Air sealing electrical box
View Patent ↗An electrical box with a peripheral flange and channel element which in shape and placement provides and vapor sealing of wall assemblies and also facilitates wall assembly construction. The flange will consist of a generally flat surface connected to a channel which in turn will be attached to electrical box bodies of various sizes and shapes. In addition, the electrical box may employ rectangular elements with optional integral holes attached to the box body for fastening the box to wall or ceiling assembly materials.
1. An air sealing electrical box for placement in wall or ceiling assemblies, the box comprising:
four box body sides and a back joined where they meet which together with an open face form an electrical box body, and
a flange and channel element joined to the electrical box body, said flange and channel element further comprising:
a flange channel bottom portion integrally connected to and proceeding distally from the box body sides in a generally orthogonal fashion,
a flange channel outside vertical portion integrally connected to and proceeding orthogonally from a flange channel bottom portion distal edge and proceeding generally parallel to the box body sides towards the box body open face, and
a flange face portion integrally connected to a flange channel outside vertical portion edge opposite the channel bottom portion and proceeding distally from the box body sides,
said flange channel bottom, flange channel outside vertical and flange face portions together serving to obstruct air and/ or vapor movement at the interface between the air sealing electrical box and wall and ceiling assembly materials and serving to facilitate placement of said assembly materials.
2. The air sealing electrical box of claim 1 , wherein a plurality of support and fastening blocks are joined to the electrical box body to facilitate box placement in wall and ceiling assemblies.
3. The support and fastening blocks of claim 2 , wherein the blocks possess openings to receive fasteners for fastening the box to wall and ceiling assembly materials.
4. The support and fastening blocks of claim 2 , further comprising a slit in the blocks to facilitate manufacture.
5. The air sealing electrical box of claim 1 , wherein the flange and channel element enhances wall or ceiling assembly air and/ or vapor sealing.
6. The air sealing electrical box of claim 1 , wherein the flange and channel element flange face portion provides a substrate for sealing materials.
7. The air sealing electrical box of claim 1 , wherein the flange and channel element provides box placement depth calibration during attachment of box to wall and ceiling assembly materials.
8. The air sealing electrical box of claim 1 , wherein the flange and channel element provides a router or cut- out tool routing guide.
9. The air sealing electrical box of claim 1 , wherein the flange and channel element has pre- formed openings in the flange face portion to receive fasteners for fastening the box to wall and ceiling assembly materials.
10. The air sealing electrical box of claim 1 , wherein the box body and flange and channel element are manufactured of plastic and joined to each other by single shot or double shot plastic injection mold manufacturing.
11. The electrical box of claim 1 , wherein a round or ovalized cylinder and back ioined where they meet together with an open face form an electrical box body.
12. An air sealing electrical box for placement in wall or ceiling assemblies, the box comprising:
four box body sides and a back joined where they meet which together with an open face form an electrical box body, and
an alternative flange and channel element further comprising:
an alternative flange channel bottom portion, an alternative flange channel outside vertical portion integrally connected to and proceeding orthogonally from an alternative flange channel bottom portion distal edge and proceeding generally parallel to the box body sides towards the box body open face, and
an alternative flange face portion integrally connected to an alternative flange channel outside vertical portion edge opposite the alternative channel bottom portion and proceeding distally from the box body sides,
said alternative flange channel bottom, alternative flange channel outside vertical and alternative flange face portions together serving to obstruct air and/ or vapor movement at the interface between the electrical box and wall and ceiling assembly materials and serving to facilitate placement of said assembly materials, and
a flange attachment collar joining the electrical box body sides and the alternative flange and channel element said collar further comprising:
a flange attachment collar bottom portion,
a flange attachment collar top portion, and
a flange attachment collar vertical portion.
13. The air sealing electrical box of claim 12 , wherein a plurality of support and fastening blocks are joined to the electrical box body to facilitate box placement in wall and ceiling assemblies.
14. The support and fastening blocks of claim 13 , wherein the blocks possess openings to receive fasteners for fastening the box to wall and ceiling assembly materials.
15. The support and fastening blocks of claim 13 , further comprising a slit in the blocks to facilitate manufacture.
16. The air sealing electrical box of claim 12 , wherein the alternative flange and channel element enhances wall or ceiling assembly air and/ or vapor sealing.
17. The air sealing electrical box of claim 12 , wherein the alternative flange and channel element alternative flange face portion provides a substrate for sealing materials.
18. The air sealing electrical box of claim 12 , wherein the alternative flange and channel element provides box placement depth calibration during attachment of box to wall and ceiling assembly materials.
19. The air sealing electrical box of claim 12 , wherein the alternative flange and channel element provides a router or cut- out tool routing guide.
20. The air sealing electrical box of claim 12 , wherein the alternative flange and channel element has pre- formed openings in the alternative flange face portion to receive fasteners for fastening the box to wall and ceiling assembly materials.
21. The air sealing electrical box of claim 12 , wherein the box body and flange attachment collar are manufactured of plastic and the flange and channel element are manufactured of metal or plastic and joined to each other by single shot or double shot plastic injection mold manufacturing or overmolding.
22. The electrical box of claim 12 , wherein a round or ovalized cylinder and back ioined where they meet together with an open face form an electrical box body.