United States Patent [19] [11] Patent Number: 5,142,102
Michie [45] Date of Patent:Aug.25,1992
[54] MULTIPLE TIER JUNCTION BOX
[75] Inventor: Alexander Michie, Coquitlam, CANADA
[73] Assignee: Pacific Rim Polytech Corp., Burnaby, CANADA
[21] Appl.No.: 623,153
[22] Filed: Dec. 6, 1990
[51] Int. Cl. ..............................H02G 3/08
[52] U.S. Cl. ..............................174/50; 174/37;
174/57
[58] Field of Search.........................174/37, 48, 50, 53,
174/57
[56] References Cited
U.S. Patent Documents
3.115.539 12/1963 Stuessel st al. ..............174/48
3.346.230 10/1967 Tolf.Jr. .....................174/37 X
3.701.837 09/1972 Fork..........................174/50
3.873.757 03/1975 Berke et al. .................174/52 R
3.911.635 09/1975 Traupe .......................52/221
4.059.199 11/1977 Quaney .......................174/66 X
4.591.656 05/1986 Mohr .........................174/48
4.916.258 04/1990 Mohr .........................174/48
5.008.491 04/1991 Bowman .......................174/48
Foreign Patent Documents
528475 07/1956 CANADA
656567 01/1963 CANADA
673746 11/1963 CANADA
765970 08/1967 CANADA
767295 09/1967 CANADA
908825 08/1972 CANADA
989053 05/1976 CANADA
990843 06/1976 CANADA
1185668 04/1985 CANADA
1185688 04/1985 CANADA
Primary Examiner - Leo P. Picard
Assistant Examiner - David A. Tone
Attorney, Agent or Firm - McFadden, Finchan, Marcus & Anissimoff
[57] Abstract
There is disclosed an electrical junction box having a plurality if tiers each
of which increases in cross-sectional area from the top of the box to the bottom
thereof. The tiers, being annular are adapted to receive conduits from a
plurality of angles or levels. A releaseably engageable lid covers the box which
may be mounted to or within a substrate by a mounting member integral with the
junction box.
23 Claimes, 2 Drawing Sheets
5,142,102
- -1-
MULTIPLE TIER JUNCTION BOX
FIELD OF THE INVENTION
The present invention relates to junction boxes, more particularly it relates to
a multi-tiered junction box which can accommodate a plurality of conduits from a
variety of different levelled tiers on angles thereon.
BACKGROUND OF THE INVENTION
Generally, junction boxes are well known in the art. Such boxes are used in
residential, industrial and commercial installations and in such instances, are
of a relatively small size e.g. 4" in diameter and 1" to 3" in depth. They are
normally placed in ceilings, walls, flooring, etc. To receive spliced conduits,
valved conduits and other joints. Several examples of this junction box are
known in the art as exemplified by U.S. Pat. Nos. 3,873,757 and 4,916,258 as
well as Canadian patent Nos. 765,295, 908,825 AND 1,185,668.
Junction boxes are also used in major installations in underground construction,
where large cables are joined for high voltage lines. In such cases, the
junction boxes are many times the size of the above type and may, for example,
be 2'to 4'in diameter and 1' to 4' high. In the latter case, the construction
and structural characteristics required for such junction boxes are
significantly different than the small residential or like installations. Where
such junction boxes are used exteriorly, they may be buried in the ground or
mounted on a slab construction which is subsequently covered with earth, sand,
or the like. In addition to other factors, such junction boxes must obviously
meet requirements for exposure to outdoor criteria e.g. water resistance, etc.
In the case of outdoor junction boxes, for large electrical installations, one
possibility has been to construct a fixed enclosure of suitable material e.g.
concrete, metal housings ot the like. Apart from the cost effectiveness of such
construction, there are also other considerations such as transportation,
installation, etc. Which add to the total economic factor for such apparatus.
It would be desirable if there could be provided a junction box structure and
apparatus which can readily be mounted exteriorly as well as one which can be
manufactured in an economic and simple manner while a the same time providing a
unit which can be readily secured in place under different locations and
circumstances.
Conventionally the known junction boxes include clamps to fasten a cable therein
entering the box. Typically the boxes include "knockouts" to permit reception of
a conduit within the box. Further, the known junction boxes comprise an
electroconductive material which requires that electrical conduits be grounded
thereto.
SUMMARY OF THE INVENTION
The present invention provides a junction box adapted for mounting to or within
a substrate.
Applicant, in one aspect on the invention, provides a multi-tiered integrally
molded junction box. The tiers are preferably circular in increase in
cross-sectional are from the top of the junction box to the bottom.
The box is preferably molded from a rigid material, e.g. a polyelastomer to
provide a non-electroconductive housing which may be apertured by drilling, etc.
This material, in combination with the multiple circular tiered structure allows
a pluity of conduits to enter the box via apertures provided by the user from a
variety of angles and tiers. Further, the tiers may be cut, etc. For different
applications, e.g. variable level terrain, underground applications, etc.
According to another aspect of the present invention, there is provided mounting
means for mounting the junction box to or within a substrate. In one form, the
mounting means includes a circular wall extending outwardly and spaced from a
bottom tier. Spacer means between the wall and the lowest tier impart structural
integrity to the wall. A base wall extending between the circular wall and the
lowest tier cooperates with the spacer means to provide an open top mounting
means. This arrangement stabilizes the box when positioned within a substrate.
According to a further aspect of the invention, there is provided integrally
molded reinforcement means extending vertically down the integral periphery of
the box. Since the reinforcing means are molded with the box. Removal of one or
some of the tiers will not affect the reinforcing capability for the remaining
tiers.
In a further aspect of the present invention. Applicant provides a lower member
having engages means for cooperation with cover receiving means associated with
the junction box. The cover, as in the junction box, includes reinforcing means.
In a further aspect of the present invention, the junction box may be turned
upside down with the mounting means facing upward. Means for interconnection
with another similarly disposed. As such, the assembled boxes have been found to
function effectively as a manhole.
According to a particularly preferred aspect of the present invention, there id
provided a junction box adapted for connection of one or more electrical
members, the improvement wherein the junction box comprises a hollow body having
a plurality of tiers, the tiers comprising a plurality of diverging stages, each
of the tiers having a cross-sectional area greater than a preceding stage and
less than a succeeding stage.
In an alternate form, the junction box may include an adapter ring which fits
around the top of the box to anchor the same fopr applications where cement
sidewalls are being installed around the opening thus preventing any shifting.
Further, the ring may be adapted to fit the junction box regardless of which
tier is cut.
In another form where several boxes may be required, the boxes may include
cooperating engaging means for connection with an adjacent box. Further, the
boxes may be linked with a conduit integrally molded therewith for communication
between a plurality of boxes.
According to further preferred features of the present invention, the junction
box may be formed of a suitable thermoplastic or thermoset material and the
choice of such material will depend on various factors such as location of the
junction box, i.e. above or below ground, whether moisture is a consideration,
etc. Typically, Suitable thermoplastic materials include various types of resins
such as polyolefins, e.g. polypropylenes, polyamides, such as the "nylon"
polyamides, polycarbonates, etc. In Addition, such resinous materials allow for
the junction boxes to be produced by a simple molding techniques, for example,
by injection molding. Still further, the junction box may, however, be formed of
suitable metal materials such as aluminum, iron, steel or the like for other
specific applications by suitable techniques such as molding, casting or the
like.
In Accordance with the invention, the junction boxes having the multi-tiered
configuration preferably have a substantially circular configuration although it
will be understood that for various applications, other configurations such as
oblong or oval shapes may be employed. In other cases, a polygon shaped
configuration may be desirable. However, in the preferred form of the junction
box, the circular shape of the junction box provides substantially greater
strength for the outer walls to withstand horizontal forces, when installed in
the ground, from ground pressure in order to maintain shape integrity.
The preferred configuration of a circular structure also facilitates provision
of entry apertures into the junction box from any direction, for insertion of
wiring or conduits. Thus, this preferred configuration is not limited as in the
case of square junction boxes.
In accordance with this invention, the junction box may be provided with cover
means for closing one end of the junction box, or both ends, if required. The
cover means preferably has a structure corresponding to and dimensioned for the
size and configuration of the opening at one or both ends of the junction box.
In the case of a circular or cylindrically shaped body, a circularly shaped lid
will be employed, which in turn, results in a combination having several
advantages over a square shaped junction box which would employ a square shaped
lid. Thus, for example, a circularly shaped lid, when subjected to downwardly
exerted pressure as would result from vehicular traffic running over the top of
a junction box, would result in a substantially uniformed distribution of the
downward pressure about the complete junction box. Still further, a circularly
shaped lid cannot drop pr fall into the junction box during installation of the
lid, in contrast to a square shaped lid which may accidentally penetrate through
the open top and fall into the interior chamber of the junction box resulting in
damage.
In general, the tiered body structure preferably comprises three or more tiers
although the exact number will depend on the height or overall size of the unit.
Preferably between three to eight tiers are employed depending on the
requirements for each application; preferably, the tiers are such that each
succeeding tier, of a diverging nature, increases the cross-sectional size of
the junction box by between 2% to 20% and desirably 5% to 15%.
The electrical junction box of the present invention includes means for
permitting the same to be secured or anchored to a substrate; for example, when
the junction box is placed on a supporting surface, in an outdoor underground
installation, the locale surrounding the junction box may be backfilled with
earth or suitable filing material and in order to ensure the stability and
prevent the apparatus from shifting, suitable means may be associated with or
form an integral part of the junction box for this purpose. To this end, the
junction box may be provided with an outwardly and upwardly extending rim,
preferably in the form of a coextensive wall of a generally co-planar nature,
which is exteriorly located, and which is adapted to receive such fill material
to position the box in place. In other embodiments, suitable brackets (one or
more) or arms may project exteriorly and laterally of the lower outer wall,
which may be anchored by a suitable means to the substrate (e.g. by placing
anchor bolts, etc. into the soil through the brackets). Still Further, such
anchoring means may also be located interiorly of the lower wall so that
anchoring of the device may be accomplished during initial installation of the
unit.
The junction box of the present invention may optionally have incorporated
therein individual "knock-outs" provisions and means for securing incoming and
outgoing electrical connections, e.g. clamps although for most purposes, these
will be separately provided where and as required.
The device of the present invention includes several advantageous features
compared to prior art structures for instance, tiering allows for the adding of
strengthening gussets along the inside of the junction when it is buried. The
tiering itself adds strength to withstand horizontal sidewall forces from the
earth pushing in against the junction box when it is buried. The tiering itself
adds strength to withstand horizontal sidewall forces as the top of each tier
adds horizontal thickness to the walls. Still further, tiering allows the top of
the junction box to be smaller than the body. As the top of the junction box is
at ground level, the lid can be made smaller and consequently, a smaller area is
exposed at ground level.
BRIEF DESCRIPTION OF THE DRAWINGS
Having thus generally described the invention, reference will now be made to the
accompanying drawings illustrated preferred embodiments and, in which:
FIG.1 is a perspective view of the present invention;
FIG.2 is a bottom view of the junction box of the present invention;
FIG.3 is a sectional view taken along line 3-3 of FIG.1;
FIG.4 is a top view of the cover member of the junction box of the
present invention;
FIG.5 is a sectional view taken along line 5-5 of FIG.4; and
FIG.6 is a side view of FIG.4.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG.1. shown is a perspective view of the junction box of the
present invention, generally indicated by numeral 10. The box 10 has an open top
12 and open bottom 14 with a plurality of tiers preferably circular in
cross-sectional extending there between. It is particularly preferred that each
of the tiers 16 have a greater cross-sectional area than a preceding tier, while
having a smaller cross-sectional area than a succeeding tier. In this
arrangement, the tubular junction box 10 diverges from top 12 to bottom 14.
In greater detail the bottom 14 of the box 10 preferably includes mounting the
box 10 to or with a substrate, e.g. concrete, ground, etc. Th mounting mean 24
includes a circular wall 20 extending outwardly from and concentrically with
tier 16 adjacent bottom 14of the junction box 10. The wall 20 is maintained in a
spaced relationship from tier 16 adjacent bottom 12 by spacer means. The spacer
means comprise a plurality of individual spaced apart plate members 26
preferably radiating externally from tier 16 adjacent bottom 14 and extending
between this tier and wall20. The mounting means 24 additionally provides a base
member 28 integrally molded with the box 10. The base member 28 extends
perpendicularly from the bottom 22 of wall 20 to the exterior of tier 16
adjacent bottom 14 to thus provide a closed bottom-open top mounting means 24.
As briefly mentioned herein, the box 10 preferably is molded using a suitable
material for such a structure which houses electrical conduits, pipes, etc. Such
suitable materials include polymeric substances, more particularly rigid
polymers. These materials provide strength and are light weight
non-electroconductive. When electrical conductivity is not a concern, e.g. for
housing pipe junctions, etc. other materials such as cast aluminum, steel, etc.
may be employed. By incorporating the polymeric material however, one may easily
drill, for example, into the structure at any position aling a tier 16 and at
any selected tier.
Referring to FIG. 2 shown is a bottom view of the junction box 10.
The base member 28, discussed previously herein, preferably includes first
engaging means 30.e.g. projections extending perpendicularly and projecting
downwardly therefrom regularly spaced apart therefrom second engaging means
32.e.g. recesses extending upwardly therein. The engaging means 30 and 32 extend
about the circumference of base 28; the recesses 32 are dimensioned to
frictionally engage the projections 30. Thus, the first and second engaging
means 30 and 32 of one junction box 10 can engage and interlock the second and
first engaging means 32 and 30 respectively of a similar base 28 of a similar
junction box 10 in a superimposed relationship. this allows the superimposed and
interlocked junction boxes to provide double the height of one individual box 10
to thus accommodate a variety of applications. Further, since the boxes diverge,
as illustrated in FIG. 3 they may be stacked. The stacking allows the height of
box 10 to be increased by an amount equal to the width of the circular walls 20
of mounting means 24; the spacer means 26located therein additionally provide
support for boxes 10 stacked in this manner.
In one application, the box 10 may be situated within the ground and the
open top of the mountings means filled with earth. The spacer means 26 prevent
the rotation along a vertical axis in the box 10 while mounted in the ground and
keep the same from rising upward from underground forces, etc. The tier 16,
comprising the polymeric materially previously mentioned herein, allows the same
to be cut to thereby "customize" the junction box 10 to any terrain.
Applicant has found that the circular tiered structure of the box 10
adequately withstands horizontal forces externally exerted on the same while in
situ. To further enhance the strength of the tiers 16, reinforcing means 34 are
provided and integrally molded within the internal periphery of box 10,
(preferably vertically therein) in a regularly spaced apart manner. This is
shown if FIG. 3. The reinforcing means 34, being integrally molded with the box
10, thus conform to each of the tiers 16; this provides reinforcement for
subsequent tiers 16 in the event one is removed, cut, etc.
Referring back to FIG. 3 the top 12 of the box 10 preferably includes,
spaced inwardly from the internal periphery, receiver means 36. The cover
receiving means 36 comprises a groove adapted to frictionally engage engagement
means 38 of cover 40 (shown in FIGS. 4 and 5). The engaging means 38 of cover 40
preferably comprises a downward projection extending about the internal
periphery of the cover 40.
In addition, the top 12 of the box 10 includes an aperture flange 37
extending inwardly thereof. The flange 37 may receive a threaded insert to
accommodate a bolt etc. (not shown) which may extend through a suitable
dimensioned aperture in the cover 40 for connection therewith.
The cover 40 comprises a similar material as the box 10 and additionally
includes integrally molded reinforcing means 42 extending radially from the
center of the cover 40. An annual reinforcement 44 is provided intermediate of
the periphery and center of the cover 40. The central portion of 46 of the cover
40 is preferably frustoconical as illustrated in FIG. 6.
Applicant, by incorporating the reinforcement means 42 and 44 has found
that the circular cover 40, while positioning on box 10, substantially
dissipates any weight placed thereon by distribution to the periphery thereof.
This, in turn, applies equivalent downward force to all areas of the box. Thus,
the cover 40 effectively releases engages the receiving means 36 of the box 10
to provide re-enterable, non-electrical conductive junction box 10, which can
receive conduits, etc. from plurality of angles and levels.
Although various embodiments have been described herein, it will be
understood that various modifications can be made to the above-described
embodiments without departing from the spirit and scope of the invention.
I claim:
1. In a junction box for connection of one or more electrical members, the
improvement wherein said junction boxes comprises a hollow circular body, having
a plurality of circular tiers, said tiers comprising a plurality of diverging
stages, each of said tiers having a cross-sectional area greater than a
preceding stage and less than a succeeding stage; an inwardly extending support
member extending circumferentially within said open top, said support member
including an annular recess in an upper surface, a circular cover for
positioning in said open top, said cover including annular means for engagement
in said annular recess and also including radially extending reinforcement means
dissipating weight on said cover by distribution of said weight to the periphery
thereof, and subsequently to the body.
2. The junction box as defined in claim 1, wherein said junction box
includes means for mounting said box to a substrate, said mounting means
extending outwardly and concentrically from a bottom tier of said box.
3. The junction box as defined in claim 2, further including an outer
circumferential wall, said mounting means extending outwardly and concentrically
from a bottom tier of said box.
4. The junction box as defined in claim 3, wherein said circumferential
wall includes a base member.
5. The junction box as defined in claim 4, wherein said base member
includes first engaging means projecting therefrom and spaced apart second
engaging means and said first engaging means being adapted for reception in
respective second and first engaging means of a similar bar member of similar
structure thereby inter-engaging said junction box are in superposed relation.
6. The junction box as defined in claim 1, wherein said junction box
includes a circular, said circular wall including spacer means for spacing said
wall from a bottom tier.
7. The junction box as defined in claim 6, wherein said spacer means
comprises a plurality of individual spaced apart members.
8. The junction box as defined in claim 7, wherein said spaced apart
members radiate laterally from said bottom tier.
9. The junction box as defined in claim 8, wherein said spaced apart
members extend between said circumferential walls and said bottom tier.
10. The junction box as defined in claim 1, wherein each of said tiers
includes reinforcing means.
11. The junction box as defined in claim 1, wherein said reinforcing means
are integrally molded with said cover member.
12. The junction box as defined in claim 11, wherein said reinforcing means
are annular reinforcing means spaced inwardly from said periphery of said cover
member.
13. The junction box as defined by claim 11, wherein said reinforcing means
comprise radially oriented reinforcing means radiating from a central portion of
said cover member.
14. The junction box as defined in claim 1, wherein said cover member is
frustoconical in profile.
15. The junction box as defined in claim 1, wherein said cover member
comprises a polymeric material.
16. The junction box as defined in claim 1, wherein said cover member
ccomprises a non-electroconductive material.
17. The junction box as defined in claim 1, wherein said cover comprises a
molded polymeric material.
18. A multi-tiered electrical junction box having a body defining a chamber
therein, said body having an open top and an open bottom. said body having a
plurality of spaced apart circular tiers forming diverging stages in said body,
each of said circular tiers having a cross-sectional area greater than a
preceding stage and less than a succeeding stage to thereby from a tiered
internal and external configuration: mounting means for mounting said box to a
substrate, said mounting means extending outwardly and concentrically from at
least one of said tiers to permit said body to be secured to a substrate; an
inwardly extending support member extending circumferentially within said open
top, said support member including an annular recess in an upper surface, a
circular cover for positioning in said open top on said support member to close
said open top, said cover including annular means for engagement in said annular
recess and also including radially extending reinforcement mean, said radially
extending reinforcement means dissipating weight on said cover by distribution
of said weight to periphery therof, and subsequently to the body.
19. The junction box as defined in claim 18, wherein said mounting in
L-shaped in cross section.
20. The junction box as defined in claim 18, wherein said junction box
comprises a rigid material.
21. The junction box as defined in claim 18, wherein said junction box
comprises a non-electroconductive material.
22. The junction box as defined in claim 18, wherein said junction box
comprises a polymeric material.
23. The junction box as defined in claim 18, wherein said junction box
comprises a molded polymeric material.