A waterproofing recessed electrical junction box

Abstract

14 Abstract A recessed electrical junction box designed to house electrical apparatus within walls and ceilings consists of a container with an integrated flange that interfaces with the container’s rim. The container and flange are one piece, often plastic injection- moulded, and create a flush surface with the interior wall when installed. The flange can be sealed to the wall or a waterproof barrier, forming a watertight seal meeting codes and standards related to internal wet area waterproofing. Installation may involve inserting the container through a wall opening, allowing the flange to interface with a waterproof membrane to prevent water ingress. Holes for electrical cabling can be made and sealed, or the container may have destructible tabs for creating these holes. The junction box may also include angled sides to allow for stacking and prevention of water collection. The container may have interior side projections which serve as attachment holes for the electrical apparatus and through which electrical wiring may be run. Abstract A recessed electrical junction box designed to house electrical apparatus within walls and ceilings consists of a container with an integrated flange that interfaces with the container's rim. The container and flange are one piece, often plastic injection- moulded, and create a flush surface with the interior wall when installed. The flange can be sealed to the wall or a waterproof barrier, forming a watertight seal meeting codes and standards related to internal wet area waterproofing. Installation may involve inserting the container through a wall opening, allowing the flange to interface with a waterproof membrane to prevent water ingress. Holes for electrical cabling can be made and sealed, or the container may have destructible tabs for creating these holes. The junction box may also include angled sides to allow for stacking and prevention of water collection. The container may have interior side projections which serve as attachment holes for the electrical apparatus and through which electrical wiring may be run. 14 20 25 23 81 02 26 S ep 2 02 5 A b s t r a c t A r e c e s s e d e l e c t r i c a l j u n c t i o n b o x d e s i g n e d t o h o u s e e l e c t r i c a l a p p a r a t u s w i t h i n w a l l s 2 0 2 5 2 3 8 1 0 2 2 6 S e p 2 0 2 5 a n d c e i l i n g s c o n s i s t s o f a c o n t a i n e r w i t h a n i n t e g r a t e d f l a n g e t h a t i n t e r f a c e s w i t h t h e c o n t a i n e r ' s r i m . T h e c o n t a i n e r a n d f l a n g e a r e o n e p i e c e , o f t e n p l a s t i c i n j e c t i o n - m o u l d e d , a n d c r e a t e a f l u s h s u r f a c e w i t h t h e i n t e r i o r w a l l w h e n i n s t a l l e d . T h e f l a n g e c a n b e s e a l e d t o t h e w a l l o r a w a t e r p r o o f b a r r i e r , f o r m i n g a w a t e r t i g h t s e a l m e e t i n g c o d e s a n d s t a n d a r d s r e l a t e d t o i n t e r n a l w e t a r e a w a t e r p r o o f i n g . I n s t a l l a t i o n m a y i n v o l v e i n s e r t i n g t h e c o n t a i n e r t h r o u g h a w a l l o p e n i n g , a l l o w i n g t h e f l a n g e t o i n t e r f a c e w i t h a w a t e r p r o o f m e m b r a n e t o p r e v e n t w a t e r i n g r e s s . H o l e s f o r e l e c t r i c a l c a b l i n g c a n b e m a d e a n d s e a l e d , o r t h e c o n t a i n e r m a y h a v e d e s t r u c t i b l e t a b s f o r c r e a t i n g t h e s e h o l e s . T h e j u n c t i o n b o x m a y a l s o i n c l u d e a n g l e d s i d e s t o a l l o w f o r s t a c k i n g a n d p r e v e n t i o n o f w a t e r c o l l e c t i o n . T h e c o n t a i n e r m a y h a v e i n t e r i o r s i d e p r o j e c t i o n s w h i c h s e r v e a s a t t a c h m e n t h o l e s f o r t h e e l e c t r i c a l a p p a r a t u s a n d t h r o u g h w h i c h e l e c t r i c a l w i r i n g m a y b e r u n . 1 4 2 0 2 5 2 3 8 1 0 2 2 6 S e p 2 0 2 5

Description

Field of the Invention

[0001] This invention relates generally to electrical junction boxes and, more particularly, to a waterproofing recessed electrical junction box. Background of the Invention

[0002] An electrical outlet enclosure is a protective housing designed to encase and safeguard electrical outlets and apparatus installed within a wall. This enclosure is typically made of durable materials such as plastic or metal and may feature a cover that can be securely sealed to prevent dust, moisture, or contaminants from infiltrating the electrical components.

[0003] These enclosures not only enhance safety but also ensure compliance with electrical codes and standards, including codes and standards related to internal wet area waterproofing.

[0004] Various types of enclosures exist including US6239365B1 (2001-05-29) McEvers which discloses a one-piece, unitary sealable electrical junction box with built-in sealing chambers for electrical wires. The wires pass through these chambers before entering the main box, and they can be sealed with expandable foam to create an airtight barrier. The box has an outer flange that allows for a vapor barrier to be securely attached, ensuring an airtight seal around the outside.

[0005] The junction box includes a front flange that protrudes outward from its outer wall. This front flange is positioned parallel to the box's front opening and set back to accommodate a wall lining such as sheetrock, It features attachment holes for securing the box to a stud using nails, screws, or similar means. The flange's width allows for the attachment of a vapor barrier using adhesive.

[0006] US4757158A (1988-07-12) Lentz discloses a five-sided air-vapor barrier box used to seal an electrical outlet box within a building's wall. The barrier box features outwardly extending reinforced flanges around its open side, with these flanges secured to a wall stud. The electrical outlet box and barrier box are attached to the stud, and a moisture-proof sheet is placed over them, with an opening cut to match 2025238102   26 Sep 2025 the barrier box's open side. Caulk is applied to the flanges, and the film is pressed against them to create an airtight and moisture-proof seal. The entire assembly is then covered with the final wall finish. The barrier box walls have varying thicknesses, with thicker portions near the flanges for added strength and thinner sections near the back wall for easier wire insertion.

[0007] US4673097A (1987-06-16) Schuldt discloses an electrical box which is designed for wall and ceiling installation to enclose the ends of sheathed electrical conductors connected to a switch or socket within the box's hollow interior. It features an integrally moulded flange that surrounds the box's exterior walls and is parallel to its open front face. The flange is set back from the open face to ensure it aligns with the interior wall's surface when installed. This flange can be secured to the wall material or a vapor and air barrier using adhesive, preventing moisture and air from passing through the box. Additionally, alignment spacers are included for precise installation on a rigid building wall surface.

[0008] The present invention seeks to provide a recessed electrical junction box which will overcome or substantially ameliorate at least some of the deficiencies of the prior art, or to at least provide an alternative.

[0009] It is to be understood that, if any prior art information is referred to herein, such reference does not constitute an admission that the information forms part of the common general knowledge in the art, in Australia or any other country. Summary of the Disclosure

[0010] According to one aspect, there is provided a recessed electrical junction box comprising a container defining an interior for accommodating electrical apparatus and a surrounding flange interfacing a rim of the container, wherein the container and the flange are integrally formed as one piece, an intersection of the container and the flange defining an opening, and wherein the container defines interior side projections for reticulation of electrical wiring therethrough which define interior attachment holes and exterior side recesses.

[0011] In some embodiments, the junction box further defines a lip projecting forward of the flange surrounding the opening. The flange may be installable against a rear 2025238102   26 Sep 2025 surface of a wall lining, with the lip projecting through an opening in the wall lining to cover interior edges thereof. The lip may be rectangular with opposed long straight edges and opposed short straight edges, optionally joined by rounded corners. A height of the lip may correspond to a thickness of the wall lining, for example 10 mm, 13 mm, 16 mm or 25 mm plasterboard, and in some embodiments the lip is frangible or cuttable to permit adjustment of its height during installation. Faces of the interior side projections defining the attachment holes may be recessed behind edges of the lip such that a cover plate of the electrical apparatus is recessed within the lip.

[0012] In other embodiments, openings to the attachment holes are coplanar with the opening so that cover plates of the electrical apparatus are flush with a front face of the flange. The attachment holes may be blind holes formed in thickened portions of the projections. The container may comprise angled sides such that when the flange is installed vertically a bottom one of the sides is angled down towards the opening, thereby directing water out of the container. The angled sides may further permit stacking of multiple containers. The container may be defined by four planar side walls and a planar floor, and the interior projections may define raised surfaces to direct water away from wiring passing therethrough. Exterior surfaces of the exterior recesses may be angled with respect to the flange so that water drains away from the container when installed.

[0013] According to another aspect, there is provided a system comprising a wall lining defining an opening and a recessed electrical junction box as described above installed therein, wherein the lip projects through the opening of the wall lining and conceals interior edges of the opening. In some embodiments, the flange lies against a rear surface of the wall lining and interfaces with a waterproofing membrane applied across the wall lining.

[0014] According to a further aspect, there is provided a method of installation comprising forming an opening in a wall lining, inserting the recessed electrical junction box so that the flange is positioned against the wall lining, passing the lip of the junction box through the opening, and mounting electrical apparatus to the 2025238102   26 Sep 2025 junction box so that a cover plate of the electrical apparatus is recessed within the lip and substantially flush with a front surface of the wall lining.

[0015] Other aspects of the invention are also disclosed. Brief Description of the Drawings

[0016] Notwithstanding any other forms which may fall within the scope of the present invention, preferred embodiments of the disclosure will now be described, by way of example only, with reference to the accompanying drawings in which:

[0017] Figure 1 shows a front view of a recessed electrical junction box in accordance with a first embodiment.

[0018] Figure 2 shows a rear perspective view of the junction box of Figure 1.

[0019] Figure 3 shows a side cross-sectional view of the junction box of Figure 1.

[0020] Figure 4 shows a front view of a recessed electrical junction box in accordance with a second embodiment including a projecting lip.

[0021] Figure 5 shows a rear view of the junction box of Figure 4.

[0022] Figure 6 shows a rear perspective view of the junction box of Figure 4.

[0023] Figure 7 shows a front perspective view of the junction box of Figure 4.

[0024] Figure 8 shows a side cross-sectional view of the junction box of Figure 4. Description of Embodiments

[0025] A recessed electrical junction box 100 is designed to accommodate electrical apparatus such as nurse call points, electrical outlets, and the like.

[0026] The junction box 100 comprises a container 101 recessed within a wall cavity in use. The container 101 defines an interior 103 for receiving the electrical apparatus. The junction box 100 further comprises a surrounding flange 102 interfacing with a rim 116 of the container 101.

[0027] The container 101 and the flange 102 are integrally formed as a single piece. In embodiments, the junction box 100 may be plastic injection-moulded. An intersection of the container 101 and the flange 102 defines an opening 104 that is coplanar with the flange 102. According to the embodiment of Figures 1 -3, no part of the junction box 100 protrudes beyond a front face 105 of the flange 102. In other 2025238102   26 Sep 2025 words, when the junction box 100 is installed, the junction box 100 terminates flush with the front face 105 of the flange 102.

[0028] The container 101 has interior attachment holes 106 recessed with respect to the opening 104. These attachment holes 106 are spaced to align with fixation screws of the electrical apparatus. For installation, an aperture is cut through a wall lining into the wall cavity therebehind. The container 101 is then inserted through the aperture until the flange 102 lies flat against an outer face of the wall lining. The surface area of the flange 102 interfaces with a waterproofing membrane applied over the wall lining so that the junction box 100 forms a watertight barrier to prevent water ingress or egress, thereby complying with applicable codes or standards relating to internal wet-area waterproofing.

[0029] A hole may be drilled through the container 101 for electrical cabling, which may be sealed with a plug or sealant. Alternatively, the container 101 may comprise destructible tabs which are displaced to form holes for electrical cabling.

[0030] In an alternative installation, the junction box 101 is mounted with the flange 102 against a rear surface of the wall lining, and a cover plate of the electrical apparatus is selected so that its front surface lies substantially flush with the front surface of the wall lining. In this way, the thickness of the cover plate is chosen to correspond to the thickness of the wall lining, thereby allowing the junction box 101 to be used with wall linings of different thicknesses. In this installation, the waterproofing barrier is applied behind the wall lining.

[0031] As best shown in Figure 3, openings 107 to the attachment holes 106 are preferably coplanar with the opening 104. Thus, the faceplate of the electrical apparatus can be mounted flush across the front face 105 of the flange 102.

[0032] At least one side 108 of the container 101 is preferably angled with respect to the flange 102 so that, when the junction box 100 is installed with the flange 102 vertical and the angled side 108 positioned at the bottom of the container 101 as shown in Figure 3, an interior surface 109 of that side 108 slopes downward toward the opening 104. Consequently, any water collected within the container 101 flows down to the opening 104 rather than pooling inside the container. 2025238102   26 Sep 2025

[0033] Preferably, the container 101 has angled sides 108 so that the container 101 can be stacked with adjacent similar containers. In the embodiment shown, the container 101 has a generally rectangular cross-section defined by four planar angled side walls 108, and may further comprise a planar floor 117 between the sides.

[0034] The container 101 may comprise interior side projections 110 disposed with respect to a frontal plane as shown in Figure 1. The sides 108 may be of uniform thickness so that the container 101 defines exterior side recesses 111 corresponding to respective interior side projections 110. These interior side projections 110 are preferably sufficiently wide (i.e. substantially wider than the attachment apertures 106) to allow electrical wiring to pass through holes formed therein. Any such wiring may be tucked away within the corresponding exterior side recesses 111.

[0035] Preferably, exterior surfaces 112 of the recesses 111 are angled with respect to the flange 102. With reference to Figure 3, when the junction box 100 is installed with the flange 102 vertical, a top one of the exterior surfaces 112 slopes downward away from the flange 102. Thus, any water collected in the recess 111 flows away from the flange 102 and from the rear of the container 101, instead of pooling in the recess 111.

[0036] The interior side projections 110 may define the attachment holes 106. As shown in Figure 3, the interior side projections 110 may comprise a thick section 113 at the opening 104, with the attachment holes 106 formed as blind holes within these thick sections 113. Such blind holes 106 do not compromise the watertight integrity of the junction box 100.

[0037] With reference to Figure 1, the container 101 may be elongate, with a pair of interior side projections 110 provided at respective ends of the container 101. With further reference to Figure 1, when the junction box 101 is installed with the flange 102 vertical, a bottom interior side projection 110 defines a raised surface 114 relative to adjacent surfaces 115. As noted above, electrical wiring may pass through holes in the interior side projections 110. Thus, any water collected within the container 101 pools against the adjacent surfaces 115, away from wiring routed through the bottom projection 110. 2025238102   26 Sep 2025

[0038] The interior side projections 110 preferably also have angled sides so that the container 101 can be stacked with adjacent similar containers.

[0039] The flange 102 may define attachment apertures 121 therethrough. In the embodiment shown, the flange 102 defines apertures 121 at respective corners thereof.Figures 4-8 illustrate a second embodiment of the recessed electrical junction box 100 in which the box further defines a lip 118 projecting forward of the surrounding flange 102 at the opening 104 defined at the intersection of the container 103 and the flange 102. Figures 4 and 5 respectively show front and rear views of the junction box 100, while Figures 6 and 7 show rear and front perspective views, and Figure 8 shows a side cross-sectional view of the junction box 100.

[0040] As is evident in particular from Figure 7, the lip 118 is preferably of generally rectangular form and comprises planar walls 119 defining a pair of opposed long straight edges 120a and a pair of opposed short straight edges 120b. The corners between the planar walls 119 may be rounded in order to reduce stress concentrations and to ease insertion of the lip 118 through a corresponding aperture in the wall lining.

[0041] In accordance with this embodiment, the surrounding flange 102 may be installed against a rear surface of a wall lining, with a rectangular aperture formed through the wall lining dimensioned to receive the lip 118. In this manner, the lip 118 extends forwardly through the aperture and overlies the raw interior edges of the wall lining, thereby concealing those edges and at the same time maintaining a waterproof barrier across the junction between the box and the wall lining. By covering the cut edges of the wall lining, the lip 118 also reduces the likelihood of water ingress into the wall cavity and assists in preserving the integrity of any waterproofing membrane applied in the vicinity of the wall lining.

[0042] The height of the lip 118 is preferably selected to match the thickness of the wall lining into which the junction box 100 is installed. In the embodiment shown, the lip 118 projects forward of the flange 102 by approximately 13 mm, which corresponds to the nominal thickness of a standard plasterboard or drywall lining commonly employed in residential and commercial building construction in Australia. Other 2025238102   26 Sep 2025 versions of the junction box 100 may be provided with lips 118 of alternative heights suitable for other commonly available lining thicknesses, for example 10 mm, 16 mm or 25 mm. In further alternatives, the lip 118 may be manufactured in a range of standard depths, or may be formed with a frangible or cuttable extension that allows an installer to adjust its height at the time of installation to suit a particular wall lining thickness.

[0043] As further evident from Figure 7, the interior side projections 110 that define the attachment holes 106 are arranged so that their front faces, including the openings 107 to the attachment holes, are recessed slightly rearward of the edges 120a, 120b of the lip 118. In this configuration, the cover plate of the installed electrical apparatus can be received entirely within the lip 118 such that the outer surface of the cover plate lies flush with, or slightly recessed relative to, the frontmost plane of the lip 118. This arrangement provides a neat and aesthetically pleasing finish, while maintaining the waterproof barrier created by the flange 102 and lip 118.

[0044] For installation according to the first embodiment, an aperture is cut through a wall lining into a wall cavity located behind the lining. The container 101 of the junction box 100 is inserted through the aperture until the surrounding flange 102 lies flat against the outer surface of the wall lining. The flange 102 interfaces with a waterproofing membrane applied across the wall lining so that the junction box 100 forms a watertight barrier. The installer may then drill a hole through the container 101, or alternatively displace a destructible tab, to provide a passage for electrical cabling. The cabling can be sealed with a plug or sealant to maintain the watertight integrity. The electrical apparatus is secured to the interior attachment holes 106, with the cover plate applied flush across the front face 105 of the flange 102. In this manner, the junction box 100 is fixed in place, provides a recessed housing for the apparatus, and maintains waterproofing compliance.

[0045] For installation according to the second embodiment, the flange 102 is positioned against a rear surface of the wall lining. A rectangular aperture is cut through the wall lining corresponding to the lip 118. The lip 118 projects forward of the flange 102 and extends through the aperture such that the planar walls 119 of the 2025238102   26 Sep 2025 lip 118 overlie and conceal the raw interior edges of the wall lining. The lip 118 thereby assists in maintaining the waterproof barrier by preventing water ingress at the cut edge of the wall lining. The height of the lip 118 is chosen to correspond to the thickness of the wall lining—for example, 10 mm, 13 mm, 16 mm or 25 mm plasterboard commonly employed in Australian construction. In some forms, the lip 118 may be frangible or cuttable to allow trimming to the appropriate height.

[0046] Once installed, the interior side projections 110 with openings 107 for the attachment holes 106 preferably remain recessed relative to the forward edges 120a, 120b of the lip 118. This arrangement allows the cover plate of the electrical apparatus to be positioned within the lip 118 so that the outer surface of the cover plate lies flush with, or slightly recessed relative to, the plane defined by the edges 120a, 120b. The wiring may be passed through holes formed in the interior side projections 110 and, as previously described, may be tucked into the exterior side recesses 111 to facilitate insertion and removal of the junction box 100 through the wall aperture. The raised surface 114 of the bottom projection 110 directs any incidental water away from electrical wiring, thereby further reducing risk of water ingress into live connections.

[0047] Following installation in either embodiment, the junction box 100 provides a recessed housing that satisfies both functional and waterproofing requirements. The electrical apparatus is secured in the interior 103, wiring is protected and directed by the interior projections 110, and water drainage is promoted by the angled sides 108 and interior surface 109. The cover plate is mounted either flush with the flange 102 in the first embodiment, or recessed within the lip 118 in the second embodiment, to present a neat finish in line with the front surface of the wall lining.

[0048] The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the invention. However, it will be apparent to one skilled in the art that specific details are not required in order to practise the invention. Thus, the foregoing descriptions of specific embodiments of the invention are presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed as 2025238102   26 Sep 2025 obviously many modifications and variations are possible in view of the above teachings. The embodiments were chosen and described in order to best explain the principles of the invention and its practical applications, thereby enabling others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. It is intended that the following claims and their equivalents define the scope of the invention.

Claims

1. A recessed electrical junction box comprising:a container defining an interior for accommodating electrical apparatus; anda surrounding flange interfacing a rim of the container, wherein:the container and the flange are integrally formed as one piece;an intersection of the container and the flange defines an opening, wherein the container defines interior side projections for reticulation of electrical wiring therethrough which define interior attachment holes and exterior side recesses.

2. The recessed electrical junction box of claim 1, wherein the junction box defines a lip projecting forward of the flange surrounding the opening defined at the intersection of the container and the flange.

3. The recessed electrical junction box of claim 2, wherein the flange is installable against a rear surface of a wall lining and wherein the lip projects through an opening in the wall lining.

4. The recessed electrical junction box of claim 2, wherein the lip defines a rectangular configuration comprising opposed long straight edges and opposed short straight edges.

5. The recessed electrical junction box of claim 4, wherein the long straight edges and short straight edges are joined by rounded corners.

6. The recessed electrical junction box of claim 3, wherein a height of the lip corresponds to a thickness of the wall lining.

7. The recessed electrical junction box of claim 6, wherein the lip projects forward of the flange by approximately 13 mm.2025238102   26 Sep 20258. The recessed electrical junction box of claim 6, wherein the lip is frangible or cuttable to permit adjustment of its height during installation.

9. The recessed electrical junction box of claim 2, wherein faces of the interior side projections defining the attachment holes are recessed behind edges of the lip such that a cover plate of the electrical apparatus is recessed within the lip.

10. The recessed electrical junction box of claim 1, wherein the attachment holes are blind holes.

11. The recessed electrical junction box of claim 1, wherein sides of the container are angled with respect to the flange so that when the flange is installed vertically in use, a bottom one of the sides is angled down toward the opening.

12. The recessed electrical junction box of claim 1, wherein the container has angled sides so that the container can be stacked with an adjacent similar container.

13. The recessed electrical junction box of claim 12, wherein the container has four planar angled side walls and a planar floor between the side walls.

14. The recessed electrical junction box of claim 1, wherein exterior surfaces of the exterior side recesses are angled with respect to the flange.

15. The recessed electrical junction box of claim 14, wherein, when the flange is installed vertically in use, a top one of the exterior surfaces is angled down away from the flange.

16. The recessed electrical junction box of claim 1, wherein a bottom interior side projection defines a raised surface relative to adjacent surfaces so that water is directed away from wiring extending therethrough.2025238102   26 Sep 202517. A system comprising:a wall lining defining an opening; andthe recessed electrical junction box of claim 2 installed therein, wherein the lip projects through the opening of the wall lining and conceals interior edges of the opening.

18. The system of claim 17, wherein the flange lies against a rear surface of the wall lining and interfaces with a waterproofing membrane applied across the wall lining.

19. A method of installation comprising:forming an opening in a wall lining;inserting the recessed electrical junction box of claim 2 such that the flange is positioned against the wall lining;passing a lip of the junction box through the opening of the wall lining; andmounting electrical apparatus to the junction box so that a cover plate of the electrical apparatus is recessed within the lip and substantially flush with a front surface of the wall lining.

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