outlet box which facilitates mounting of the outlet box within the wall opening.
Another object of this invention is to provide a new and improved electrical outlet box in which each end wall includes portions which are offset from one another so as to create recessed areas along the outermost periphery of the outlet box wall structure.
Another object of this invention is to provide new and improved means for mounting an electrical outlet box in a wall opening.
Another object of this invention is to provide a new and improved electrical outlet box in which the means for mounting the box in a wall opening is housed in an area recessed inwardly from the outermost periphery of the box wall structure.
Another object of this invention is to provide new and improved means for mounting an electrical outlet box in a wall opening which fully eliminates or overcomes the disadvantages of previously known wall mounting devices.
Another object of this invention is to provide a new and improved electrical outlet box mounting means which is greatly simplified in its manufacture and exceptionally durable in use.
Objects and advantages of the invention are set forth in part herein and in part will be obvious herefrom, or may be learned by practice with the invention, the same being realized and attained by means of the instrumentalities and combinations pointed out in the appended claims.
The invention consists in the novel parts, constructions, arrangements, combinations and improvements herein shown and described.
Summary of the Invention
Briefly described, the electrical outlet box configuration of the present invention has wall portions which are laterally offset from one another so as to create wall areas recessed inwardly from the outermost periphery of the box wall structure. In the preferred embodiment of the invention illustrated in the drawings, each end wall of the box is laterally offset on either side of the electrical fixture mounting post, creating diagonally opposed inwardly recessed areas in the outermost periphery of the box wall structure.
As preferably embodied, one or more cable entry ports for the passage of electrical power cable into the outlet box are housed in a portion of the box wall structure which is recessed inwardly from the outermost periphery of the box wall.
Also as preferably embodied, the cable entry ports include a pair of window closure panels which are formed integral with the end wall at the rim of the port along opposed sides thereof and extend angularly inwardly therefrom. The free ends of the panels may terminate at points which are closely adjacent but spaced apart from one another or, alternatively, may be joined together at their inner ends by a frangible web which preferably is readily pierceable by manually forcing the end of the electrical power cable against the web.
The electrical outlet box mounting means of the present invention comprises, in the preferred embodiment, two or more flanges formed integral with the front edge of the box wall structure and extending laterally outwardly therefrom beyond the outermost periphery of the box walls. A single stop flange is formed as an integral extension of one side wall of the box and extends longitudinally in a direction from the open front of the box toward the bottom wall of the box. An approximately quartercylinder arcuately-shaped rib extends along the side of the stop flange and preferably terminates at a point beyond the end of the stop flange. The rib is formed integrally with the end wall of the box which is joined to the aforesaid side wall and forms both a groove-like guide channel and a slotted channel adjacent and parallel to the stop flange. Each of the aforesaid stop flange and rib extend from a boss member formed integrally therewith on the end wall adjacent the front opening of the box, the boss including an opening extended therethrough which is adapted to receive a threaded mounting screw.
As preferably embodied, the aforesaid mounting means of the invention also includes a pawl arm member having a semicylindrical hub portion into which the aforesaid threaded mounting screw is fastened, and which moves linearly back and forth in the aforesaid grooved guide channel upon rotation of the threaded screw. The pawl arm extends tangentially of the hub and terminates at one end in a right-angled clamping flange and terminates at the other end in a small tab extending away from the hub in the opposite direction from the right-angled flange. The pawl tab is adapted to freely move linearly back and forth in the aforesaid slotted channel as the pawl hub moves within the grooved guide channel.
Also as preferably embodied, the pawl mounting means of the present invention is housed in the portion of the box wall structure which is recessed inwardly from the outermost periphery of the box wall.
It will be apparent from the aforegoing general description that the objects of the invention specifically enumerated herein are accomplished by the invention as here embodied.
Thus, the novel configuration of the electrical outlet box of this invention, wherein portions of the box wall structure are recessed from the outermost periphery of the box walls and both cable entry ports and the pawl mounting device are located in recessed wall regions, facilitates cable entry and mounting of the box within the wall opening. The provision of recessed wall areas enables the pawl mounting device to be located entirely within the confines of the outermost periphery of the box wall structure in its retracted position.
Also, the pawl mounting means of the invention requires only a single stop flange and the configuration of the pawl arm is both easy to manufacture and exceptionally durable in use.
It will be understood that the foregoing general description and the following detailed description as well are exemplary and explanatory of the invention but are not retrictive thereof.
The accompanying drawings, referred to herein and constituting a part hereof, illustrate preferred embodiments of the invention, and together with the description, serve to explain the principles of the invention.
Brief Description of the Drawings
FIG. 1 is a top plan view of an electrical outlet box constructed in accordance with a preferred embodiment of the invention;
FIG. 2 is a rear perspective view of the outlet box of FIG. 1, the view illustrating the box positioned within a wall opening and further illustrating a preferred embodiment of the pawl mounting means of the invention with the pawl arm in its retracted position;
FIG. 3 is a fragmentary rear perspective view of the outlet box of FIG. 1, illustrating the pawl arm in its extending position engaging the back surface of the wall structure in which the outlet box is mounted;
FIG. 4 is a fragmentary view, partly in elevation and partly in section, taken along line 4--4 of FIG. 3, the view illustrating the outlet box clamped to the wall structure;
FIG. 5 is a fragmentary view, partly in section and partly in bottom plan, of the cable entry port structure of the outlet box of FIG. 1; and
FIG. 6 is a fragmentary sectional view of an alternative embodiment of a cable entry port constructed in accordance with the invention.
Description of the Preferred Embodiments
Referring now more particularly to the embodiments of the invention shown in the accompanying drawings, wherein like reference numerals refer to like parts, there is illustrated an electrical outlet box, indicated generally by reference numeral 1, mounted in a suitably sized opening 2 in a wall structure 3.
As here preferably embodied, electrical outlet box 1 is of a generally rectangular shape and includes a bottom wall 10, a pair of opposed end walls 11, 12, a pair of opposed side walls 13, 14 extending between the aforesaid end walls, each of the end and side walls terminating in a continuous front edge 15 lying in a frontal plane which is parallel to the bottom wall 10 and defines the front opening 16 of the box. Outlet box 1 also includes an opposed pair of conventional mounting post members 20 adjacent each of the end walls 11, 12 for securing an electrical fixture to the box by threaded fasteners, as is well known in the art. Advantageously, each of posts 20 includes an unthreaded borehole 22 and a mounting clip 23 (see FIG. 2) slidably lockably received in each of the posts adjacent the borehole for quick fastening of a threaded screw thereto, such as is more fully described in U.S. Pat. Nos. 3,955,463 and 4,105,862, the disclosures of which are incorporated herein by reference.
In accordance with the invention, outlet box 1 is provided with recessed areas in the outermost periphery of the wall structure. To this end, as here preferably embodied, diagonally opposed sections 11a, 12a of the end walls 11, 12 respectively, are recessed inwardly between one side of the electrical fixture mounting post member 20 and the adjoining side walls 13, 14, respectively.
In the embodiment of the invention illustrated in the drawings, outlet box 1 is approximately 3 inches deep, 23/8 inches wide, 35/8 inches long and approximately 18 cubic inches interior volume. In this embodiment, sections 11a, 12a of outlet box 1 are recessed inwardly approximately one-quarter of an inch (1/4") from the outer surface of the adjacent end wall sections 11b, 12b, respectively. While it has been found that approximately 1/4" is the preferred depth of recessed sections 11a, 12a for carrying out the invention in an outlet box having the aforesaid dimensions, the invention is not limited to any particular size box or depth of recess and the foregoing dimensions are given as an example, from which other equivalent dimensions will be apparent to those of ordinary skill in the art.
Also, as previously mentioned, it will be understood that, although the illustrated rectangular outlet box presently is the preferred embodiment of the invention, the invention is not limited to any particular box configuration, and its application to boxes of other configurations, such as round boxes, will be readily apparent to those of ordinary skill in the art.
Advantageously, and as here preferably embodied, recessed areas 11a, 12a house cable entry port means for the passage of conventional electrical power cable, illustrated at 25 in FIGS. 2 and 6, into outlet box 1 for connection to an electrical fixture (not shown) mounted in the outlet box.
The cable entry port means are adapted to facilitate entry of the electrical power cable into the outlet box as well as to facilitate mounting of the wired outlet box in a wall opening.
To this end, as best depicted in FIGS. 1, 2 and 5, the preferred cable entry port means is comprised of an opening or port 30 in the end walls 11, 12 adjacent bottom wall 10 which is preferably formed with a pair of opposed closure panels 32, 33 extending from the rim of the port opening diagonally inwardly toward each other and terminating at points which are closely adjacent but spaced apart from one another a distance which is preferably less than the narrowest width of conventional electrical power cable. A frangible web 35 preferably joins the adjacent innermost ends of the closure panels. Advantageously, and as preferably embodied, web 35 is adapted to be broken by manually forcing the end of a conventional electrical power cable against the web. Although web 35 is shown extending along the entire length of the convergent ends of panels 32, 33, alternatively, and with equally satisfactory results, web 35 may extend between the convergent ends of panels 32, 33 along only a short portion of their length, on the order of approximately 1/8-1/4 inch, preferably at the mid-section thereof.
In the embodiments shown in FIGS. 1, 2 and 5, also by way of example rather than limitation, the port openings 30 are approximately one-half inch wide (1/2") and one-half inch long (1/2"). When formed from an injection moldable thermoplastic resin material, more fully described hereinafter, the point of convergence of closure panels 32, 33 is approximately three-eighths inch (3/8") from the inside surface of end wall 12a, frangible web 35 is approximately 0.010" thick, and panels 32, 33 taper from a thickness of about 0.030" (approximately 1/32") thick at their convergent ends to about 0.060" (approximately 1/16") thick at their bases adjacent the aperture rim.
Also, as preferably embodied, the generally V-shaped space between closure panels 32, 33, which opens in a direction perpendicular to the frontal plane of the box, is at least substantially closed by a third closure panel 36 extending transversely and closely adjacent to the frontmost edges of the angled closure panels 32, 33. Advantageously, a reinforcing rib or strut 38 is formed to extend between the top of port closure panel 36 and the inside surface of end walls 11, 12. Also, as best seen in FIGS. 1 and 5, angled closure panels 32, 33 preferably are tapered, having increased thickness at the base thereof adjacent the rim of the port opening, and include supplementary cable gripping projections 39 on their opposed facing surfaces.
It will be seen from the foregoing that the cable entry port means as preferably embodied are both self-opening and self-clamping. The port means are self-opening in that no separate tool such as a screwdriver or the like is required in order to break the frangible closure web 35. In the embodiment where the closure panels are tapered, depicted in FIGS. 1, 2 and 5, the port means are also self-clamping since, upon inward movement of the cable into the box chamber, the angularly inwardly directed closure panels are slightly spread apart to thereby resistingly bear against the cable and, consequently, a reverse outward force applied to the cable thereafter causes the inner end portions of the closure panels to be urged by means of a camming action progressively more tightly against the cable, into increasing gripping engagement therewith, thereby effectively clamping the cable against reverse outward movement.
The cable entry port means as preferably embodied are also both self-centering and self-adjusting for different sizes of electrical power cables passing into said box chamber. Thus, the provision of inwardly angled closure panels serves to guide the electrical power cable into the box at a predetermined, consistent location, which is at the apex of the converging panels, irrespective of the cable size. Also, the preferred lengths and thicknesses of the closure panels, particularly when formed from a moldable plastic material, as is more fully described hereinafter, provide the panels with sufficient flexibility and resiliency so that they deflect laterally away from the point of convergence, thereby permitting the panels to adjust to the different cable sizes, and yet resistingly bear against the cable in their deflected condition. By recessing the base of the closure panels away from the aperture rim, as illustrated in FIG. 5, cables having thicknesses up to a thickness equal to the width of the entry aperture can be accommodated with satisfactory results.
In an alternative embodiment depicted in FIG. 6, the cable entry port closure panels extend angularly inwardly from the rim of the port opening and are self-opening, as well as self-centering and self-adjusting, but provide only slight clamping action against the electrical power cable. As alternatively embodied, the opposed closure panels 40, 41 are of a uniform thickness throughout which is relatively thin, on the order of about 0.030" (approximately 1/32") thick, and the frangible connecting web 35 is on the order of about 0.010" thick, when injection molded from a thermoplastic resin material, more fully described hereinafter. In this embodiment, the inwardly converging closure panels 40, 41 are advantageous in use since, in a manner similar to closure panels 32, 33, they flex only a distance sufficient to permit the cable to pass through the port, thereby maintaining a substantially closed opening even in use. In addition, as depicted in FIG. 2, both of the aforesaid embodiments of the cable entry port means of the invention facilitate mounting of the box in a wall opening, since the cable enters the box partially through the generally V-shaped opening provided in the bottom wall of the box at the cable entry ports. As depicted in FIG. 2, particularly where the cable entry port is formed in the recessed wall sections 11a, 12a, the aforesaid structure enables the electrical power cable to be easily extended from the box with no part thereof protruding laterally beyond the outermost periphery of the box wall structure.
The foregoing embodiments of the cable entry port means are described in greater detail in copending application Ser. No. 879,767, filed Feb. 21, 1978, also assigned to the assignee of this application. The disclosure of application Ser. No. 879,767 is hereby expressly incorporated herein by reference, and reference may be made to that application for a discussion of the further advantages of these structures.
Although the cable entry port structures illustrated here and in application Ser. No. 879,767 show the base of the closure panels attached to the box wall structure along the longitudinal rim portions of the port opening which extend in a direction from the front to the back of the box, it will be understood that the principles underlying the invention are not limited to this particular orientation, but are equally applicable to the attachment of the closure panels along the top and bottom rim portions of the port opening, in which case the third closure panel extends in a plane parallel to the opposed side walls and adjacent the lateral converging side edges of the opposed closure panels so as to cover the generally V-shaped space therebetween opening in a direction perpendicular to the opposed side walls of the box. This alternative configuration is illustrated in copending application Ser. No. 22,993, filed concurrently herewith and assigned to the assignee of this application, the disclosure of which is hereby expressly incorporated herein by reference as if fully set forth herein.
Also, while the cable entry ports illustrated here and in application Ser. No. 879,767 are rectangular in shape and include a pair of opposed converging closure panels, it will be understood that the invention is equally applicable to other port entry configurations, such as an aperture having a circular shape, and to the provision of either a single or a plurality of closure panels extending angularly inwardly from the rim of the port opening such, e.g., as is shown in the aforesaid copending application Ser. No. 22,993.
As here preferably embodied, recesses 11a, 12a also house means for mounting outlet box 1 to the wall structure surrounding an opening suitably sized to receive an outlet box therethrough. To this end, outlet box 1 includes two or more flanges 45 on the front edge of the box wall structure extending perpendicular to the box walls laterally outwardly beyond the outermost periphery thereof, and pawl mounting means 50 adapted to clamp the edge of the wall structure 3 between box flanges 45 and pawl clamping flange 55, more fully described immediately hereafter.
In accordance with the invention, pawl mounting means 50 includes a pawl clamping arm 51 adapted to be rotated between retracted and extended positions and to travel in a linear direction in the extended position into and out of clamping engagement with the back side of wall 3. Pawl mounting means 50 also is adapted to restrain rotational movement of the pawl clamping arm 51 in both clockwise and counterclockwise directions over at least a portion of the linear travel of the pawl arm by means of a single stop flange on the outlet box wall.
To this end, pawl arm 51 includes a generally semi-cylindrical hub portion 52 into which a threaded mounting screw 53 is fastened. Hub 52 may be provided with internal threads mating the threads of screw 53 or, alternatively, screw 53 may be a thread-cutting screw which cuts threads into hub 52 upon being threadedly fastened thereto. Planar clamping arm 51 extends tangentially of hub 52, terminating on one side of the hub in a right-angled clamping flange 55 and terminating on the other side of the hub in a small tab member 56, coplanar with and preferably an integral part of pawl clamping arm 51.
A stop flange 60 extends laterally outwardly, preferably as an integral extension, from the portions of side walls 13, 14 which adjoin the end wall recessed areas 11a, 12a, respectively. Advantageously, as depicted in FIGS. 2 and 3, flange 60 extends laterally outwardly a distance equal to the recess of the end wall sections 11a, 12a, so as to terminate in the plane of the outermost end wall sections 11b, 12b, respectively. Flange 60 extends in the longitudinal direction from the front edge 15 of the box walls preferably to the approximate mid-point between the frontal plane and back wall of the box.
A rib 62 extends in parallel, spaced apart relation to flange 60 and preferably has a concave arcuate side 63 facing flange 60. Rib 62 is spaced from flange 60 a distance sufficient to form a groove-like guide channel adjacent flange 60 adapted to slidably receive and guide hub 52 of the pawl arm 51 in back and forth linear travel.
Rib 62 extends along at least the length of flange 60, and preferably extends a short distance beyond the end 60a of flange 60 in order to ease assembly of pawl 51 onto box 1, more fully described hereinafter. Rib 62 extends laterally outwardly from end wall 12a a distance approximately equal to the width of the pawl clamping flange 55 so that the pawl arm is located fully within the confines of the recessed area 12a in its retracted position.
As best seen in FIG. 4, arcuate face 63 of rib 62 holds hub 52 away from the outer surface of end wall 12a a distance at least equal to the distance that tab 56 extends beyond the periphery of the hub, so as to create an additional slot-like channel 65 adjacent flange 60 adapted to freely receive tab 56 of pawl 51 therein and permit tab 56 to freely ride in channel 65 in back and forth linear travel.
Finally, a boss member 67 is formed integral with the end wall section 12a adjacent the front edge 15 of the box wall structure and is provided with an aperture 68 therein aligned with the channel between flange 60 and rib 62, aperture 68 being adapted to receive threaded mounting screw 53 therethrough.
It will be apparent from the foregoing that the pawl mounting means of the present invention is assembled by partially threading mounting screw 53 into the hub 52 of the pawl arm 51 by means of a screwdriver 70 or the like so as to draw a portion of the hub 52 into the grooved guide channel between flange 60 and rib 62, as shown in FIG. 2. At this time, pawl arm 51 is in a retracted or "nested" position, where it rests on the top edge of rib 62 and clamping flange 55 rests against the outer surface of end wall 12a, the entire device being positioned within the confines of the recessed area between flange 60 and end wall 12b.
Thereafter, continued rotation of mounting screw 53 in a clockwise direction when viewed from the handle end of screwdriver 70, illustrated by arrow A in FIG. 3, rotates the pawl arm 51 from the retracted position into an extended position where it engages stop flange 60 which prevents further rotation of the arm in the clockwise direction. Thereafter, continued clockwise rotation of the threaded mounting screw 53 causes the pawl hub 52 to travel linearly, illustrated by arrow B in FIG. 3, within the groove-like guide channel between flange 60 and rib 62 toward clamping engagement with wall 3, at which time the pawl clamping flange 55 engages the back side of wall 3. As the pawl hub 52 travels linearly toward clamping engagement with wall 3, the pawl tab 56 rides freely within channel 65 adjacent the flange wall 60, while the pawl arm 51 engages and is urged into sliding relationship against the outer portion of flange wall 60. Upon rotation of screw 53 in an opposite counterclockwise direction, pawl tab 56 engages and is urged into sliding relationship against the bottom portion of flange wall 60, restraining rotation of pawl arm 51 so as to cause the pawl hub 52 and clamping flange 55 to again travel linearly in the opposite direction of arrow B, out of clamping engagement with wall 3 and toward the retracted position. As pawl hub 52 travels beyond the end 60a of the flange wall 60, tab 56 no longer restrains rotation of the pawl arm 51, whereupon the pawl once again rotates into its original retracted or "nested" position.
Thus, in the operation of the invention as here embodied, flange wall 60 serves as a single pawl stop to prevent rotation of the pawl arm 51 during both clockwise and counterclockwise movement of the mounting screw 53 as the pawl moves linearly in its extended position into and out of clamping engagement with wall 3.
While the foregoing description of the pawl mounting means of the invention has been primarily directed to the structure provided at the recessed wall area 12a, depicted in the drawings, it will be understood that an identical structure is also provided at the recessed wall area 11a.
While it will be understood from the foregoing description that neither the outlet box nor the pawl mounting means of the invention are in any way limited to the use of particular materials, the outlet box is preferably formed integrally from a molded thermoplastic resin material and the pawl arm member is preferably formed by die stamping a suitable metal.
With respect to the material from which the outlet box is formed, a certain injection moldable thermoplastic resin material has been found to produce highly satisfactory results and is given as an example of the preferred mode of carrying out the invention, together with other examples of suitable materials, from which still further equivalent materials will be apparent to those of ordinary skill in the art. Thus, it has been found that a thermoplastic resin blend of ABS (i.e., acrylonitrilebutadiene-styrene) and PPO (i.e., polyphenylene oxide) sold by the General Electric Company under the trade name "NORYL", Grade SE-100 or SE-1, is a particularly preferred material from the standpoint of ease of moldability, strength and high temperature resistance. Moreover, the "NORYL" material is sufficiently strong to meet the current standards of Underwriters' Laboratories, Inc. for outlet box cable clamping devices. It has also been found that a vinyl resin material such as PVC (i.e., polyvinyl choride) sold by the Ethyl Corporation under the trade designation "Ethyl 7042" operates satisfactorily where only slight clamping action against the cable is desired or necessary, as in the embodiment of the invention shown in FIG. 6. However, this material does not meet the aforementioned current Underwriters' Laboratories' standards for cable clamps in outlet boxes. In addition to the foregoing, the outlet box of the present invention may be formed integrally from a metallic material, for example, by cast molding from aluminum or an aluminum alloy, or by die stamping the appropriate recessed wall portions and closure panel members from a suitable metal, such as, e.g., steel, the latter being thereafter bent inwardly to provide the cable entry port structure.
The invention in its broader aspects is not limited to the specific embodiments herein shown and described but departures may be made therefrom within the scope of the accompanying claims, without departing from the principles of the invention and without sacrificing its chief advantages.
Claims
What is claimed is:
1. An electrical outlet box having a wall structure providing front to rear wall means and a bottom wall interconnected therebetween, the front to rear wall means and bottom wall defining a chamber within the wall structure which opens through the front of the box, said front to rear wall means comprising a pair of opposed side walls and a pair of opposed end walls interconnected between said side walls, each of said side and end walls terminating in a common frontal plane defining the front opening of said box, said box further including electrical fixture mounting post members adjacent the inside surface of each opposed end wall in opposed alignment generally centrally of said end walls, said wall means also defining an outermost periphery of said box and including end wall portions which are recessed inwardly from said periphery and inwardly from the remainder of said end wall so as to define recessed areas extending along said periphery of said box from the front to the rear thereof, said recessed areas in said end walls being in diagonally opposed alignment on opposite sides of said electrical fixture mounting post members, first flange means secured to said front to rear wall means extending laterally outwardly beyond said outermost periphery of said box, pawl means mounted in said recessed areas, said pawl means being rotatably actuable between a retracted position within the confines of said outermost periphery of said box and an extended position beyond said outermost periphery of said box, said pawl means including clamping flange means adapted to engage the wall surface adjacent said wall opening when said pawl means is in said extended position, means restraining rotational movement of said pawl means in both clockwise and counterclockwise directions in said extended position, said means restraining rotational movement of said pawl means includes a single pawl stop flange member extending in a plane parallel to the plane defined by said pawl arm and pawl tab portions when said pawl means is in said extended position, a hub portion, an arm portion extending tangentially of said hub portion and terminating on one side thereof in said clamping flange means, and a tab portion extending coplanar with said arm portion and terminating on the side of said hub portion opposite said clamping flange means, whereby said pawl means travels linearly both into and out of clamping engagement with said wall surface adjacent said wall opening.
2. An electrical outlet box as claimed in claim 1, including threaded screw means threadedly fastened to said pawl means so as to rotatably mount said pawl means to said outlet box.
3. An electrical outlet box as claimed in claim 1, wherein said first flange means are secured to said front to rear wall means at said inwardly recessed end wall portions.
4. An electrical outlet box as claimed in claim 1, wherein said first flange means extends laterally outwardly beyond said outermost periphery of said box in said frontal plane.
5. An electrical outlet box as claimed in claim 1, including guide means extending parallel to said pawl stop flange member for guiding said pawl means in said linear travel into and out of clamping engagement with said wall surface.
6. An electrical outlet box as claimed in claim 5, wherein said guide means includes at least a partially grooved channel adapted to slidably receive said pawl hub portion therein, said grooved channel being raised from the outer surface of said inwardly recessed end wall portions.
7. An electrical outlet box as claimed in claim 5, including a slot-like channel immediately adjacent said pawl stop flange adapted to receive said pawl tab portion for free linear movement therein.
8. An electrical outlet box as claimed in claim 1, wherein said pawl stop flange extends laterally outwardly to said outermost periphery of said box.
9. In an electrical outlet box having a wall structure providing front to rear wall means and a back wall interconnected therebetween, the front to rear wall means terminating in a common frontal plane and together with the back wall defining a chamber within the wall structure which opens through the frontal plane of the box, means mounting said box in a wall opening comprising: first flange means secured to said wall structure extending in said frontal plane laterally outwardly beyond the outermost periphery of said front to rear wall means; pawl means rotatably actuable between a retracted position within the confines of said outermost periphery of said front to rear wall means, and an extended position beyond said outermost periphery of said front to rear wall means, said pawl means including clamping flange means adapted to engage the wall surface adjacent said wall opening when said pawl means is in said extended position, a hub portion, an arm portion extending tangentially of said hub portion and terminating on one side thereof in said clamping flange means, and a tab portion extending coplanar with said arm portion and terminating on the side of said hub portion opposite the side on which said clamping flange means is located; and means restraining rotational movement of said pawl means in both clockwise and counterclockwise directions in said extended position, said restraining means including a single pawl stop flange member extending in a plane parallel to the plane defined by said pawl arm and pawl tab portions when said pawl means is in said extended position, whereby said pawl means travels linearly both into and out of clamping engagement with said wall surface adjacent said wall opening.
10. An electrical outlet box as claimed in claim 9, including threaded screw means threadedly fastened to said pawl means so as to rotatably mount said pawl means to said outlet box.
11. An electrical outlet box as claimed in claim 9, including guide means extending parallel to said pawl stop flange member for guiding said pawl means in linear travel into and out of clamping engagement with said wall surface.
12. An electrical outlet box as claimed in claim 11, wherein said guide means includes at least a partially grooved channel adapted to slidably receive said pawl hub portion therein, said grooved channel being raised from the outer surface of said inwardly recessed wall portion.
13. An electrical outlet box as claimed in claim 11, including a slot-like channel immediately adjacent said pawl stop flange adapted to receive said pawl tab portion for free linear movement therein.
14. An electrical outlet box as claimed in claim 9, wherein said pawl stop flange extends laterally outwardly to said outermost periphery of said box.
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