Quick Connect

Abstract

The present invention is entitled "Quick Connect". An electrical connection assembly is disclosed, which includes an electrical box, the electrical box including a shell having an inner surface defining an interior volume of the shell. An electrical connector is positioned outside the interior volume of the shell and is secured to the shell by a fastener. The shell includes a hole with an opening that defines an insertion path extending from a position outside the shell to a position within the interior volume of the shell. The assembly includes a plug having a flange portion and a plurality of resilient legs. A bracket for mounting the electrical box to a structure includes a corner connecting a first flange to a second flange. The present invention also provides an assembly including an electrical box and a bracket.

Description

Technical Field

[0001] The present disclosure relates to connectors and brackets. More particularly, the present disclosure relates to connectors and post mounting brackets for electrical boxes. Background Art

[0002] Power can be supplied from active devices (e.g., power sources) to passive devices (e.g., load sources). For example, power plants can generate electricity; power companies can supply electricity to consumers through circuits (e.g., power grids); and consumers can employ one or more devices to convert electricity into energy to achieve various goals. Electricity consumers include household and residential consumers as well as commercial and industrial consumers.

[0003] The electrical box houses various electrical components electrically connected to the current through the wires carrying the current. Various wires and various electrical components can be selected and electrically connected for various applications. Electrical connectors are connected to the electrical box to facilitate and support the various wiring and electrical components. Therefore, in order to distribute power safely and efficiently, a connector for the electrical box and an electrical box having the connector are required. Summary of the invention

[0004] In one embodiment, an electrical connection assembly includes an electrical box including a housing having an inner surface defining an interior volume of the housing. The electrical connection assembly also includes an electrical connector positioned outside the interior volume of the housing and secured to the housing by a fastener. The housing includes a side wall including a pair of holes having a pair of openings defining a corresponding insertion path extending along a frame of the electrical connector from a position outside the housing to a position within the interior volume of the housing. The electrical connection assembly also includes a plug having a flange portion and a plurality of resilient legs extending from the flange portion, the plug being positioned relative to the opening to block the insertion path.

[0005] In one embodiment, an electrical assembly includes an electrical box including a housing. The assembly includes a bracket having a first flange connected to a side of the housing. The bracket includes a corner connecting the first flange and the second flange. The second flange extends from the corner in a direction away from the side of the housing. The second flange includes a first edge, a second edge, and a third edge that form a continuous perimeter and define a central body portion defined by the corner. The first edge and the third edge intersect at a first intersection, and the second edge and the third edge intersect at a second intersection. The first intersection is spaced a first distance from the corner, and the second intersection is spaced a second distance from the corner. The first distance is greater than the second distance.

[0006] In another embodiment, a bracket for mounting an electrical box to a structure includes a corner connecting a first flange of the bracket to a second flange of the bracket. The first flange extends from the corner in a first direction, and the second flange extends from the corner in a second direction different from the first direction. The second flange includes a first edge, a second edge, and a third edge that form a continuous perimeter and define a central body portion bounded by the corner. The first edge and the third edge intersect at a first intersection, and the second edge and the third edge intersect at a second intersection. The first intersection is spaced a first distance from the corner, and the second intersection is spaced a second distance from the corner. The first distance is greater than the second distance. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] In the accompanying drawings, structures are shown which, together with the detailed description provided below, describe exemplary embodiments of the claimed invention. Identical elements are identified with the same reference numerals. It should be understood that elements shown as a single component may be replaced with multiple components, and elements shown as multiple components may be replaced with a single component. The drawings are not drawn to scale, and for illustrative purposes, the proportions of certain elements may be exaggerated.

[0008] Figure 1 is a schematic diagram of a perspective view of an electrical connection assembly including an electrical box and an electrical connector according to an embodiment of the present disclosure;

[0009] Figure 2 yes Figure 1 A plan view of an electrical box and an electrical connector of an electrical connection assembly;

[0010] Figure 3 is along Figure 2 A cross-sectional view of the electrical box and the electrical connector taken along line 3-3;

[0011] Figure 4 is a perspective view of an electrical connector according to an embodiment of the present disclosure;

[0012] Figure 5 yes Figure 4 An alternative perspective view of an electrical connector;

[0013] Figure 6 is with Figure 1 A perspective view of an electrical connection assembly similar to an electrical connection assembly, the electrical connection assembly including an electrical box and Figure 4 and Figure 5 Electrical connector;

[0014] Figure 7 is a perspective view of an electrical connection assembly including an electrical box and an electrical connector according to an embodiment of the present disclosure;

[0015] Figure 8 Includes electrical box and electrical connector Figure 7An alternative perspective view of an electrical connection assembly of

[0016] Fig. 9 Including knocking down the plate Figure 6 A partial perspective view of an electrical connection assembly including an electrical box and an electrical connector;

[0017] Fig.10 is an exploded perspective view of an embodiment of an electrical connector including an electrically insulating bushing according to an embodiment of the present disclosure;

[0018] Fig.11 is a perspective view of another embodiment of an electrical connector including an electrically insulating bushing having a diaphragm with some features removed for clarity;

[0019] Fig.12 yes Fig.11 an exploded perspective view of an electrical connector including an electrically insulating bushing having a diaphragm with some features removed for clarity;

[0020] Fig.13 is an exploded perspective view of an embodiment of an electrically insulating bushing having a reusable diaphragm with a tab;

[0021] Fig.14 is an exploded perspective view of another embodiment of an electrically insulating bushing having a reusable diaphragm with a tab;

[0022] Fig.15 is an exploded perspective view of yet another embodiment of an electrically insulating bushing having a reusable diaphragm with a tab;

[0023] Fig.16 is a perspective view of an embodiment of an electrically insulating bushing having a hinged reusable diaphragm;

[0024] Fig.17 yes Fig.16 An exploded perspective view of an electrically insulating bushing having a hinged reusable diaphragm;

[0025] Fig.18 is a perspective view of an electrical connection assembly including an electrical box, an electrical connector, and a support bracket according to an embodiment of the present disclosure;

[0026] Fig.19 is oriented to attach to Fig.18 A perspective view of a clamp for cable management at the end of a support bracket;

[0027] Fig. 20 yes Fig.18 A partial rear view of an electrical connection assembly including an electrical box, an electrical connector and a support bracket;

[0028] Fig.21is a plan view of a sheet of material including a pattern for providing an electrical attachment including an electrical connector according to an embodiment of the present disclosure;

[0029] Fig. 22 After performing a method of manufacturing a sheet according to a pattern to provide an electrical attachment including an electrical connector Fig.21 A plan view of a sheet of material;

[0030] Fig.23 is a perspective view of an electrical attachment including an electrical connector, the electrical attachment being connected according to Fig. 22 A method of manufacturing a sheet material to form a pattern;

[0031] Fig.24 yes Fig.23 an end view of an electrical attachment including an electrical connector;

[0032] Fig.25 yes Fig.23 a side view of an electrical attachment including an electrical connector;

[0033] Fig.26 is a schematic diagram of a perspective view of an alternative embodiment of an electrical box according to an embodiment of the present disclosure;

[0034] Fig. 27 An alternative embodiment of an electrical connector is included Fig.26 Alternative perspective view of an electrical box;

[0035] Fig.28 is along Fig. 27 a cross-sectional view of the electrical connection assembly taken along line 28-28 showing the cable connected to the electrical connector;

[0036] Fig.29 is an illustration of a perspective view of an embodiment of a stent according to the present disclosure;

[0037] Fig.30 is an illustration of a perspective view of another embodiment of a stent according to the present disclosure;

[0038] Fig.31 yes Figure 1 The electric box passes Fig.29 an illustration of a perspective view of the bracket mounted to the support column; and

[0039] Fig.32 Shows Fig.31 An enlarged partial view of the bracket. DETAILED DESCRIPTION

[0040] Figure 11 is a schematic diagram of a perspective view of an electrical connection assembly 100 including an electrical box 110 and an electrical connector 120. The electrical box 110 and the electrical connector 120 provide a structure having a connection point to mechanically and electrically connect one or more devices (not shown) to the electrical box 110 or the electrical current supplied to or from the electrical box (e.g., via wires, not shown). For example, the electrical box 110 and the electrical connector 120 can be combined with electronic devices (e.g., a panel with a device having decision-making capabilities that define a closed-loop system), electrical devices (e.g., a panel without decision-making capabilities), and electromechanical devices (e.g., a motor load) that supply current to or from the electrical box 110. The electrical box 110 and the electrical connector 120 can also be used as a junction box that combines one or more wires.

[0041] The electrical box 110 and the electrical connector 120 can be used in various locations where power distribution is desired, including factories, commercial buildings, and industrial facilities. Additionally, the electrical box 110 and the electrical connector 120 can be employed indoors or outdoors and can be configured for permanent installation (e.g., in a building) or for temporary installation (e.g., at a construction site). Unless otherwise specified, the electronic connection assembly 100 of the present disclosure including the electrical box 110 and the electrical connector 120 can be employed in various applications for power distribution and control, including residential and commercial applications with various electronic devices (e.g., panels with devices having decision-making capabilities that define a closed-loop system), electrical devices (e.g., panels without decision-making capabilities), and electromechanical devices (e.g., motor loads).

[0042] Throughout the present disclosure, an electrical box 110 and an electrical connector 120 are schematically illustrated, wherein it should be understood that, for example, various electrical components (e.g., wires, capacitors, inductors, transformers, reducers, amplifiers, fuses, switches, connectors, detectors, sensors, transducers, resonators, semiconductors, cables, timers, tubes, suppressors, terminals, etc.) oriented between one or more active devices and one or more passive devices to provide one or more operations or functions regarding distribution and control of electrical power to / from the electrical box 110 and the electrical connector 120 may be provided in additional embodiments without departing from the scope of the present disclosure.

[0043] The electrical box 110 includes a housing 111 having an outer surface 112 and an inner surface 113. The inner surface defines an interior volume 114 of the housing 111. In some embodiments, a cover (not shown) may be provided to isolate the interior volume 114 from the external environment in which the electrical box 110 may be employed. For example, in some embodiments, the housing 110 may define an enclosure including the interior volume 114, in which one or more electrical components (switches, dimmers, controllers, electrical connectors, not shown) may be contained. The housing 111 may be made of metal, plastic, polymer, or other suitable material oriented to protect the electrical components from various external forces, elements, and contacts. In addition, the electrical box 110 may be provided in a variety of shapes (e.g., rectangular, cubic, polyhedral, etc.) and sizes (e.g., small, medium, large) without departing from the scope of the present disclosure.

[0044] The electrical box 110 may include one or more apertures 116 oriented to provide access to the interior volume 114 of the housing 114. Figure 1 In the illustrated embodiment, three holes 116 are shown on each side of the housing 111, but in other embodiments, one hole or multiple holes may be provided. A disk 115 (e.g., a knockout) may be positioned to block the hole 116, thereby limiting or preventing access to the interior volume 114 of the housing 111. The disk 115 may be attached to the housing 111 by a fastening connection, a threaded connection, or other temporary or removable link that may hold the disk 115 in place relative to the housing 111, thereby blocking the hole 116, until the link is disconnected and access through the hole 116 is allowed. Typically, a technician (e.g., an electrician, a maintenance worker, an engineer) may remove (e.g., hit, pry, bend, knock, contact) the disk 115 by a tool (e.g., a screwdriver, a machine tool, a hand, a finger) to provide access to the interior volume 114 of the housing 111 through the hole 116. After removing the disk 115, the technician may discard the disk 115 because it may no longer provide utility relative to the electrical box 110.

[0045] In addition, after removing the tray 115, the technician can then connect a connector (not shown) to the housing 111 to facilitate placement of one or more wires or cables (not shown) into the holes 116. The connector (not shown) can support and hold the wires within the electrical box 110 and connect the wires to the electrical box while providing electrical current to one or more electrical components housed in the electrical box 110. The process of removing the tray 115, connecting the connector (not shown) to the electrical box 110, and then placing the wires can be time consuming and cumbersome when performed in various environments and when repeated multiple times. In addition, certain electrical codes may require that any holes 116 from which the tray 115 has been removed and through which wires have not subsequently been placed be blocked or plugged, thereby adding yet another step and additional inconvenience to the technician.

[0046] Optionally, when manufacturing the electrical box 110, the disc 115 can be removed from the hole 116 and a connector (not shown) can be fixed to the hole 116 (e.g., threaded engagement, snap fit). For example, a known connector (not shown) is connected to the electrical box by removing the disc 115 and mechanically connecting with the hole 116. In other words, in order to connect the known connector to the electrical box, the disc 115 must be removed to expose the hole 116. The electrical box 110 and the attached connector can then be supplied to the technician as an assembled unit. Although this method reduces the number of initial steps that the technician can take to place the wires, as described above, some electrical specifications may require that any hole 116 from which the disc 115 has been removed and through which the wire is not subsequently placed be blocked or plugged. Therefore, to the extent that one or more discs 115 are removed so that a known connector (not shown) can be attached to the electrical box 110, unless the wire is placed through the exposed hole 116, the technician is still required to block or plug the unused hole 116, thereby again adding another step and bringing additional inconvenience to the technician.

[0047] Additionally or alternatively, one or more connectors (not shown) may be disposed within housing 111 to retain cables or wires placed through aperture 116. While such connectors may adequately retain wires, such connectors occupy at least a portion of interior volume 114 of housing 111 and thus hinder placement of electronic devices within housing 111 and similarly reduce the space available within the housing for placement of multiple electronic devices or relatively large electronic devices.

[0048] Therefore, it can be understood that in order to safely and efficiently distribute and control power, a connector for an electrical box and an electrical box having a connector are needed to provide one or more advantages at least relative to the above-mentioned deficiencies of known electrical boxes and connectors. The present disclosure provides an assembly 100 for power distribution, which includes an electrical box 110 and an electrical connector 120, which have features that can be provided individually or in combination to facilitate safe and efficient electrical connection and power distribution, while achieving advantages that cannot be obtained by known electrical boxes or known electrical connectors.

[0049] Figure 2 yes Figure 1 1 is a plan view of an electrical box 110 and an electrical connector 120 of an electrical connection assembly 100, which shows the electrical connector 120 attached to the electrical box 110 by a fastener 125 (e.g., screws, bolts, rivets, nails, pins, adhesives, material bonding techniques, welding). The electrical connector 120 includes a frame 121, which includes a flange 126, and the housing 111 includes a recess 123 (e.g., a hole, a notch). The fastener 125 mechanically couples the flange 126 of the frame 121 of the electrical connector 120 to the recess 123 of the housing 111 of the electrical box 110.

[0050] As shown, the electrical connector 120 is fixed to the exterior of the housing 111 without displacing the disc 115 fixed in the hole 116. That is, the electrical connector 120 is mechanically attached to the electrical box 110 relative to the hole 116, wherein the disc 115 blocking the hole 116 remains intact and is not affected by the attachment of the electrical connector 120. Therefore, according to certain electrical specifications, because the electrical connector 120 is connected without displacing the disc 115 of the hole 116, the technician may have the following options: (a) remove the disc 115 and place the wire through the hole 116; or (b) leave the disc 115 in place to block the hole 116. When the connector 120 is connected to the electrical box 110 and remains connected, the option (a) or (b) can be performed.

[0051] Thus, the electrical connector 120 and electrical box 110 of the electrical connection assembly 100 eliminate the initial step of removing the disc 115 from the hole 116 and connecting a known connector (not shown) to the hole 116 (e.g., by threaded engagement or snap fit). In addition, the electrical connector 120 and electrical box 110 of the electrical connection assembly 100 also eliminate the additional step of blocking or plugging the hole 116 to which the known connector has been attached (requiring removal of the disc 115) but through which the wire has not been subsequently placed.

[0052] Furthermore, by fastening the electrical connector 120 to the exterior (e.g., the exterior surface 112 of the housing 111), the interior volume 114 of the housing 111 is not occupied by the electrical connector 120, and thus the interior volume 114 provides maximum space for placing various electrical components and wiring. Thus, the electrical connector 120 secured to the exterior of the electrical box 110 by the fasteners 125 provides an efficient and versatile electrical connection assembly 100. Furthermore, the electrical connection assembly 100 enables the technician to have increased flexibility and reliability with respect to the types of electrical components housed within the interior volume 114 of the housing 111 and the types and arrangements of wiring configurations employed by the electrical connector 120, thereby achieving desired power distribution and control for a variety of different applications.

[0053] In the illustrated embodiment, the electrical connector 120 includes one or more protruding tabs 122a, 122b extending from the frame 121 of the connector 120 and configured to mate with corresponding recesses on the wall of the housing 111 disposed relative to the aperture 116. The protruding tabs 122a, 122b serve as additional fasteners or hooks that further secure the electrical connector 120 to the electrical box 100 together with the fastener 125. For example, in some embodiments, the protruding tabs 122, 122b may be disposed in an "L" shape or a "T" shape.

[0054] To facilitate the fastening of the wires to the electrical connector 120, the electrical connector 120 may include a retainer 140. Figure 2 A cross-sectional view of the electrical box 110 and the electrical connector 120 taken along line 3-3 Figure 3 As shown, the retainer 140 can be assembled, inserted or formed in the frame 121. The retainer 140 can define an insertion path 165 extending from the front opening of the frame 121 to the rear opening of the adjacent housing 111 of the frame 121. The insertion path 165 can define a linear or non-linear path and corresponding opening along which one or more wires can pass. For example, wires and cables and tools can be inserted into the frame 121 and pass through the retainer 140 along the insertion path 165 into the interior volume 114 of the housing 111. The retainer 140 may include one or more teeth 145 extending radially inward from the frame 121 to clamp and grip the wire (e.g., the electrical insulation coating or protective sheath of the wire) inserted into the electrical connector 120. Although three teeth 145 are shown as being radially spaced around the inner boundary of the retainer 140, a single tooth or more than three teeth can be provided in other embodiments.

[0055] Additionally, the teeth 145 can be angled and can include various shapes and structures oriented to grip and clamp the wires, including mechanically flexible or depressible teeth 145 that, when pressed (e.g., by the wires), exert opposing resilient forces on the wires to retain the wires within the retainer 140 and frame 121 of the electrical connector 120. Without departing from the scope of the present disclosure, multiple retainers 140 can be coupled with corresponding multiple frames 121 to provide simplex, duplex, triplex, quadruplex, or other multi-type electrical connectors 120. The retainer 140 can be positioned to align with the aperture 116 to define the insertion path 165 as extending through the connector 120 and into the electrical box 110. For example, one retainer 140 can be used for a simplex connector associated with a single aperture 116, two retainers 140 can be used for a duplex connector 120 associated with two apertures 116, and so on.

[0056] Figure 4 1 is a perspective view of a duplex type electrical connector 120 with the electrical box 110 removed for clarity. As shown, the frame 121 includes two retainers 140, each retainer having corresponding teeth 145. The fastener 125 and the flange 126 and the protruding tab 122a are also shown. Similarly, Figure 5 yes Figure 4 1 is an alternative perspective view of the duplex type electrical connector 120 showing the protruding tab 122b.

[0057] Figure 6 yes Figure 11, which shows the disk 115 (e.g., a knockout) removed and without blocking the hole 116. Unless otherwise specified, it should be understood that such a disk 115 can be provided to block the hole 116 (e.g., Figure 1 The electrical connection assembly 100 includes an electrical box 110 and two electrical connections fastened to the exterior of a housing 111 of the electrical box 110 by fasteners 125. Figure 4 and Figure 5 A duplex electrical connector 120 is provided.

[0058] in addition, Figure 7 is a perspective view of an electrical connection assembly 100 including an electrical box 110 and a housing 111 fastened to the exterior of the electrical box by fasteners 125. Figure 4 and Figure 5 A duplex electrical connector 120 is provided. Figure 8 The device includes an electrical box 110 and an electrical connector 120. Figure 7 An alternative perspective view of an electrical connection assembly 100 is shown.

[0059] Fig. 9 Yes Figure 6 1 and 120, with a portion of the electrical box 110 removed for clarity. The protruding tabs 122a, 122b are inserted through the corresponding recesses 124a, 124b without interfering with the tray 115 and further securing the electrical connector 120 to the electrical box 100. In some embodiments, the protruding tabs 122a, 122b and the fasteners 125 can securely fasten the electrical connector 120 to the exterior of the electrical box 110 so that wires placed through the holes 116 (e.g., after the tray 115 is removed) will not be pulled out or disconnected from the electrical connector 120 or the electrical box 110.

[0060] The notches 124a, 124b may be provided as slots or openings in the housing 111 adjacent the aperture 116, or integrally formed as part of the perimeter (e.g., border) of the aperture 116. For example, the aperture 116 may define a keyhole or notched perimeter, and the disk 115 may define a circular perimeter that, when positioned within the aperture 116, substantially blocks the aperture 116 (e.g., to comply with certain electrical codes) while providing a keyhole or notched opening as the notches 124a, 124b. Although two protruding tabs 122a, 122b and two corresponding notches 124a, 124b are shown, in further embodiments, one protruding tab and one notch, or more than two protruding tabs and more than two corresponding notches, may be provided without departing from the scope of the present disclosure.

[0061] As shown, the disc 115 is attached to the housing 111 and blocks the hole 116, while the electrical connector 120 is also attached to the housing 110. Additionally, the protruding tabs 122a, 122b extending through the corresponding recesses 124a, 124b abut the inner surface 113 of the housing 111 to secure the frame 121 to the exterior of the housing 111 together with the fasteners 125. The electrical connector 120 and the electrical box 110 are supplied to the technician as a complete assembly 100, wherein the electrical connector 120 is secured to the electrical box 110 and wherein the disc 115 is in place to block the hole 116, such as according to certain electrical codes. When it is decided to insert the wire through a particular hole 116, the disc 115 can be removed from the housing 111 (e.g., at least partially disconnected therefrom) to provide an insertion path 165 for inserting the wiring through the connector 120, wherein the wire is retained by the retainer 140.

[0062] Fig.10 1 is an exploded perspective view of an embodiment of the electrical connector 120, showing the retainer 140 separated from the frame 121 for visual purposes. In some embodiments, the retainer 140 can include an electrically insulating bushing 150 surrounding the insertion path 165. For example, the electrically insulating bushing 150 can be attached, pressed, or formed to the retainer 140 of the frame 121. The electrically insulating bushing 150 is made of an electrically insulating material (e.g., plastic, rubber, polymer) and can be inserted into the retainer 140. In some embodiments, the bushing 150 is positioned within the retainer 140 near the front end of the frame 121. The bushing is then inserted along the insertion path 165 (see FIG. 1 ) within the retainer 140. Figure 3 ) until bushing 150 is securely seated within the rear portion of frame 121. For example, a technician inserts a wire from the front end of frame 121 of connector 120 to the rear end of frame 121 of connector 120, and the wire can contact bushing 150, thereby exerting a force on bushing 150, thereby causing bushing 150 to slide (e.g., translate) along insertion path 165 while the wire moves through connector 120 and is ultimately placed within interior volume 114 of electrical box 110.

[0063] The bushing may fit snugly within the rear portion of the retainer 140, may be snapped or pressed into place at the rear portion of the retainer 140, or otherwise positioned within the retainer 140 to electrically isolate (e.g., insulate) the current carried by the conductive wire from inadvertent electrical contact (e.g., arcing, sparking) with one or more conductive features of the electrical connection assembly 100. For example, back Figure 3In some embodiments, electrically insulating bushing 150 may extend around the inner periphery of aperture 116 to prevent the wire from breaking electrical contact or arcing or sparking with one or more of conductive frame 140, housing 111, or aperture 116. By extending around the inner periphery of aperture 116, electrically insulating bushing 150 may also cover and shield sharp protrusions that may be present around the inner periphery of aperture 116 that could otherwise snag, tear, cut, or penetrate an electrically insulating coating or protective sheath in which the wire may be encased.

[0064] Fig.11 1 is a perspective view of another embodiment of an electrical connector 120 including an electrically insulating bushing 150 having a diaphragm 155, with some features removed for clarity. For example, the frame 121 of the connector 120 and the electrical box 110 are removed for explanation purposes, wherein it should be understood that the electrically insulating bushing 150 having the diaphragm 155 can be employed alone or in conjunction with one or more features of the electrical connection assembly 100 without departing from the scope of the present disclosure. Fig.12 yes Fig.11 15 is an exploded perspective view of an electrical connector 120 including an electrically insulating bushing 150 having a diaphragm 155. When provided, the membrane 155 can function as a disc 115 (e.g., a knockout as described above) and can comply with certain electrical specifications that require unused holes 116 (e.g., holes 116 through which no wires are placed) to be blocked, plugged, or otherwise obstructed. Therefore, in some embodiments, an electrical connector 120 including an electrically insulating bushing 150 having a diaphragm 155 can be provided with or without a corresponding disc 115 to block the hole 116. Providing the diaphragm 155 allows a technician to have greater flexibility in wiring configurations and to comply with certain electrical specifications that cannot be obtained with conventional discs 115.

[0065] The diaphragm 155 can be a solid piece connected to the body 151 of the bushing 150 by a frangible attachment 157 that can be broken by a tool (e.g., screwdriver, wire). When the wire is inserted into the connector 120 along the insertion path 165, the frangible attachment 157 can be broken as a separate step or broken simultaneously in a single step, thereby reducing the number of steps a technician takes to connect the wire to the electrical box 110.

[0066] The diaphragm 155 may be formed as a portion of the insulating bushing 150 that defines a cover or closed end of the bushing 150. In some embodiments, the diaphragm 155 may be positioned at various locations within the retainer 140 relative to the body 151 of the bushing 150 to block the insertion path 165 to the hole 116. Similarly, the diaphragm 155 may be formed or positioned at various locations within the body 151 of the bushing 150 (e.g., between the first end and the second end of the bushing 150) to block the insertion path 165 to the hole 116. In some embodiments, the diaphragm 155 may block the entire opening 159 defined in the body 151 of the bushing 150 to completely cover or close the opening 159. Alternatively, the diaphragm 155 may at least partially block the opening 159 of the bushing 150 to at least partially cover or close the opening 159. The diaphragm 155 acts as a disc 115 until the frangible attachment 157 is broken and the membrane 155 is released. Once the frangible attachment 157 is broken, the opening 159 of the bushing 150 is unobstructed to allow insertion of the wire (e.g., Figure 3 ). The frangible attachment 157 may be made of the same or different material as either the diaphragm 155 and the body of the bushing 150, such that upon application of a force, the attachment 157 breaks, fails, separates, or otherwise disconnects the diaphragm 155 from the body of the bushing 150.

[0067] Additionally or alternatively, the diaphragm 155 itself can be formed in whole or in part of a frangible material such that a force (e.g., contact by a tool, contact with a wire) breaks, punctures, tears, or otherwise fails the diaphragm 155 to allow the wire to be inserted through the connector 120 and into the electrical box 110. The frangible material of the diaphragm 155 can be made of a variety of materials, such as plastic, a brittle material, an elastic or elastomeric material that fails at a predetermined stress, or a rubber or other puncturable (e.g., partially penetrable) material that fails when exposed to a predetermined force or stress. In some embodiments, the frangible material of the diaphragm 155 can be defined to fail when a predetermined stress is applied, where the predetermined stress is less than the stress at which the body of the bushing 150 fails when applied.

[0068] Figures 13 to 17 An alternative embodiment of an electrical bushing 150 with an optional reusable diaphragm is shown. For example, Fig.13A diaphragm 180 is shown having one or more tabs 181 extending from a rear side 183 of the diaphragm 180. The tabs 181 are configured to engage a channel 182 that extends circumferentially around the inner diameter of the opening 159 of the body 151 of the bushing 150. For example, the tabs 181 may include a flange, lip, protrusion, or other extended structure configured to contact the channel 182 to hold the diaphragm 180 in a position blocking the opening 159. The channel 182 is recessed relative to the inner surface of the opening 159 so that the tabs 181 are positioned and secured within the channel 182 to hold the diaphragm 180 in the bushing 150. Although in the illustrated embodiment, the channel 182 completely surrounds the opening 159, in alternative embodiments, the channel 182 may be formed as one or more segmented channels that at least partially surround the opening 159.

[0069] As with other examples discussed herein, a technician can remove the diaphragm 180 from the opening 159 by a tool or by manually applying force (e.g., with a finger or with a cable) to disengage one or more tabs 181 from the channel 182. The tabs 181 can be resilient and flexible to optionally allow the diaphragm 180 to be repositioned in the opening 159 after removal. Thus, the diaphragm 180 with tabs 181 can be optionally reused one or more times (e.g., removed and repositioned) within the bushing 150 to block the opening 159 of the bushing 150 or allow access through the opening 159 of the bushing 150. The reusable nature of the diaphragm 150 allows a technician to reconfigure the electrical box assembly 100 at any time (e.g., during installation or at a later time when the wiring destination changes). Additionally, in some embodiments, the diaphragm 180 with tabs 181 can be removed from the opening 159 by disengaging the tabs 181 from the channel 182, so that the force used is less than the force applied to remove the metal knockout. Thus, the diaphragm 180 with the tab 181 may provide faster installation and a better user experience for the technician.

[0070] Fig.14Another embodiment of a reusable septum 184 is provided that has one or more flanges 185 extending from a rear side 187 of the septum 184. The flanges 185 are configured to engage with a lip 186 on the inner diameter of the opening 159. The lip 186 is elevated relative to the inner surface of the opening 159 so that the flange 185 is positioned and secured against the lip 186 to retain the septum 184 in the bushing 150. For example, when the septum 184 is positioned in the opening 159, the flange 185 may flex inwardly (e.g., elastically deform) to clear the lip 186. Then, once the septum 184 is positioned in the opening 159, the flange 185 may rebound outwardly to contact the lip 186. The engagement between the flange 185 and the lip 186 secures the septum 184 in the bushing 150. The lip 186 may completely surround the opening 159 or may be formed as one or more segmented lips that at least partially surround the opening 159. Fig.13 The reusable bushing 180 is the same as Fig.14 The bushing 184 is optionally reusable and provides the same or similar advantages as discussed above.

[0071] Fig.15 Another embodiment of an optional reusable septum 188 having a tab 189 is provided. Fig.13 and Fig.14 Compared to the diaphragms 180, 184 of the embodiment of the present invention, the tab 189 of the diaphragm 188 is formed at the edge 191 of the diaphragm 188, rather than extending from the back side of the diaphragm. The inner surface of the opening 159 may include at least one of a channel and a lip 190 similar to the channel 182 and the lip 186 discussed above. The tab 189 is configured to engage the channel or the lip 190 to retain the diaphragm 188 within the bushing 150. Although shown as a plurality of tabs 189, in some embodiments, the diaphragm 188 may include a single tab formed along the entire edge 191 of the diaphragm 188.

[0072] Fig.16 and Fig.17 150 having a hinge 199 that connects the septum 195 to the body 151 of the liner 150. The septum 195 includes one or more tabs 196 that engage at least one of the channel and the lip 197 to allow the septum 195 to be removed and replaced in the opening 159. When the septum 195 blocks the opening 159 (e.g., Fig.16 ) and when the diaphragm 195 is removed to allow access through the opening 159 (as Fig.17150 ), hinge 199 connects diaphragm 195 to bushing 150. Hinge 199 can be formed as an integral component connecting diaphragm 195 and bushing 150, and can be configured to bend and flex without breaking. Hinge 199 can be a barrel hinge, a living hinge, or any other type of hinge. In addition to the advantages discussed above with respect to the reusable diaphragm, diaphragm 195 with hinge 199 is always attached to bushing 150 and reduces the possibility of diaphragm 195 being lost or misplaced, as well as ensuring that diaphragm 195 can be repositioned and reused by any technician servicing electrical assembly 100.

[0073] Fig.18 1 is a perspective view of an electrical connection assembly 100 including an electrical box 110, an electrical connector 120, and a support bracket 130. The support bracket 130 includes a first end 131 and a second end 132 (not visible in this view). The first end 131 may include one or more wiring accessories to facilitate positioning, placement, and support of wires or cables connected to the electrical box 110 via the electrical connector 120. For example, Fig.19 is oriented to attach to Fig.18 1 . A perspective view of a clamp 160 for cable management at a first end 131 of a support bracket. The clamp 160 includes fingers 161, 162 oriented to clasp and retain cables in a neat, controlled, and manageable manner. The clamp can be secured to the first end 131 of the support bracket by one or more fasteners (e.g., screws, bolts, rivets, nails, pins, adhesives, material bonding techniques, welding) and can be selected to include specific sizes, shapes, or features depending on, for example, the type, number, and size of wires connected to the electrical box 110.

[0074] As including Fig.18 A partial rear view of the electrical connection assembly 100 including the electrical box 110, the electrical connector 120 and the support bracket 130 Fig. 20 As shown, the second end 132 of the support bracket 130 is connected to the electrical connector 120 or the electrical box 110 by a fastener 135 (e.g., a screw, bolt, rivet, nail, pin, adhesive, material bonding technique, welding). The cable management clamp 160 is cantilevered from the electrical box 110 or the electrical connector 120 through the support bracket 130. The support bracket 130 alone or in combination with the clamp 160 supports the wires at a predetermined distance from the connector 120. Certain electrical codes may specify a specific predetermined distance measured from the electrical box 110 or the electrical connector 120 at which the wires are to be supported. Therefore, in some embodiments, the support bracket 130 and the clamp 160 may be selected to meet certain electrical codes while providing additional support for the wires connected to the electrical box 110 through the connector 120.

[0075] Fig.21is a plan view of a sheet of material 205 (e.g., metal, plastic, polymer) including a pattern 203 for providing an electrical attachment 200 for an electrical box 210 including an electrical connector 210 according to an embodiment of the present disclosure. The sheet 205 can be a single unitary piece of material on which the pattern 203 can be provided (e.g., stretched, stamped, etched, cut, punched, pressed, engraved) and from which the electrical attachment 200 is formed. In other embodiments, the sheet 205 can include multiple sheets that are mechanically attached (e.g., welded, bonded) together to provide a unitary sheet 205 on which the pattern 203 is provided and from which the electrical attachment 200 is formed.

[0076] Various features (e.g., protrusions, depressions, cuts, bends, folds, seams, holes, notches, flanges, tabs, and slots) may be formed (e.g., machined, fabricated, stretched, embossed, etched, cut, stamped, pressed, engraved) on, in, and through the sheet 205. For example, the holes 211, 212 of the electrical connector 210 may be formed with the fold line 214 and the tab 225. Additionally, the protrusion 215 and one or more holes 220 may be formed in the sheet 205.

[0077] Fig. 22 After performing the method of manufacturing the sheet 205 according to the pattern 203 to provide the electrical attachment 200 Fig.21 203. The electrical connector 210 is formed by folding or bending a section of the sheet 205 that is at least partially separated (e.g., severed, cut) from the sheet 205 according to the pattern 203. For example, folding or bending the patterned section along line 214 forms a frame of the electrical connector 210, which includes holes 211 and 212 through which wires (not shown) can be placed. Similarly, the tab 225 secures the electrical connector 210 to the sheet 205 (e.g., by mating engagement, mechanical fasteners, adhesives, material bonding techniques) to hold the folded or bent section defining the electrical connector 210 in place. The protrusion 215 can help position and mechanically secure a retainer (e.g., retainer 140) and an electrically insulating bushing (e.g., bushing 150, bushing 150 and diaphragm 155).

[0078] After forming the electrical connector 210, a portion of the sheet 205 extending between the first end 201 and the second end 202 provides a support bracket 206 (e.g., similar to the support bracket 160). The clamp 160 can be attached to the first end 201 of the attachment 200, and the hole 220 can be formed at the second end 202 of the attachment 200. In some embodiments, features can be provided at the first end 201 of the attachment 200 to retain the clamp 160. The attachment 200 can then be mechanically coupled to the electrical box (e.g., the electrical box 110) by fasteners (not shown) that interact with the holes 220 to secure the attachment 200 to the box 210 (e.g., the underside of the box).

[0079] Fig.23 After being formed by a method of manufacturing a sheet 205 according to a pattern 203 Fig.21 and Fig. 22 2 is a perspective view of an electrical attachment 200. The electrical attachment 200 is an integral attachment including an electrical connector 210 and a support bracket 206 that are integrally formed together. Fig.24 yes Fig.23 An end view of the electrical attachment 200, and Fig.25 yes Fig.23 2 is a side view of the electrical attachment 200 , which shows the overall structure of the attachment 200 including the electrical connector 210 and the support bracket 206 .

[0080] The present disclosure provides several embodiments and features of an electrical connector 120 secured to the exterior of an electrical box 110 that facilitates and supports a variety of wiring configurations and electrical components. The electrical connection assembly 100 enables safe and efficient power distribution through the electrical box 110 and electrical connector 120 of the present disclosure.

[0081] Figure 26 to Figure 28 An alternative embodiment of an electrical assembly 300 is shown, which includes a housing for receiving an alternative electrical connector 320 (in Fig. 27 and Fig.28 ) of the alternative features. Except for the differences discussed herein, assembly 300 is similar to the above Figures 1 to 12 The assembly 100 described is substantially the same. The same reference numerals are used for the same elements. Fig.26 As shown, electrical box 110 includes a pair of apertures 315 oriented to provide access to interior volume 114 of housing 111 .

[0082] like Fig. 27As shown, the holes 315 are spaced apart and configured to accommodate a larger electrical connector 320, which is configured to accommodate a larger cable 325. Although the term "larger" is a relative term, for exemplary purposes, the pair of holes 315 can be spaced apart from each other by a non-standard distance to accommodate a connector larger than a connector of holes spaced apart by a standard distance. Standard can refer to a common size manufactured in consideration of one or more of the safety specifications or manufacturing guidelines for specific parameters defining a feature. In addition, the pair of holes 315 are described to illustrate the versatility of the electrical connector 320 of the present disclosure for accommodating cables of various shapes, sizes and styles. In addition to the pair of holes 315, the electrical box 111 also includes an eccentric opening 318, which is positioned in a third hole 319 on the same side 312 of the electrical box 111 as the pair of holes 315. Providing an eccentric opening 318 on the same side 312 as the pair of holes 315 enables the electrical box 111 and the connector 320 to accommodate a variety of cables and electrical components.

[0083] Fig.28 Shown along Fig. 27 28-28 of the electrical connection assembly 300. The electrical connector 320 includes a frame 321 having a retainer 140 having one or more teeth 145 extending radially inward from the frame 121 to clamp and hold the cable 325. The electrically insulating bushing 150 is securely seated in the hole 315 and around the insertion path 165. As shown, the body 151 of the bushing 150 has a groove 152 and a flange 153 at the front end. The size of the groove 152 is designed to cooperate with the hole 315, wherein the flange is positioned in the interior volume 114 of the electrical box and the rear end of the body 151 of the bushing 150 is located in the retainer 140 or the frame 321. Once positioned, the flange 153 and the groove 152 secure the bushing 150 in the hole 315.

[0084] The plug 330 is positioned in the opening 154 of the electrical bushing 150 to block the insertion path 165. The size of the flange portion 331 of the plug 330 is larger than the size of the opening 154 of the bushing 150. The plug also includes a plurality of resilient legs 335 extending from the flange portion 331. The resilient legs 335 are oriented to flex in a radial direction relative to the insertion path 165. For example, the resilient legs 335 can be oriented to provide a structure that is larger than the opening 154, and when inserted into the opening 154, the structure flexes inwardly in a radial direction relative to the insertion path 165. The resilient legs 335 apply a radial force to frictionally fit the plug 330 within the opening 154 of the bushing 150. The plug 330 can be removed from the opening 154 using a tool. Alternatively, when the cable 325 is inserted along the insertion path 165, the front end 326 of the cable 325 can contact the plug 330 and exert a lateral force on the plug 330, which causes the resilient legs 335 to flex radially inward as the end 326 of the cable 325 pushes the plug 330 toward the opening until the plug 330 is displaced from the opening 154 and the insertion path 165 is unobstructed.

[0085] Figure 29 to Figure 32 An alternative embodiment of an electrical assembly 400 is shown that includes substantially the same features as the assemblies 100 and 300 described above, except for the differences discussed herein. Like reference numerals are used for like elements. When used in various applications, the electrical box 110 ( Figure 1 Such structures include, but are not limited to, pillars, frames, supports, columns, racks, hardware, cabinets, enclosures, walls, and other structural members found in various applications where electrical box 110 is employed. Electrical assembly 400 includes one or more brackets (such as brackets) that can be used to secure electrical box 110 to a structure. Fig.29 and Fig.30 shown).

[0086] Known electrical boxes and brackets may have limitations. For example, physical space may be limited, and the structure of the structural member to which the electrical box is secured may present physical limitations on how and where the electrical box may be mounted to the structure. Additionally, bracket geometry may limit the number of electrical boxes that may be mounted to the structure, as well as the manner and location in which the electrical boxes may be mounted. Furthermore, when mounting an electrical box to a structure, a user may encounter challenges with proper placement (e.g., height, alignment, orientation) of the electrical box relative to the structure, relative to other electrical boxes, and relative to other components that may be found within the predetermined physical space defined by the structure (such as ductwork, insulation, wiring, and additional structural support members).

[0087] Therefore, in order to safely and efficiently distribute electricity, there is a need for racks and electrical boxes that address the above limitations. The present disclosure provides an assembly for distributing electricity, which includes an electrical box and a rack having features that can be provided individually or in combination to facilitate safe and efficient power distribution while achieving advantages not available through known electrical boxes and racks.

[0088] Fig.29 is a perspective view of one example of a bracket 410 of an electrical assembly 400, and Fig.30 4 is a perspective view of another example of a bracket 510 of an electrical assembly 400. Identical or similar features between bracket 410 and bracket 510 are identified using the same reference numerals. For simplicity and not limitation, the features of bracket 410 will be described, wherein it should be understood that bracket 510 includes identical or similar features unless otherwise stated.

[0089] refer to Fig.29 The bracket 410 includes a first flange 411 and a second flange 412. The first flange 411 is configured to be connected to the electrical box 110 (at Figure 1 ), and the second flange 412 is configured to be connected to the structure (in Fig.31 ). The first flange 411 can be coupled to the electrical box using one or more fasteners (eg, screws, bolts, rivets, nails, pins, adhesives, material bonding techniques, welding).

[0090] Bracket 410 includes a corner 413 connecting a first flange 411 and a second flange 412. The first flange 411 extends from the corner 413 along a first direction 421 away from the corner 413, and the second flange 412 extends from the corner 413 along a second direction 422 away from the corner 413. The first direction 421 is different from the second direction 422. In the illustrated embodiment, the first direction 421 and the second direction 422 are oriented perpendicular to each other, and the corner 413 extends linearly along a third direction 423 along the joint between the first flange 411 and the second flange 412. The first direction 421, the second direction 422, and the third direction 423 define a three-dimensional Cartesian coordinate system.

[0091] Bracket 410 is shown having inverted corners 413 configured to receive a cover (not shown) and hold the cover flush with second flange 412 and the open face of electrical box 110. In other embodiments, corners 413 may be standard or non-inverted corners, inverted or non-inverted radiused corners, or corners having other linear, non-linear, or polygonal shapes, depending on the type of cover or the particular application in which assembly 400 is employed.

[0092] The second flange 412 includes a first edge 431, a second edge 432, and a third edge 433, which form a continuous perimeter of the second flange 412 and define a central body portion 435 of the second flange 412 located within the continuous perimeter and bounded by the corner 413. The central body portion 435 is shown as a flat surface, but in other embodiments, the central body portion 435 may include a non-planar surface. The first edge 431 and the third edge 433 intersect at a first intersection 441, and the second edge 432 and the third edge 433 intersect at a second intersection 442.

[0093] The first intersection 441 is spaced a first distance "d1" from the corner 413, and the second intersection 442 is spaced a second distance "d2" from the corner 413. The first distance "d1" is not equal to the second distance "d2". In the illustrated embodiment, the first distance "d1" is greater than the second distance "d2", but in other embodiments the second distance "d2" may be greater than the first distance "d1".

[0094] The center body portion 435 includes a first hole 451 positioned between the first edge 431 and the third edge 433 and a second hole 452 positioned between the second edge 432 and the third edge 433. The first hole 451 is spaced apart from the corner 413 by a distance greater than the distance the second hole 452 is spaced apart from the corner 413 relative to the corner 413. In other embodiments, where "d2" is greater than "d1", the second hole 452 is spaced apart from the corner 413 by a distance greater than the distance the first hole 451 is spaced apart from the corner 413. Spacing the holes 451, 452 at offset locations within the center body 435 relative to the corner 413 can better stabilize and prevent rotation of the electrical assembly 400 than two equally spaced holes.

[0095] like Fig.29 As further shown in FIG. 4 , the third edge 433 includes an inflection point 460 at which the third edge 433 changes from a convex profile 461 to a concave profile 462. The convex profile 461 extends from the first intersection 441 to the inflection point 460, and the concave profile 462 extends from the second intersection 442 to the inflection point 460. The third edge 433 defines a continuous profile extending between the first intersection 441 and the second intersection 442. The inflection point 460 is located at an intermediate position between the first intersection 441 and the second intersection 442, but in other embodiments, the inflection point 460 can be located anywhere along the third edge 433 without departing from the scope of the present disclosure.

[0096] Additionally, in the case where "d2" is greater than "d1", the concave profile may extend from the first intersection 441 to the inflection point 460, and the convex profile may extend from the second intersection 442 to the inflection point 460. Fig.30As shown, the third edge 433 can extend linearly from the first intersection 441 to the second intersection 442, thereby defining a linear profile 465 oriented at a non-parallel angle relative to the corner 413. In other embodiments (not shown), the third edge 433 can include one or more features, including planar and non-planar profiles and one or more inflection points.

[0097] Fig.31 Shown includes attachment to Figure 1 Electric box 110 Fig.29 400 of the electrical assembly 400 of the bracket 410. Although not shown, it should be understood that Fig.30 The bracket 510 can be similarly attached to Figure 1 The assembly 400 is mounted to the structure 610, wherein one or more fasteners 615 (e.g., screws, bolts, rivets, nails, pins, adhesives, material bonding techniques, welding) are fixed in the first hole 451 and the second hole 452 (e.g., Fig.29 The structure 610 is shown as a pillar 610, wherein it should be understood that the structure 610 may include one or more pillars, frames, supports, columns, racks, hardware, cabinets, enclosures, walls, or other structural members in other embodiments.

[0098] The bracket 410 and the electrical box 110 are supplied to the technician as a complete assembly 400 in which the bracket 410 is secured to the electrical box 110. Alternatively, the bracket 410 is provided alone or in combination with the electrical box 110 as a separate component for the technician to fasten to the electrical box 110 to provide the complete assembly 400. The assembly 400 is mounted to the structure 610. In some embodiments, multiple assemblies 400 can be mounted to the structure 610. For example, in the embodiment shown, two assemblies 400 are mounted to the structure 610. The bracket 410 includes a marking 415 that indicates one or more of the positioning or location of the bracket 410 relative to another object (e.g., another bracket, structure 610). The marking 415 can be a visual marking (e.g., a color, paint, a sticker) or a physical marking (e.g., a notch, a score, a ridge).

[0099] When fastened to the electrical box 110, the first flange 411 is attached to one side of the outer surface 112 of the housing 111 of the electrical box 110, and the second flange 412 extends away from the side at a non-parallel angle relative to the first flange 411. The first flange 411 and the second flange 412 are perpendicular to enable the assembly 400 to be mounted on a structure 610 having a flat or planar surface parallel to the open face of the box 110. The second flange 412 is mounted to the structure 610, wherein the open face of the box 110 is parallel to the second flange 412. In other embodiments, the structure 610 may include a non-planar surface, or the assembly 400 may be mounted on a structure wherein the open face of the box 110 is not parallel to the second flange 412.

[0100] Fig.32 For greater clarity, the Fig.31 400 . Two brackets 410a, 410b are shown. For the purpose of explanation, features corresponding to bracket 410a are identified as "Xa", and features corresponding to bracket 410b are identified as "Xb", where X corresponds to the figure number of the feature described herein. As shown, when mounted side by side at the same height, brackets 410a, 410b are configured to be positioned in a mating relationship relative to each other. For example, bracket 410b is identical to bracket 410a and is oriented or rotated 180 degrees about inflection point 460b so that the third edge 433b of bracket 410b corresponds in profile to the third edge 433a of bracket 410a to provide a complementary mating engagement between brackets 410a, 410b.

[0101] The third edge 433a of bracket 410a is a mirror image of the third edge 433b of bracket 410b. The inflection point 460a of bracket 410a is aligned with the inflection point 460b of bracket 410b, so that the convex profile 461a of bracket 410a mates with the concave profile 462b of bracket 410b, and the concave profile 462a of bracket 410a mates with the convex profile 461b of bracket 410b. This mating relationship between the third edge 433a of bracket 410a and the third edge 433b of bracket 410b provides a structural and visual guide to a technician installing assembly 400 on structure 610.

[0102] For example, in some applications, as shown, it may be desirable to install at least two electrical boxes side by side at the same height. In addition, the marking 415a of the bracket 410a is aligned with the marking 415b of the mating bracket 410b to provide the brackets 410a, 410b at the same height on the 610 structure. The markings 415a, 415b are shown as dashed lines and may include other shapes, such as arrows, dots, text, and detents. Compared to known methods using known brackets, the brackets 410a, 410b of the present disclosure enable technicians to achieve this goal in a shorter time and with greater accuracy and reliability.

[0103] The size and shape of the brackets 410a, 410b are configured to enable two brackets 410a, 410b to be placed side by side at the same height on the same structure 610. The size and shape of the brackets 410a, 410b can be predetermined and selected based on the predetermined size of the structure 610. For example, the size and shape of the brackets 410a, 410b can be predetermined and selected based on the size of the pillar. The brackets 410a, 410b can be made of various materials (e.g., metal, plastic, polymer) and can be a single single piece of material on which a pattern can be provided (e.g., stretched, stamped, etched, cut, stamped, pressed, engraved) and the brackets 410a, 410b can be formed (e.g., machined, manufactured, stretched, stamped, etched, cut, stamped, pressed, engraved) therefrom. In other embodiments, the brackets 410a, 410b can include a plurality of sheets mechanically attached (e.g., welded, bonded) together to provide a monolithic piece on which a pattern is provided and from which the brackets 410a, 410b are formed. Various features (e.g., protrusions, recesses, cuts, bends, folds, seams, holes, notches, flanges, tabs, and slots) may be formed (e.g., machined, manufactured, stretched, embossed, etched, cut, stamped, pressed, engraved) on the brackets 410a, 410b without departing from the scope of the present disclosure.

[0104] The present disclosure provides several embodiments and features of brackets 410, 510 secured to electrical box 110 that facilitate and support various wiring configurations and electrical components. Electrical assembly 400 achieves safe and efficient power distribution by mounting electrical box 110 and brackets 410, 510 of the present disclosure to structure 610.

[0105] In one embodiment, an electrical connection assembly includes an electrical box including a housing having an inner surface defining an interior volume of the housing. An electrical connector is positioned outside the interior volume of the housing and is secured to the housing by a fastener. The housing includes a hole having an opening defining an insertion path extending along a frame of the electrical connector from a position outside the housing to a position within the interior volume of the housing. The assembly includes a disk mechanically secured to the housing relative to the opening to block the insertion path.

[0106] In another embodiment, a bushing for surrounding an insertion path of an electrical connector includes a body having an opening, the body defining a passage along which the insertion path is configured to extend, and a diaphragm mechanically coupled relative to the body to at least partially block the opening.

[0107] In yet another embodiment, a method of manufacturing an electrical connector from a sheet of material includes cutting the sheet according to a predetermined pattern. The method includes forming the cut section of the sheet to provide a shaped section having a first opening and a second opening, which defines an insertion path extending from the first opening to the second opening, and the wire is configured to extend along the insertion path. The method includes inserting a retainer into the shaped section, the retainer at least partially surrounding the insertion path.

[0108] A. An electrical connection assembly includes an electrical box including a housing having an inner surface defining an interior volume of the housing. An electrical connector is positioned outside the interior volume of the housing and secured to the housing by a fastener. The housing includes a hole having an opening defining an insertion path extending along a frame of the electrical connector from a location outside the housing to a location within the interior volume of the housing. The assembly includes a disk mechanically secured to the housing relative to the opening to block the insertion path. The present invention also provides a retainer and a bushing including a diaphragm for the electrical connector, and a method of manufacturing the electrical connector.

[0109] C1. An electrical connection assembly, the electrical connection assembly comprising: an electrical box including a housing having an inner surface defining an interior volume of the housing; an electrical connector positioned outside the interior volume of the housing and secured to the housing by a fastener; the housing including a hole having an opening defining an insertion path extending along a frame of the electrical connector from a position outside the housing to a position within the interior volume of the housing; and a disk mechanically secured to the housing relative to the opening to block the insertion path.

[0110] C2. The electrical connection assembly of C1, comprising a retainer coupled to a frame of the electrical connector, the retainer at least partially surrounding the insertion path.

[0111] C3. The electrical connection assembly according to C2, comprising a bushing at least partially positioned within the holder and surrounding the insertion path, the bushing being made of an electrically insulating material.

[0112] C4. The electrical connector assembly of C3, wherein the bushing is slidable along the insertion path from the first end of the retainer to the second end of the retainer.

[0113] C5. The electrical connection assembly according to C1, comprising a support bracket having a first end and a second end, wherein the second end is fixed to at least one of the electrical connector and the electrical box, and wherein the first end cantilevers from the electrical connector in a direction away from the electrical box.

[0114] C6. The electrical connection assembly of C5, comprising a clamp mechanically coupled to the first end of the support bracket.

[0115] C7. The electrical connection assembly of C1, wherein the electrical connector is formed from a sheet of material.

[0116] C8. A bushing for surrounding an insertion path of an electrical connector, comprising: a body having an opening, the body defining a passage along which the insertion path is configured to extend; and a diaphragm mechanically coupled relative to the body to at least partially block the opening.

[0117] C9. The bushing according to C8, wherein the bushing is made of an electrically insulating material.

[0118] C10. A bushing according to C8, wherein the diaphragm is mechanically coupled to the body of the bushing by a frangible attachment.

[0119] C11. The bushing of C8, wherein the diaphragm is made of a brittle material configured to fail upon application of a predetermined stress that is less than a stress at which the body of the bushing fails.

[0120] C12. A method of manufacturing an electrical connector from a sheet of material, comprising: cutting the sheet according to a predetermined pattern; forming a cut section of the sheet to provide a shaped section having a first opening and a second opening, which defines an insertion path extending from the first opening to the second opening, and the wire is configured to extend along the insertion path; and inserting a retainer into the shaped section, the retainer at least partially surrounding the insertion path.

[0121] C13. The method of C12, comprising mechanically connecting the clamp to the first end of the sheet after cutting the sheet according to the predetermined pattern.

[0122] C14. The method of C12, comprising inserting a bushing into a retainer, the bushing having a body including an opening defining a passageway along which the insertion path is configured to extend, the opening surrounding the insertion path.

[0123] C15. The method according to C14, wherein the bushing is made of an electrically insulating material.

[0124] C16. The method of C14, wherein the bushing includes a diaphragm that at least partially blocks the opening.

[0125] C17. The method of C16, wherein the diaphragm is attached to the body of the bushing by a frangible attachment.

[0126] C18. The method according to C12, wherein the shaped section is formed at a position of the sheet defined between a first end of the sheet and a second end of the sheet.

[0127] C19. The method of C18, wherein the sheet includes a support bracket extending from the forming section to a first end of the sheet.

[0128] C20. The method according to C18, wherein the sheet includes a hole at a location between the forming section and the second end of the sheet.

[0129] To the extent the term "includes" or "including" is used in the specification or claims, it is intended to be inclusive in a manner similar to the term "comprising," as interpreted when that term is used as a transitional word in a claim. Furthermore, to the extent the term "or" (e.g., A or B) is used, it is intended to mean "A or B or both." When applicants intend to indicate "only A or B but not both," the term "only A or B but not both" will be employed. Thus, the use of the term "or" herein is inclusive, not exclusive. See Bryan A. Garner, A Dictionary of Modern Legal Usage 624 (2d. Ed. 1995). Furthermore, to the extent the term "in" or "into" is used in the specification or claims, it is intended to additionally mean "on" or "onto." Furthermore, to the extent the term "connected" is used in the specification or claims, it is intended to mean not only "directly connected to" but also "indirectly connected to," such as connected through another component or components.

[0130] Although the present disclosure has been illustrated by the description of the embodiments of the present disclosure, and although the embodiments have been described in considerable detail, it is not the intention of the applicant to restrict or in any way limit the scope of the appended claims to such details. Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the present disclosure in its broader aspects is not limited to the specific details, representative systems and methods, and illustrative examples shown and described. Therefore, such details may be deviated from without departing from the spirit or scope of the applicant's general inventive concept.

Claims

1. An electrical connection assembly, comprising: an electrical box comprising a housing having an inner surface defining an interior volume of the housing; an electrical connector positioned outside of the interior volume of the housing and secured to the housing by a fastener; the housing including a sidewall including a pair of apertures having a pair of openings defining respective insertion paths extending along a frame of the electrical connector from a location exterior to the housing to a location within the interior volume of the housing; and a plug having a flange portion and a plurality of resilient legs extending from the flange portion, the plug being positioned relative to the opening to block the insertion path; The plurality of resilient legs are oriented to flex in a radial direction relative to the insertion path, and when a cable is inserted along the insertion path, a front end of the cable is able to contact the plug and exert a lateral force on the plug, causing the plurality of resilient legs to flex radially inward as the end of the cable pushes the plug toward the opening until the plug is displaced from the opening and the insertion path is unobstructed. 2 . The electrical connection assembly of claim 1 , wherein the side wall includes a third hole having an off-center opening. 3 . The electrical connection assembly of claim 1 , comprising a retainer coupled to the frame of the electrical connector, the retainer at least partially surrounding the insertion path.

4. The electrical connection assembly of claim 3, comprising a bushing at least partially positioned within the retainer and surrounding the insertion path, the bushing being made of an electrically insulating material.

5. The electrical connection assembly of claim 4, wherein the plug is positioned in the opening of the bushing, wherein the flange portion is disposed in the interior volume and the plurality of resilient legs extend away from the flange toward the electrical connector.

6. An electrical component comprising: The electrical connection assembly according to any one of claims 1 to 5; a bracket having a first flange connected to a side surface of the housing, the bracket including a corner connecting the first flange and a second flange, the second flange extending from the corner in a direction away from the side surface of the housing; in The second flange includes a first edge, a second edge, and a third edge forming a continuous perimeter and defining a central body portion defined by the corner, wherein the first edge and the third edge intersect at a first intersection point, and the second edge and the third edge intersect at a second intersection point, wherein the first intersection point is spaced a first distance from the corner, and the second intersection point is spaced a second distance from the corner, and wherein the first distance is greater than the second distance. 7 . The electrical assembly of claim 6 , wherein the third edge defines a continuous profile extending between the first intersection point and the second intersection point. The electrical assembly of claim 6 , wherein the third edge is linear.

9. The electrical assembly of claim 6, wherein the third edge comprises an inflection point.

10. The electrical component of claim 9, wherein the inflection point is located midway between the first intersection point and the second intersection point along the third edge.

11. The electrical assembly of claim 9, wherein the third edge changes from a convex profile to a concave profile at the inflection point.

12. The electrical assembly of claim 11, wherein the convex profile extends from the first intersection to the inflection point, and the concave profile extends from the second intersection to the inflection point.

13. The electrical assembly of claim 6, wherein the central body portion includes a first hole positioned between the first edge and the third edge and a second hole positioned between the second edge and the third edge, and wherein the first hole is offset from the second hole relative to the corner.

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