Systems and methods for rearranging branch circuit cables from existing electrical enclosures

Abstract

A system and method for rearranging a branch circuit cable that enters an existing electrical enclosure and cannot achieve an additional cable length to a novel enclosure having a cable entry point advantageously arranged to receive an existing branch circuit cable without requiring an additional length, and the system and method are in a safe and repeatable manner for a plurality of branch circuit cables to be rearranged currently or in the future.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. Provisional Application No. 63 / 333,333, filed on April 21, 2022, the entire contents of which are incorporated herein by reference. Technical Field

[0003] The present invention relates to cabling, wiring and electrical enclosures and more particularly to the rerouting of existing branch circuit cables from within an electrical enclosure. Background Art

[0004] Electric load centers are usually deployed to distribute electricity and are located in a central location that distributes electricity to power branch circuits. Load centers exist within electrical enclosures. Branch circuits are circuits that distribute electricity to end uses and require overcurrent protection. Load centers receive electricity from sources inside or outside the building. For example, a typical single-family home will have a single load center that receives external power from a public power utility. This electricity is usually delivered as single-phase alternating current (AC) electricity, most often delivered through two "live" wires, each of which carries 120 volts AC (VAC), and it can be combined to deliver 240VAC. In addition to the two live wires, there is also a neutral wire. The utility power supply usually passes through an electric meter before any use. The output of the electric meter then typically enters the load center through its enclosure, which usually passes through a main circuit breaker inside the enclosure, which provides overcurrent protection for all of the utility power supply.

[0005] A typical residential load center will contain two hot busbars that provide connection points for multiple branch circuit breakers, each of which provides overcurrent protection at the maximum current that the branch circuit is designed to safely carry. In this example, each hot busbar provides 120VAC to each hot line from the power company. A single-pole branch circuit breaker will be connected to either of the hot busbars, delivering 120VAC to that branch circuit at the desired maximum current. A double-pole branch circuit breaker will be connected to both hot busbars, delivering 240VAC to that branch circuit at the desired maximum current. By combining single-pole and double-pole circuit breakers at various maximum currents, a typical residential electrical system can deliver different electrical power levels to different branch circuits as needed.

[0006] In a typical residential electrical system as described above, all branch circuits are served by AC power of 120VAC or 240VAC. The power limit of the branch circuit is determined by the current delivered and the choice of single-pole (120VAC) or double-pole (240VAC) circuit breakers. Because the available voltage is fixed at 120VAC or 240VAC, the branch power capacity is determined by the current capacity of the connected circuit breaker. Common branch circuit breakers exist at rated currents of 15 amperes (A), 20A, 30A, 40A, and 50A, and some residential electric vehicle (EV) chargers require double-pole circuit breakers rated at 80A.

[0007] Branch circuit cables must be sized based on the maximum current of their branch circuit breakers, as defined in the National Electrical Code (NEC), and any other requirements of the Local Authority Having Jurisdiction (AHJ) having jurisdiction over electrical system requirements. Current limitations on branch circuit cables exist due to the heat generated by the electrical resistance of the electrical conductors within the cable itself. According to the basic laws of electricity, electrical power lost due to the electrical resistance of the conductor itself is lost as heat generated within the conductor. It is this heat that must be limited to safe levels as determined by the NEC to ensure the integrity of the insulation of wires and cables, as well as to limit the ability of conductor generated heat to directly cause fires in other building components, appliances and materials. The heat losses from conductor resistance are a function of the conductor resistance and the current passing through the conductor, and are independent of the electrical voltage. The general formula for conductor heat generated is PCH = IC 2 *RC, where IC is the current carried by the conductor, RC is the resistance within the conductor, and PCH is the power lost as conductor heat. There are other factors that must be considered that are described in detail in various electrical codes, but the general formula is sufficient to illustrate the importance of the current carried to the branch capacity, especially since the square of the current determines the heat generated. The general formula also shows that the conductor heat generated is independent of the branch voltage, so that a single-pole branch circuit at 120VAC and limited to 20A capacity will generate the same amount of heat in its conductors as a double-pole branch circuit at 240VAC and also limited to 20A. This is true even though the 240VAC circuit is delivering twice as much electrical power as the 120VAC circuit. The power delivered by the branch circuit (ignoring resistive losses in the conductors and other minor factors) is determined by the general formula PBC=VBC*IBC, where VBC is the voltage of the branch circuit, IBC is the current carried by the branch circuit, and PBC is the electrical power delivered by the branch circuit. Applying the power formula above, an exemplary single pole 120VAC circuit at 20 amps will deliver approximately 2400 Watts (W) or 2.4 kilowatts (kW). An exemplary 240VAC double pole circuit at 20 amps will deliver approximately 4.8 kW.

[0008] It is clearly stated above that the electrical power delivered to the electrical load by the branch circuit cable is determined by the voltage and is limited only by the current. In theory, an example bipolar branch circuit limited to 20A can deliver 20kW at 1000 volts, or even 1000kW at 50,000 volts. In practice, modern branch circuit cables are limited by rated voltage capacity in addition to their maximum rated current capacity. Modern branch circuit cables in the United States are generally rated to carry 600 volts, and therefore their power capacity is limited. However, the rated voltage of 600V is substantially higher than the existing highest voltage (240VAC) available in the above-mentioned typical residential electrical system. Therefore, when delivering power at a voltage higher than the voltage available in the typical residential electrical system, there is an opportunity to increase the power delivered by the existing branch circuit cables.

[0009] An additional factor related to the electrical service provided by a residential utility is the rated capacity of the service provided. The most common levels of residential service provided by a utility are 100 amp service and 200 amp service. Although there are other service levels, 100 amp and 200 amp are discussed here. The electrical service provided by a residential utility most often provides split-phase 240VAC, delivered as two "hot branches" of 120VAC that can be combined to deliver 240VAC. When the power required for the operation of a residence increases, it may be necessary to increase the electrical service provided by the utility. Many old-fashioned homes use 100 amp 240VAC service wiring, which may need to be increased to 200 amp 240VAC electrical service. Upgrading the electrical service provided by a residential utility usually requires an upgraded load center with a main circuit breaker upgraded to 200 amps, and a higher-gauge transmission cable rated for carrying the upgraded electrical service. The power company also needs to upgrade some of its equipment that delivers power to the meter. If the local utility circuit and the local utility transformer have available unused capacity, utility-side upgrades can be as simple as upgrading to a higher gauge cable to carry the increased current to the meter. However, if the local utility circuit and utility transformer do not have available capacity, the utility will have to upgrade the local circuit and / or transformer. These costs are typically passed on to the upgrade customer and can be substantial.

[0010] As concerns about climate change increase, methods to reduce carbon dioxide (CO2) releases have become more prevalent. One of the methods to reduce CO2 is building electrification, including residential building electrification. Broadly speaking, electrification refers to replacing existing fossil fuel residential end uses with electric end uses. The most important building fossil fuel uses that are converted to electricity include building space heating, water heating, cooking, and clothes drying. If the existing home uses natural gas for space heating, water heating, cooking, and clothes drying, all of these uses will need to replace the energy delivered by natural gas with energy delivered as electricity. This will greatly increase the electricity required for each of these end uses. The sum of the existing electricity required for the building and the additional electricity required for each of these electrified end uses typically significantly increases the total electricity required for the building. Individually, one of the most expensive parts of residential electrification is to increase the capacitance of the branch circuit cables used to deliver electricity to these electrified terminals.

[0011] Residential building electrification also typically includes the incorporation of solar photovoltaic (PV) generation and battery power storage systems. While solar PV is a generator rather than an electrical load, wiring solar PV into an existing load center can itself trigger the need for electrical service upgrades and / or electrical load center upgrades.

[0012] The electrification of passenger vehicle transportation is also expected to increase residential electricity demand, and therefore may require an increase in utility-provided electrical service. Although EVs can be charged using standard 120VAC 15 amp outlets (Level 1 EV charging), the charging is very slow, in some cases taking 24 hours or more to deliver a full charge. Most EV owners will prefer to have Level 2 charging, which uses 240VAC and anywhere from 20 amps to 80 amps for most residential Level 2 chargers. Because EV charging is almost always a completely new electrical load, adding the required two-pole 20-80 amp circuit breakers to an existing residential load center can often trigger a distribution board upgrade and / or require an electrical service upgrade.

[0013] Unlike the additional electrical requirements for residential building electrification, many components of building electrification naturally use DC power. Solar photovoltaic panels generate DC power, and all electrochemical batteries store DC power. Variable-speed-drive (VSD) motor appliances must also first convert the building AC power to DC power before powering their motors. The most notable VSD residential loads are advanced high-efficiency heat pumps. These heat pumps are used for space heating and cooling, water heating, and clothes drying. VSD motors are also commonly found in washing machines and refrigerators.

[0014] There are particular challenges in converting gas powered home appliances to electric home appliances. For example, a gas range is often connected to a 120VAC 20 amp branch circuit. The primary source of heat energy for cooking is natural gas, and electricity only provides supplemental services, such as gas ignition and some electronic equipment. When a gas range is converted to an electric range, the electric range will require more electricity to replace the heat energy previously delivered by the natural gas. Most electric ranges require a 240VAC circuit at 40 or 50 amps. As mentioned above, this installation may trigger the need for a distribution board upgrade or an electrical service upgrade. In addition, the existing cabling, which carries 120VAC at 20 amps, cannot safely carry the additional power required, and larger capacity cabling must be installed.

[0015] One solution to the electrification challenge is to install a second branch circuit load center slightly closer to the original residential load center. The separate load center can distribute the DC power into two "hot branches" of DC power, one branch at 285VDC and the second branch at -285VDC, each of which feeds the hot bus within the DC load center. Since DC power is incompatible with the AC power of the original load center, the two electrical systems remain separate, with any link requiring electrical isolation. For example, a rectifier can rectify the AC power from the existing load center as long as the rectifier is also isolated. Because of this isolation of the DC electrical system, the capacitance of the DC system does not affect the capacity of the AC system. The capacitance of the additional, separate DC load center is in addition to the existing capacitance of the existing AC load center and the electrical service provided by the existing utility. Thus, the capacitance of the entire building is increased (within the separate DC load center) without the need to increase the capacity of the AC load center. If sufficient power can be generated, stored, and released via a DC-coupled solar PV array and battery storage system coupled to a separate DC load center, and / or the AC power drawn from the utility-provided electric service can be managed to avoid exceeding peak capacity, then the building can serve the increased power required by electrified homes without increasing the utility-provided electric service.

[0016] An additional benefit of a separate DC branch circuit electrical system is that the increased voltage can be used to transmit increased electrical power over the existing branch circuit cables. In the above example, the existing gas range (electrical) is connected to a 120VAC 20 amp circuit. This circuit delivers a maximum of 2400 watts. As mentioned above, a typical electric range requires (at least) a 240VAC 40 amp circuit, which delivers a maximum of 9600 watts. However, a double-pole DC rated circuit breaker installed in a separate DC load center as described above can safely deliver 570VDC at the same 20 amps, with a maximum power of 11400 watts.

[0017] Certain existing requirements of the electrical code and standard practices for routing branch circuit cables within buildings present challenges to the above-described solution of connecting an existing branch circuit to a separate and distinct electrically incompatible DC load center, where the DC load center is within a separate and distinct electrical enclosure. The first challenge arises from the requirement that all branch circuit cable jackets, whether non-metallic or metallic, be removed within approximately one inch of the cable entering an electrical enclosure (e.g., an enclosure containing a load center). This exposes the component conductors that would otherwise be within the sheathed cable, whether or not those conductors are insulated, so that they may be routed within the enclosure as desired. Note that this requirement also applies to branch circuit cables when they enter other types of electrical enclosures, whether or not they surround a load center.

[0018] A second challenge is that standard cabling practices make excess connected branch circuit cable unwound or otherwise stored and readily available outside of a load center or other electrical enclosure. If the additional connected branch circuit cable for a particular branch circuit is coiled and stored outside of the enclosure and near where the branch circuit enters the load center enclosure, the branch circuit cable can be extracted from the load center enclosure, along with the exposed component conductors previously routed within the load center or other electrical enclosure, and the coiled or otherwise stored and connected length of covered branch circuit cable can be used to safely relocate the branch circuit and its component conductors to a separate electrical enclosure mounted some distance away, provided that the coiled and stored length of additional connected branch circuit cable is sufficient to reach the separate enclosure while maintaining complete covering. In the event that the existing covered branch circuit cable is able to reach the separate enclosure, the component conductors can then be routed within the enclosure as needed. Unfortunately, it is rare for an electrical installation to include coiled or otherwise stored additional connected branch circuit cable as described above.

[0019] The third challenge is related to the second challenge because after branch circuit cables leave an electrical enclosure such as a load center, they typically become incorporated into the structure of the building so that it may not be feasible to free up sufficient lengths of installed branch circuits along their deployed length to relocate existing branch circuit cables to a separate and different enclosure without requiring extensive and expensive construction to open the building structure, where the building structure contains branch circuit cables that are difficult to access without opening the building structure. One solution is to install a freestanding junction box a short distance from the existing enclosure, as is known in the art. While this can be done in an electrically safe manner, it may not be practical if there are many different branch circuits that need to be moved from the existing enclosure to a separate, different enclosure. This need to relocate many different branch circuits may be common in situations such as those described above, where there may be many different branch circuits that are desired to be relocated from an existing load center enclosure to a separate and different enclosure containing a different and electrically incompatible load center.

[0020] The fourth challenge is that the deployment of existing separate junction boxes, as is common in the art, may not allow for convenient redeployment of additional branch circuit cables from the same existing enclosure to a separate and different enclosure previously deployed, as described above. One situation in which such a deployment may be required stems from the above situation, where a separate and different load center distributing DC current is deployed in addition to an existing AC load center. At the initial time of installation, it may be desirable to move certain existing branch circuits from the existing AC load center enclosure to the newly deployed load center distributing DC power. This may be desirable for terminal use loads that can be directly connected to branch circuit cables (e.g., hardwired) at terminal household appliances. However, AC electrical outlets are widely used in buildings, such as commonly available AC appliances with ordinary wires and plugs designed to connect to those outlets. Since there are currently no commonly available DC outlets, and there are almost no commonly available branch circuit DC insertion devices that require branch circuit power levels, it may be desirable not to transfer the branch circuit cables currently distributing AC power to the existing building AC outlets when given the current deployment of separate and different DC load centers. However, it is conceivable that over time, DC output outlets will not only become available but also become widespread. It is also contemplated that over time, DC-compatible devices requiring branch circuit voltages may also become available and widely available with different DC-compatible plugs for DC branch circuit receptacles. At this point, it may be desirable to move the additional AC branch circuits from the existing conventional AC load center enclosure to a previously deployed separate and different DC load center enclosure. It is desirable to have a new approach that will easily allow the use of previously deployed junction boxes or enclosures to deliver such subsequent expansion branch circuit cables.

[0021] Electrical enclosures, including those housing electrical load centers, are typically surface mounted or flush mounted. Regardless of whether the enclosure in question is surface mounted or flush mounted, the above conditions and challenges exist similarly.

[0022] Electrical enclosures (including enclosures housing electrical load centers) are most commonly constructed of metal, such as formed steel sheets. Electrical enclosures may also be constructed of other materials, particularly non-conductive plastics. Although enclosures containing load centers in the United States are rarely constructed of materials other than steel, other international jurisdictions have permitted plastic load centers in the past or may now permit plastic load center enclosures. The situations and challenges detailed above are similar regardless of the specific material of the enclosure. Summary of the invention

[0023] The present invention provides an improved method of rearranging cables whose jackets terminate when entering an electrical enclosure and in which unused lengths of those cables do not exist outside the enclosure. The present invention creates a new type of electrical enclosure, one use of which is as a junction box for cables, adapted to provide a replacement for existing entry points into an existing electrical enclosure by providing a cable entry point (i.e., a corner) into the new type of electrical enclosure through an angled cable entry surface adjacent to the original enclosure that terminates on both sides, so that the cables can be removed from the original electrical enclosure and rearranged through the angled cable entry surface of the new type of enclosure without requiring additional lengths of coated cables. The new type of electrical enclosure is designed so that it is installed adjacent to the existing electrical enclosure and is also fixed to the original enclosure. Any side of the new type of enclosure that is not installed against the original enclosure has sufficient material and construction so that they meet the existing requirements of electrical enclosures such as junction boxes. The new type of junction box includes a main body portion and a removable cover. The new type of junction box with its removable cover protects the cables and the connectors therein according to the existing requirements of the junction box. One side of the new type of enclosure is installed to abut at least a portion of one side of the existing enclosure. This side of the new housing has at least one opening therein (e.g., an additional cable entry hole) that allows any electrical features of the adjoining side panel of the existing housing to function as they would without the new housing installed. The other sides of the new housing, except for the removable cover, serve to complete the housing and provide cable entry points common on existing junction boxes. All sides of the new housing terminate in a back panel that also extends flat against at least a portion of the back panel of the original housing. This back panel extension behind the original housing provides additional opportunities to secure the new housing to the existing housing.

[0024] If there are existing cables exiting that side of the existing enclosure, they will enter the new junction box through openings in the adjoining side panels of the new junction box and can then be connected to the new cables to be rerouted away from the components of the existing and new enclosures, or they can be routed through different panels of the new enclosure and can exit the new enclosure without modification.

[0025] As is well known in the art, the preferred embodiment of the present invention is useful when an existing electrical enclosure is also used as an electrical load center. A load center typically has many branch circuit cables that leave the load center to power various branch circuits. These branch circuit cables typically exit primarily from one side of the load center enclosure (e.g., the top side of the enclosure). These branch circuit cables are also incorporated into the building shortly after they leave the enclosure, leaving little additional length of the coated branch circuit cables available. In this preferred embodiment of the present invention, the angled surface is the surface of the angled side of the new enclosure that begins where the top and one side of the load center enclosure meet. The angled surface of the angled side panel includes a cable entry point common in the electrical enclosure field and extends from the corner where the top side of the load center enclosure intersects the right side of the load center, as viewed from the front. The new enclosure is adjacent to an existing electrical enclosure into which cables have already entered, adjacent to a new electrical enclosure, without requiring any substantial increase in the length of the coated cables outside of either enclosure.

[0026] Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter.It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] The accompanying drawings are incorporated into and form a part of the specification, are illustrative of aspects of the present invention, which will be more fully understood together with the following detailed description, and are not meant to limit the scope of the present disclosure in any way, which should be based on the claims. The present invention will be more fully understood from the detailed description and the accompanying drawings, in which:

[0028] Figure 1 is a three-dimensional perspective elevation view with a small elevation angle and rotation of a first embodiment of the present invention, wherein the components are separated;

[0029] Figure 2A is a three-dimensional perspective elevation view with a small elevation angle and rotation of a first embodiment of the present invention, wherein the components are engaged;

[0030] Figure 2B is a three-dimensional perspective elevation view with a small elevation angle and rotation of a first embodiment of the present invention, wherein the components are separated;

[0031] Figure 3A is a three-dimensional perspective elevation view of an existing electrical enclosure with a small elevation angle and rotation;

[0032] Figure 3B is a three-dimensional perspective rear view of an existing electrical enclosure with a small elevation angle and rotation;

[0033] Figure 4A is a three-dimensional perspective elevation view with a small elevation angle and rotation of the first embodiment of the present invention, the existing housing cover and the existing electrical housing, wherein the components are separated;

[0034] Figure 4B is a three-dimensional perspective rear view with a small elevation angle and rotation of the first embodiment of the present invention, the existing housing cover and the existing electrical housing, wherein the components are separated;

[0035] Figure 5 is a three-dimensional perspective elevation view with a small elevation angle and rotation of the first embodiment of the present invention, the existing housing cover and the existing electrical housing, wherein the components are separated and the circled area is selected for magnification;

[0036] Figure 5A yes Figure 5 An enlarged view of the circled part;

[0037] Fig. 6A is a three-dimensional perspective elevation view with a small elevation angle and rotation of a first embodiment of the present invention, an existing housing cover and an existing electrical housing, wherein these elements are joined;

[0038] Figure 6B is a three-dimensional perspective rear view with a small elevation angle and rotation of a first embodiment of the present invention, an existing housing cover and an existing electrical housing, wherein these elements are joined;

[0039] Figure 7 is a three-dimensional perspective elevation view with a small elevation angle and rotation of a portion of a first embodiment of the present invention engaged with an existing electrical enclosure, wherein cables are shown entering each enclosure;

[0040] Fig. 8A is a three-dimensional perspective elevation view with a small elevation angle and rotation of a second embodiment of the present invention, separated from the engaged existing housing and the existing cover;

[0041] Figure 8B is a three-dimensional perspective rear view with a small elevation angle and rotation of a second embodiment of the present invention, separated from the engaged existing housing and the existing cover;

[0042] Fig. 9A is a three-dimensional perspective front view with a small elevation angle and rotation of a second embodiment of the present invention, a conventional housing and a conventional cover, wherein all elements are joined;

[0043] Fig. 9B is a three-dimensional perspective rear view with a small elevation angle and rotation of a second embodiment of the present invention, an existing housing and an existing cover, wherein all components are engaged;

[0044] Fig.10 is a three-dimensional perspective rear view with a small elevation angle and rotation of a third embodiment of the present invention, a conventional housing and a conventional cover, wherein all components are engaged;

[0045] Fig.11A is a three-dimensional perspective front view with a small elevation angle and rotation of a fourth embodiment of the present invention, a conventional housing and a conventional cover, wherein all components are joined;

[0046] Fig. 11B is a three-dimensional perspective rear view with a small elevation angle and rotation of a fourth embodiment of the present invention, a conventional housing and a conventional cover, wherein all components are engaged;

[0047] Fig. 12A is a three-dimensional perspective elevation view with a small elevation angle and rotation of a fifth embodiment of the present invention, wherein the elements are separated;

[0048] Fig. 12B is a three-dimensional perspective elevation view with a small elevation angle and rotation of a fifth embodiment of the present invention, wherein the elements are joined;

[0049] Fig.13A is a three-dimensional perspective elevation view with a small elevation angle and rotation of a fifth embodiment of the present invention, a prior art housing and a prior art cover, wherein all elements are engaged;

[0050] Fig. 13B is a three-dimensional perspective rear view with a small elevation angle and rotation of a fifth embodiment of the present invention, a prior art housing and a prior art cover, wherein all components are joined. DETAILED DESCRIPTION

[0051] Reference will now be made in detail to embodiments of the present invention, examples of which are shown in the accompanying drawings. Although the present invention will be described in conjunction with several embodiments, this description should not be construed as limiting, but is merely used to illustrate examples of the present invention, and by reference to these examples, in conjunction with the following description and drawings, those skilled in the art can understand the advantages and benefits of the present invention. On the contrary, the present invention is intended to cover substitutions, modifications and equivalents that may be included in the spirit and scope of the present invention as defined by the appended claims. In addition, it will be understood that embodiments of the present disclosure may adopt any combination of the features described herein. The description of known starting materials, equipment, components and processing techniques may be omitted to avoid unnecessarily obscuring the embodiments herein.

[0052] References herein to "a first embodiment," "a second embodiment," "an embodiment," "another embodiment," and similar terms mean that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. The phrases "in an embodiment" or "in an embodiment" as used herein do not necessarily all refer to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments. In addition, various features are described that may be exhibited by some embodiments but not other embodiments. Similarly, various requirements are described that may be requirements of some embodiments but not other embodiments.

[0053] The terms "comprise", "include" and "have" and their derivatives are used to represent inclusion rather than restriction, and are intended to be open terms that specify the presence of the features, elements, parts, groups and / or steps, but do not exclude the presence of other undescribed features, elements, parts, groups and / or steps, and represent that there may be additional features, elements, parts, groups and / or steps other than those listed. As used herein, the terms "connect", "couple" or any variation thereof refer to any direct or indirect connection or coupling between two or more elements. In addition, the words "herein", "above", "below" and words of similar meanings should refer to the entirety of this article when used herein rather than to any particular part of the application. If the specification states that "may", "can" or "may" include components or features or have characteristics, it is not necessary to include the specific components or features or have the characteristics.

[0054] The articles "a", "an", "the" and "said" are intended to indicate the presence of one or more elements, unless otherwise specified. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as those of ordinary skill in the art are generally understood. When used in this document, the term "exemplary" is intended to mean "by way of example" and is not intended to indicate that a particular exemplary item is preferred or required. When terms such as "first" and "second" are used to modify nouns herein, such use is intended only to distinguish one item from another, and is not intended to require a sequential order unless specifically stated. For directional purposes, it will be understood that in the case of using terms such as "top", "bottom", "front", "rear", "above", "below" and other directional terms to describe embodiments of the present invention with reference to the accompanying drawings, these terms are made for convenience and specifically refer to the orientation of the embodiment when it is oriented in the accompanying drawings, and the present invention will be used normally and should not be interpreted in any other restrictive manner.

[0055] The term "or" is inclusive, meaning and / or; the phrases "associated with" and "associated with" and their derivatives may mean include, be included, interconnected with, contain, be contained within, connected to or connected with, coupled to or coupled with, communicable, cooperating with, interlaced, juxtaposed, close to, bound to or having with, having characteristics of, etc.

[0056] Figures 1 to 13B Various embodiments of the present invention are shown. Figure 1-7 A first exemplary embodiment is shown. Now with particular reference to Figure 1 , 2A and 2B, showing two novel components of the first embodiment of the present invention. Figure 3A and 3B A third, non-novel, existing electrical enclosure component is shown to which the novel component is connected in use. Figure 1 A housing structural core 50 and a housing cover 51 are shown. Figure 2A A 3D perspective view of a structural core 50 with a cover 51 installed is shown. Figure 2B Shown is a separated but otherwise oriented similar Figure 2A 3D perspective view of the structural core 50 and cover 51. The structural core 50 and cover 51 are shown in a three-dimensional "exploded view" so that the two new components are separated to better observe the specific features of each component. The exploded three-dimensional view is slightly rotated in the XY plane so that partial front and side views can be seen. The structural core 50 includes a back panel 52, an angled top side panel 53, a long outer side panel 54, an angled bottom side panel 55, a discontinuous inner short side panel 56, and a front opening. The cover 51 includes a forward facing cover panel 57, an angled upper overhang lip 58, a Figure 1 Not visible but indicated are the long side overlapping lip 59, the angled lower overhang lip 60, the extended cover portion 61 of the forward facing cover panel 57, and the short side extended overhang lip 62. In the first embodiment of the invention, both the structural core 50 and the cover 51 are made of sheet steel using methods well known in the art of making electrical enclosures from sheet steel.

[0057] like Figure 1As shown, the back plate 52 of the structural core 50 has the following additional features in the first embodiment of the present invention. The back plate 52 has three parts. The main part 63 of the back plate 52 is bounded by the top plate 53, the bottom plate 54 and the side plate 55 and the discontinuous side plate 56, or meets the top plate 53, the bottom plate 54 and the side plate 55 and the discontinuous side plate 56. The back plate 52 also has two additional extensions 64 and 65, each extending from the main part 63 to the outside of the continuous plane containing all parts of the discontinuous side plate 56. The extension part 64 of the back plate 52 is coplanar with the main part 63 and the extension part 65 of the back plate 52, and contains two non-threaded holes 66. The position of the holes 66 is such that they are aligned with the existing holes in the third non-novel component of the present invention and serve as a means for fixing the present invention to the third component of the first embodiment of the present invention. The key hole 67 in the part 64 of the back plate 52 is a non-threaded key hole, which is positioned so that it is also aligned with the corresponding key hole in the existing third component of the present invention. The portion 65 of the rear plate 52 also includes two non-threaded holes 66 that are similarly aligned with corresponding holes in the third prior art component of this embodiment of the invention and similarly correspond to the key holes 67 .

[0058] The discontinuous short side panels 56 include Figure 1 Several different portions of the first embodiment of the present invention are shown. All portions of the side panels 56 are coplanar and include an uppermost portion 70, a center portion 72, elongated or narrow portions 71 and 73, and a lowermost portion 74. The angled top panel 53 extends from the top edge of the uppermost portion 70 of the discontinuous short side panels 56 to the location where the top panel 53 ends and the long side panels 54 begin. The angled top panel 53 also intersects with the main portion 63 of the back panel 52. The angled top panel 53 intersects with the illustrated portions of the three panels 52, 54 and 56 in a manner consistent with known standards and practices for metal electrical enclosures. The angled top panel 53 also includes a plurality of cable entry holes 68. The holes 68 still comprise the original sheet metal of the panel 53 when the core structure 52 is manufactured and act as knockouts that can be selectively removed where and when needed to facilitate cable entry. The arrangement and operation of the cable entry holes 68 and knockouts are similar to the common state of the art for cable entry holes and knockouts in existing electrical enclosures.

[0059] As in the first embodiment of the present invention Figure 1As shown, the long side panels 54 extend from the upper angled end of the angled top panel 53 to a position where they terminate at the lower angled end of the angled bottom panel 55. The side panels 54 also intersect with the main portion 63 of the rear panel 52. The long side panels 54 intersect with the illustrated portions of the three panels 52, 53, and 55 in a manner consistent with known standards and practices for metal electrical enclosures. The long side panels 54 also include two cover securing tabs 69. The tabs 69 begin at a position where they intersect with the outermost edges of the side panels 54, wherein the outermost edges extend along the length of the side panels 54, which are farthest from the position where the side panels 54 intersect with the rear panel 52, and extend in an xy plane, which is also parallel to the rear panel 52, and which extends a distance short enough to include threaded holes in the tabs 69. The threaded holes in each of the two cover securing tabs 69 enable ordinary threaded fasteners that pass through two corresponding non-threaded holes in the cover 51 to secure the cover 51 in place using existing methods of fastener and thread design. The cover securing tabs 69 may be constructed from additional material (eg, steel sheet) forming the long side panels 54 and may be sized, formed, and bent into place to form the tabs 69 using conventional methods known in the art.

[0060] The angled bottom plate 55 extends from the lowermost edge of the long side plate 54 and extends at a certain angle to the position where it terminates at the lowermost edge 74 of the discontinuous side plate 56. The angled bottom plate 55 also intersects with the main portion 63 of the rear plate 52. The angled bottom plate 55 intersects with the shown portions of the three plates 52, 54 and 56 in a manner consistent with known standards and practices for metal electrical enclosures. The angled bottom plate 55 also includes a plurality of cable entry holes 68. The holes 68 still include the original metal sheet of the plate 55 when the core structure 52 is manufactured, and act as a knock-out portion that can be selectively removed where and when needed to facilitate cable entry. The arrangement and operation of the cable entry holes and knock-out portions are similar to the common state of the art of cable entry holes and knock-out portions in existing electrical enclosures.

[0061] The uppermost portion 70 of the discontinuous side panel 56 runs a short distance from the edge of the angled top panel 53 of the portion 64 closest to the rear panel 52 and terminates at a position such as Figure 1The curve is designed to allow a large diameter cable entry hole in the portion of the side panel of the existing electrical enclosure against which the discontinuous side panel 56 will abut, so that the large cable entry hole retains its ability to function before the core structure 50 is installed against the existing electrical enclosure. The discontinuous short side panel 56 is discontinuous from the bottom curve across the uppermost portion 70 of the back panel 52 until the elongated portion 71 begins at the intersection of the lowermost edge of the extended portion 64 of the back panel 52 and the main portion 63 of the back panel 52. The elongated portion 71 extends orthogonally from the back panel 52 for a short distance in the same plane as all portions of the short side panel 56 and is parallel to the plane containing the long side panel 54. This short distance allows an existing cable entry hole in the existing electrical enclosure to which the core structure 50 will be attached to maintain functionality. The elongated portion 71 of the short side panel 56 ends at the location where the full height or center portion 72 of the side panel 56 begins. Portion 72 extends from the back panel 52 the same distance that the side panels 53, 54 and 55 extend. Portion 72 can be full height because the portion of the existing enclosure to which the full height portion 72 abuts does not contain a cable entry hole or other feature where functionality would be lost. The full height portion 72 of the side panel 56 ends at the location where the elongated portion 73 begins. The elongated portion 73 extends a short distance from the main portion 63 of the back panel 52 to maintain the functionality of the cable entry hole in the adjacent portion of the side of the existing electrical enclosure against which the portion 73 of the short side panel 56 of the core structure 50 will be mounted. The side panel 56 is discontinuous from the lowermost terminal end of the elongated portion 73, where the elongated portion 73 intersects the uppermost edge of the extended portion 65 of the back panel 52, until the lowermost portion 74 of the side panel 56 begins with a curve that is functionally similar to the uppermost portion 70 of the side panel 56.

[0062] Now, referring specifically to the first embodiment of the present invention, Figure 1 As shown in the housing cover 51, as described above, the cover 51 includes a front-facing cover plate 57, an angled upper overhanging lip 58, a long side overhanging lip 59 (which is located at Figure 151, but not directly visible), an angled lower depending lip 60, an extended cover portion 61, and an extended depending lip 62. An angled upper depending lip 58 is a lip of the same steel plate as the front plate 57, which extends a short distance behind the front plate 57 from the upper angled edge of the front plate 57 in a plane including the upper edge of the front plate 57 and normal to the front plate 57. The lip 58 is such that when the cover 51 is installed on the core structure 50, the lip 58 also covers the short portion of the angled top plate 53 of the core 50 that is farthest or most distal from the rear plate 52. The coverage of the short distal portion of the angled top plate 53 by the lip 58 does not interfere with the operation of the cable entry hole 68. When the cover 51 is installed on the structural core 50, the short distal portion of the angled top panel 53 covered by the lip 58 spans from the topmost edge of the uppermost portion 70 of the discontinuous panel 56 to where the angled top panel 53 terminates at the topmost edge of the long side panel 54. Similarly, the long side overhang lip 59 has the same shallow depth as the lip 58 from the front cover panel 57 and extends from the termination of the angled upper overhang lip 58 at the topmost edge of the long side 54, along the entire length of the leftmost or outer long edge of the front panel 57 of the cover 51 until it terminates at the bottommost left edge of the front panel 57. Similarly, when the cover 51 is mounted to the core 50, the angled lower overhang lip 60 has the same shallow depth as the lips 58 and 59 from the front cover plate 57 and extends along the entire length of the angled bottom plate 55 from the termination of the long side overhang lip 59 at the bottommost left edge of the front plate 57 and the lip 60 terminates at the bottommost location where the angled bottom plate 55 terminates at the lowermost portion 74 of the discontinuous short side plate 56. The overhang lips 58, 59 and 60 of the three covers 51 together form a single continuous lip on the portions of the three core 50 plates 53, 54 and 55, such that the lip is continuous from the location where the plate 53 meets the portion 70 of the discontinuous side 56 and continues to extend until the location where the plate 55 meets the portion 74 of the discontinuous side 56. The extended cover portion 61 and the extended overhang lip 62 are suitable for assembly into an existing electrical enclosure to which the core structure 50 and the cover 51 are to be attached. The extended cover portion 61 is coplanar with the front cover plate 57 and extends a short distance in a direction normal to the plane containing the discontinuous short side plate 56 and past the discontinuous short side plate 56, wherein the extended depending lip 62 is adapted to extend in a plane parallel to the discontinuous side plate 56 over a portion of an existing housing to which the structural core 50 and cover 51 will be attached. Two non-threaded holes 75 extending through the top and bottom ends of the front cover plate 57 near the lip 59 align with corresponding threaded holes in the two cover securing tabs 69 along the long side plates 54 of the core 50. Two non-threaded holes in the top and bottom of the extended cover portion 61 of the cover 51 align with corresponding threaded holes in the existing housing portion to which the core 50 and cover 51 will be mounted.The gaps 77 at the top and bottom of the right side of the cover 51 are the result of adapting the extended cover portion 61 and the extended depending lip 62 to the existing housing to which the core 50 and cover 51 will be attached. Three non-threaded holes 76 are located near the top, bottom and middle of the extended cover portion 61 to align with threaded holes in the existing housing to which the structural core 50 and cover 51 will be mounted.

[0063] Now refer to Figure 2A , a three-dimensional perspective view of the assembly of the shell structural core 50 and the cover 51 forming the assembly of the novel component 95 is shown. Figure 2A A view is provided of how the structural core 50 and cover 51 are assembled together, omitting the existing housing 78 of the assembly to which the new component 95 will be attached. Figure 2A The assembly of the novel component 95 shown is not considered an electrical enclosure. This is because the discontinuous plate 56 has openings of several material sizes within its length, such as the opening between the plate elongated portions 71 and 73 of the plate 56 and the lip 62 of the cover 51. Figure 2B In the Figure 1 A 3D perspective view of a similar structure core 50 and cover 51 is provided for reference.

[0064] Now refer to Figure 3A and Figure 3B , Figure 3A A 3D front view of an existing housing 78 is shown, wherein the front view is slightly rotated and the view is elevated to provide the perspective view shown. Figure 3B A different 3D view of the existing housing 78 is shown, wherein it is rotated to show an angled view of the rear of the housing 78 from a slight elevation angle.

[0065] The existing housing 78 is a common housing in the electrical field, and is a housing that most commonly functions as an electrical load center, where the load center distributes power to branch circuits as known in the electrical field. Although the existing housing 78 is selected for the first embodiment of the present invention, the present invention can also be connected to other existing housings used for different known electrical purposes. The housing 78 includes a back plate 79, a top cable entry plate 80, a side cable entry plate 81, a bottom cable entry plate 82, an opposite side cable entry plate 83, a narrow top cover support plate 84, a narrow side cover support plate 85, a narrow bottom cover support plate 86, and a narrow side cover support plate 87.

[0066] Now, special reference Figure 3A, the existing housing 78 is depicted as having side panel 81 on the left side of rear panel 79 and side panel 83 on the right side of rear panel 79. Rear panel 79 is formed of sheet steel and extends continuously and terminates at the edge of top panel 80 farthest from narrow top cover support panel 84. Rear panel 79 also extends continuously and terminates at the edge of side panel 81 farthest from narrow side cover support panel 85. Rear panel 79 also extends continuously and terminates at the edge of bottom panel 82 farthest from narrow bottom cover support panel 86. Rear panel 79 also extends continuously and terminates at the edge of side panel 83 farthest from narrow side cover support panel 87. Top panel 80 and bottom panel 82 are each perpendicular to the plane containing rear panel 79, so that panels 80 and 82 are at right angles to rear panel 79. Panels 80 and 82 are also in parallel planes. The side panels 81 and 83 each intersect the rear panel 79 on opposite sides and extend from the rear panel 79 in a plane orthogonal to the rear panel 79. All four panels 80, 81, 82 and 83 of the existing housing 78 extend the same distance from the rear panel 79, as shown in FIG. Figure 3A shown.

[0067] A narrow top cover support plate 84 extends vertically inwardly a short distance from the edge of the top plate 80 farthest from the rear plate 79 toward the bottom plate 82. The narrow plate 84 is in a plane parallel to the plane that accommodates the rear plate 79. A narrow side cover support plate 85 extends vertically inwardly a short distance from the edge of the side plate 81 farthest from the rear plate 79 toward the side plate 83. The narrow plate 85 is in a plane parallel to the plane that accommodates the rear plate 79. A narrow bottom cover support plate 86 extends vertically inwardly a short distance from the edge of the bottom plate 82 farthest from the rear plate 79 toward the top plate 80. The narrow plate 86 is in a plane parallel to the plane that accommodates the rear plate 79. A narrow side cover support plate 87 extends vertically inwardly a short distance from the edge of the side plate 83 farthest from the rear plate 79 toward the side plate 81. The narrow plate 87 is in a plane parallel to the plane that accommodates the rear plate 79. Narrow plates 84, 85, 86 and 87 all occupy a common plane. Narrow side cover support plate 85 includes three threaded cover connection holes 94, one of which is adjacent to narrow plate 84, one is located at an equal distance between narrow plates 84 and 86, and the third is adjacent to narrow plate 86. Narrow side cover support plate 87 similarly includes three threaded cover connection holes 94, one of which is adjacent to narrow plate 84, one is located at an equal distance between narrow plates 84 and 86, and the third is adjacent to narrow plate 86.

[0068] The top cable entry panel 80 extends from a ninety degree intersection with the side panel 81 to a ninety degree intersection with the side panel 83. The panel 80 includes a large cable entry hole 89 located in the center between the side panels 81 and 83, such as Figure 3AAs shown. Various smaller cable entry holes 88 are located on both sides of the large hole 89. The side cable entry plate 81 extends from a ninety degree intersection with the top plate 80 to a ninety degree intersection with the bottom plate 82. There is a large cable entry hole 89 near each ninety degree intersection at both ends of the side plate 81. The various smaller cable entry holes 88 in the side plate 81 extend from each large cable entry hole 89 near the corner toward the featureless middle or center portion 91 of the side plate 81, as shown. Figure 3A The bottom cable entry plate 82 extends from a ninety degree intersection with the side plate 81 to a ninety degree intersection with the side plate 83. The plate 82 includes a large cable entry hole 89, which is located in the center between the side plates 81 and 83, as shown in FIG. Figure 3A As shown. Various smaller cable entry holes 88 are located on both sides of the large hole 89. The side cable entry plate 83 extends from a ninety degree intersection with the top plate 80 to a ninety degree intersection with the bottom plate 82. There is a large cable entry hole 89 near each ninety degree intersection at both ends of the side plate 83. The various smaller cable entry holes 88 in the side plate 83 extend from each large cable entry hole 89 near the corner toward the featureless middle or center portion 90 of the side plate 83, as shown. Figure 3A shown.

[0069] Now refer to Figure 3B , a rear 3D perspective view of the prior art housing 78 is shown. Four non-threaded holes 93 are visible in the rear plate 79. Two holes 93 are located at the same distance from the middle of the rear plate 79 and near the top cable entry plate 80. The two non-threaded holes are similarly located at the same distance from the middle of the rear plate 79 and similarly near the end of the rear plate 79 at the bottom plate 82. Two key holes 92 in the rear plate 79 are also visible. The first key hole 92 is located in the rear plate 79, centered between the side plates 81 and 83, and is located a short distance from the top plate 80 closer to the end of the rear plate 79 than the top hole 93. The second key hole is similarly located in the center of the rear plate 79 between the side plates 81 and 83, and is a short distance from the bottom plate 82 closer to the end of the rear plate 79. Through the design of the structural core 50, all four non-threaded holes 93 in the rear plate 79 of the prior art housing 78 are aligned with the non-threaded holes 66 in the two extended portions 64 and 65 of the rear plate 52 of the first embodiment of the present invention. Similarly, the two key holes 92 in the rear panel 79 of the existing shell 78 align with the two key holes 67 in the two extended portions 64 and 65 of the rear panel 52 of the structural core 50 .

[0070] Now refer to Figure 4A, shows a three-dimensional view of the assembly of the novel component 95, the existing housing 78 and the existing cover assembly 96. The existing cover assembly 96 is a standard housing cover according to the housing cover field standard, and is particularly suitable for the cover of the existing housing, which is suitable as a load center in the existing technical standards. Figure 4A As shown, the cover assembly 96 is designed to be installed on the existing housing 78 so that the resulting combined assembly serves as a complete electrical load center, as is known in the art. The cover 96 includes four housing interface plates 97, 98, 99 and 100. These interface plates form a continuous coplanar rectangle near the perimeter of the cover assembly 96. The side interface plate 98 includes three non-threaded holes 101, which are designed to align with three threaded holes in the narrow side plate 85 of the housing 78. The side interface plate 100 similarly includes three non-threaded holes 101, which are designed to align with three threaded holes in the narrow side plate 87 of the housing 78. When the cover 96 is installed on the housing 78, the top interface plate 97 of the cover 96 abuts the narrow top cover support plate 84 of the housing 78. When the cover 96 is installed on the housing 78, the side interface plate 98 of the cover 96 abuts the narrow side cover support plate 85 of the housing 78. When the cover 96 is mounted to the housing 78, the bottom interface plate 99 of the cover 96 abuts the narrow bottom cover standoff plate 86 of the housing 78. When the cover 96 is mounted to the housing 78, the side interface plates 100 of the cover 96 abut the narrow side cover standoff plates 87 of the housing 78.

[0071] Referring now specifically to FIG. B , a three-dimensional rear view of the assembly of the novel component 95 , the existing cover assembly 96 , and the existing housing 78 is shown.

[0072] Now refer to Figure 5 and 5A , a three-dimensional perspective view of the assembly of the new component 95, the existing housing 78 and the existing cover assembly 96 is shown. Figure 5A Provided Figure 578 . When a new assembly 95 is to be installed on an existing housing 78 , the cover 51 of the assembly 95 must first be removed. This is due to the extended cover portion 61 and the extended overhang lip 62 of the cover 51 of the assembly 95 . When installed on the housing 78 , the extended overhang portion 61 of the cover 51 extends beyond the discontinuous plate 56 of the structural core 50 so that it abuts against the narrow side plate 85 of the existing housing 78 . The extended overhang lip 62 begins at the edge of the extended overhang portion 61 of the cover 51 that is closest to the opposing narrow side plate 87 , and the lip 62 is designed so that when the assembly 95 is installed on the housing 78 , the lip 62 extends from the edge of the extended portion 61 through the narrow plate 85 and extends a short distance in a plane parallel to the side plate 81 containing the existing housing 78 , thereby keeping the cover 51 and the assembly 95 secured to the existing load center 78 . Thus, when the assembly 95 is mounted to the housing 78, the cover 51 must be removed from the assembly 95, or at least lifted so that the extended overhanging lip 62 can pass through the narrow side panels 85. When the lip 62 of the cover 51 passes through the narrow panels 85 of the housing 78, the cover can abut against three edges of the panels 53, 54, 55 of the structural core 50 as designed, and also abut against the narrow side cover support panels 85, with the lip 62 in place and holding the cover 51 in place against the edges of the narrow panels 51. When the cover 51 is in place and when the assembly 95 is in place against the housing 78, the three threaded holes 94 in the narrow panels 85 align with the three non-threaded holes 76 in the extended portion 61 of the cover 51. The existing cover assembly 96 can now be installed onto the new assembly 95 and the housing 78. The existing cover assembly 96 can now be placed in place against the housing 78 and the extended portion 61 of the cover 51. When in place, the three non-threaded holes 101 in the housing interface plate 98 will align with the three non-threaded holes 76 in the extended portion 61 of the cover 51, and will also align with the three threaded holes in the narrow side panel 85 of the housing 78. The three non-threaded holes in the housing interface plate 100 also align with the three threaded holes in the narrow panel 87 of the housing 78. When the six standard threaded fasteners are secured in all of the above holes and tightened, the assembly comprising the new assembly 95, the housing 78, and the cover assembly 96 is further strengthened.

[0073] Reference now Fig. 6A and 6B , providing two different three-dimensional perspective views of the complete assembly 102. The complete assembly 102 includes the assembly of the novel component 95, the existing housing 78, and the existing cover assembly 96. The complete assembly 102 is electrically fixed, providing two separate electrical housings. With the six threaded fasteners installed in the six holes 101, the assembly is fixed in place, wherein both the cover 51 and the cover assembly 96 are fixed in place. Figure 7The rear perspective view of the complete assembly 102 shown shows that the holes 66 in the extended portions 64 and 65 of the rear plate 52 can further strengthen the strength of the complete assembly 102. The four holes 66 in the rear plate 52 are aligned with the four holes 93 in the rear plate 79 of the housing 78. If the complete assembly 102 is to be mounted to a vertical surface (such as a solid plywood), four wood screws or similar fasteners of sufficient strength can be driven through all four combinations of holes 93 and holes 66 to provide additional structural strength to maintain the integrity of the complete assembly 102. If the complete assembly 102 is not surface mounted, then a common assembly of four bolts and four nuts can be secured through all four combinations of holes 66 and 93 to further strengthen the complete assembly 102.

[0074] Now special reference Figure 7 , shows the complete assembly 102 with both the existing cover assembly 96 and the novel cover 51 removed. The existing enclosure 78 is visible as is the novel enclosure 103. Due to the discontinuity in material dimensions within the short side panels 56, neither the assembly of the structural core 50 nor the novel component 95 can be considered an electrical enclosure in isolation. Figure 7 As shown, the core 50 is positioned adjacent to the existing enclosure 78 such that the discontinuous plate 56 abuts the continuous side plate 81 of the enclosure 78 so that the new enclosure 103 can now be considered an enclosure. The branch circuit cable 104 is a portion of a fully coated non-metallic branch circuit cable that is typically distributed throughout a building. The branch circuit cable 104 terminates at a common strain reliever 105, at which point the jacket is removed from the cable 104 and the three component conductors 106 extend unsheathed within the enclosure 78. From the strain reliever 105 at the top plate 80 of the enclosure 78, the branch circuit cable 104 travels to another location within the building and there supplies power to the branch circuit. As is common in electrical practice, no additional branch circuit length is provided and the cable 104 proceeds directly to the nearest building structure, such as a wall or ceiling, where it enters the structure on its way to its destination. Thus, the utility of the present invention is that if it is desired to reroute the branch circuit cable from the enclosure 78 to another separate enclosure, this cannot be easily accomplished using the existing coated cable. As shown in FIG. Figure 7 As shown, a branch circuit cable (e.g., cable 104) can be rerouted to enter a new type of housing 103 (as shown by branch circuit cable 107), which can enter the housing 103 through strain relief 104 without the need for an additional length of coated branch circuit cable due to the presence of the angled cable entry plate 53. Once the branch circuit cable 107 reaches the strain relief 105 and enters the housing 103, its component wires 108 can be spliced ​​with the new branch circuit cable using wire splicing methods standard in the art, and can exit the housing 103 and be routed to a desired location.

[0075] Figures 8A-9B A second embodiment of the present invention is shown. Fig. 8A , in this second embodiment, the same existing housing 78 and existing cover assembly 96 as in the first embodiment are employed, as well as the same assembly of novel component 95, wherein the same structural core 50 and cover 51 are assembled. What is new in this second embodiment is a second assembly of novel component 109, which is identical in composition and components to the assembly of novel component 95, but is employed in a different manner in this second embodiment. Due to the symmetry of the components, the alignment and installation of the second assembly of novel component 109 is similar to the installation of assembly 95 to housing 78. If assembly 95 is rotated 180 degrees within the plane of cover 51, it will be arranged exactly like assembly 109, as Fig. 8A Due to this rotation, when assembled, angled plate 53 of component 95 will be adjacent to housing plate 80, but due to the 180 degree orientation of assembly 109, housing plate 80 will be adjacent to angled plate 55. In addition to the plate orientation, the second embodiment of the present invention provides the advantage that there are two housings and four angled cable entry plates, thereby providing increased options and housing space for rerouting additional branch circuit cables as described above.

[0076] Reference now Figure 8B , provides a three-dimensional perspective rear view of the second embodiment of the present invention. Figure 8BIn the rear view shown, all three portions of the rear plate 52 of the two assemblies of the novel components 95 and 109 are visible. Due to the rotational orientation of the assembly 109, the rear plate portion 64 of the assembly 109 is aligned with the rear plate portion 65 of the assembly 95, and the rear plate portion 65 of the assembly 109 is aligned with the rear plate portion 64 of the assembly 95. In this second embodiment of the invention, the assembly 95 will first be mounted to the existing housing 78 as described in the first embodiment. The two portions 64 and 65 of the rear plate 52 directly abut the rear plate 79 of the housing 78 so that all four non-threaded holes 66 are aligned with all four non-threaded holes 93 in the rear plate 52 of the housing 78. Next, the assembly 109 will be mounted to the assembly of the housing 78 and the assembly 95. The rear plate portion 65 of the assembly 109 is mounted directly to the rear plate portion 64 of the assembly 95, rather than being mounted directly to the rear plate 79 of the housing 78. The rear plate portion 64 of the assembly 109 is mounted directly to the rear plate portion 65 of the assembly 95, rather than being mounted directly to the rear plate 79 of the housing 78. When both assemblies of the novel components 95 and 109 are mounted to the housing 78, all four holes 66 in the rear plate portions 64 and 65 of the assembly 109 are aligned with all four holes 66 in the plate portions 64 and 65 of the assembly 95, and all eight holes 66 in both assemblies of the novel components 95 and 109 are aligned with all four holes 93 in the rear plate 79 of the housing 78. Four nut and bolt assemblies of sufficient strength can be tightened through all the holes 66 and 93 and further strengthen the assembly.

[0077] Reference now Fig. 9A , showing a three-dimensional perspective front view of a complete assembly 110. Assembly 110 is a complete assembly of a second embodiment of the present invention. Assembly 110 includes an existing housing 78 to which an assembly of new component 95 and an assembly of new component 109 have been installed, as described above, and to which an existing cover assembly 96 has also been installed. To secure assembly 110, suitable threaded fasteners are installed in all four holes 75, thereby securing the two covers 51 to their respective assemblies 95 and 109, and six suitable fasteners are installed in holes 101, which in turn secure covers 96 and 51 to housing 78.

[0078] Now, with particular reference to the present invention Fig. 9B, shows a 3D rear perspective view of a complete assembly 110, wherein assembly 110 is a complete assembly of a second embodiment of the present invention. In this assembled rear view, given the assembly sequence described above, the overlapping rear panel portions are visible. Since assembly 95 is first installed to housing 78, its rear panel portions 64 and 65 are partially obscured by rear panel portions 64 and 65 of assembly 109. Line 111 delineates where rear panel portion 65 of assembly 109 terminates, showing a visible portion of rear panel portion 64 of assembly 95. Line 112 similarly delineates where rear panel portion 64 of assembly 109 terminates, showing a visible portion of rear panel portion 65 of assembly 95. Assembly 110 may also be secured by installing four suitable nut and bolt assemblies through holes 66, thereby securing all rear panel portions 64 and 65 to rear panel 79 of housing 78.

[0079] Now special reference Fig.10 , the third embodiment of the present invention is shown in a 3D rear perspective view of the complete assembly 116. Fig.10 As shown, all rear panel components of the two structural cores 50 of the second embodiment are replaced by a single continuous rear panel 113. Other than the rear panel, no other modifications are made to any other components of the assembly of the novel component 95 or the assembly of the novel component 109. Thus, except for the rear panel modifications described below, the assembly 116 of this third embodiment is identical to the assembly 110 of the second embodiment. Fig.10 As shown, the third embodiment of the present invention has a rear panel 113 that extends continuously across the rear portion of the housing 78 from where the rear panel 113 intersects the side panels 54 on one side to where the rear panel 113 terminates at the intersection of a different side panel 54 on the other side, rather than as shown in FIG. Fig. 9B The portion 114 of the back plate 113 replaces the overlapping back plate portion 65 of the assembly 109 and the back plate portion 64 of the assembly 95 with one continuous portion 114. The portion 115 of the back plate 113 replaces the overlapping back plate portion 64 of the assembly 109 and the back plate portion 65 of the assembly 95. This is an improvement over the second embodiment because it reduces complexity and improves the mechanical integrity of the entire assembly 116.

[0080] Now special reference Fig.11A and Fig. 11B , each figure shows a 3D perspective view of the fourth embodiment of the present invention. Fig.11A A front perspective view of a complete assembly 119 of a fourth embodiment of the present invention is provided. Fig. 11BA rear perspective view of a fourth embodiment of the present invention is provided. The existing housing 78 and the existing cover assembly 96 are unchanged from the above-described embodiment. The complete assembly 119 is modified from the complete assembly 102, wherein those modifications from the above-described first embodiment are described herein, including reference to the above-described unmodified components and functions in this fourth embodiment of the present invention. The angled top cable entry plate 53 remains the same as the first embodiment. Similarly, as Figure 5A The attachment components of the existing housing 78 shown are unchanged, noting that due to Fig.11A and Fig. 11B The fourth embodiment of the invention does not have the lower attachment point of the housing 78. The overall modification of the complete assembly 102 of the first embodiment is to remove the lower attachment point of the housing 78. Figure 2A More particularly, the remainder of this fourth embodiment of the invention may be better described by first describing the midpoint of the assembly 95 as it relates to this fourth embodiment. This particular midpoint is described as the midpoint of the edge of the front plate 57, which is a distance of Figure 1 The extended overhang lip 62 is shown as far away. The second midpoint can be described as the midpoint of the edge of the front plate extension plate 61 that intersects the extended overhang lip 62. The third midpoint is defined by the location of a non-threaded hole 76 in the extension plate 61 of the cover plate 57, which is closest to the full height portion 72 of the core structure 50, as shown. Figure 2A A line can be drawn through three or more defined midpoints, where the line delineates Figure 2A The midpoint of the assembly of the illustrated novel component 95. The holes 76 shown in the exemplary embodiments included in this specification have fixed positions because they align with the threaded holes 94 in the existing housing 78 and they additionally align with the non-threaded holes 101 in the existing cover assembly 96. Therefore, any exemplary embodiments that secure these exemplary embodiments to an existing housing 78 and an existing cover assembly 96 must maintain the location of any securing holes 76 included in the particular exemplary embodiment.

[0081] By clearly defining the midpoint as applying to Figure 2A The vertical dimensions of the assembly of the novel component 95 shown, resulting in a modification of this fourth embodiment of the invention can be described as the terminal end of the assembly 95, which is a short distance below the midpoint of the vertical axis of the assembly 95, such as Figure 2A The assembly 95 shown. This modification results in a new structural core 117 and a new cover plate 118 similarly modified, as shown in FIG. Fig.11A and Fig. 11B As shown. The core 117 includes Fig. 11BA new back panel 125 is shown, which includes a new back panel portion 126 (which terminates a short distance below the midpoint defined above, where portion 126 intersects with a new bottom cable entry panel 122), and an unchanged back panel portion 64. The new bottom panel 122 occupies a plane orthogonal to the plane containing the back panel 79 of the housing 78. The bottom panel 122 contains various cable entry holes 68. The bottom panel 122 extends from the edge of the side panel 91 of the housing 78 adjacent the featureless portion 91 to a position where it terminates along the lowermost edge of the new side panel 121. The new side panel 121 is orthogonal to the plane containing the bottom panel 122, and is orthogonal to the plane containing the new back panel 125. As shown in FIG. Fig.11A and 11B As shown, side panel 121 extends from its lower edge at bottom panel 122 to its top edge at unmodified panel 53. New cover panel 118 is similarly modified and extends from the unmodified upper lip 58 to a new lip 124 that slightly overlaps bottom panel 122. Similarly, modified lip 123 extends from existing lip 58 to its termination at lip 122. Lip 121 occupies a plane orthogonal to the plane containing cover panel 118, and lip 121 is shown as Fig.11A and 11B Attached to the cover panel 118 as shown. The truncated discontinuous side panels 56 of the structural core 117 are not shown. Referring now to Figure 1 , showing portions 70, 71 and 72 of the first embodiment of the present invention. Portions 70 and 71 of the discontinuous side 56 are not modified in the fourth embodiment of the present invention. Portion 72 of the discontinuous side 56 is truncated in the fourth embodiment of the present invention so that the truncated portion 72 terminates at the bottom plate 122 (e.g. Fig. 11B The edge of the plate 122 shown. Fig.11A 1 shows a new non-threaded hole 120 in the new cover plate 118. The hole 120 is similar in design and function to the hole 75 in the cover 118. The hole 120 is aligned with a relocated cover securing tab, which is not shown in the figure. The relocated cover securing tab is similar in design to the hole 75 in the cover 118. Figure 1 The cover securing tabs are shown in FIG. 1 and aligned with the new holes 120 in the core structure 117 .

[0082] Now special reference Fig. 12A and Fig. 12B , showing a fifth embodiment of the present invention. Fig. 12A A three-dimensional front perspective view showing two separated modified components of the fifth embodiment. The structural core 127 is shown as it has been removed from the structural core 50 (eg Figure 1127) is modified from the structural core 50 shown in FIG. The core 127 includes a modified back panel 128, a modified angled upper cable entry panel 129, a new horizontal top cable entry panel 130, a modified long side panel 131, a new horizontal bottom cable entry panel 132, a modified angled lower cable entry panel 133, and a modified discontinuous side panel 134. The modified discontinuous side panel 134 includes a modified portion 135, unmodified portions 71, 72, and 73, and a modified portion 136. The back panel 128 of the core 127 includes three portions, namely a modified interior 137 and unmodified back panel portions 64 and 65. As shown in FIG. Figure 1 As shown, in the fifth embodiment of the present invention, the rear panel portions 64 and 65 each include two non-threaded holes 66 and one key hole 67. The floor portions 137, 64 and 65 are all coplanar. The rear panel portion 137 extends continuously from the rear panel portions 64 and 65 to the rear edge of the following structural core 127 panels and panel portions: a portion 135 of a discontinuous side panel 134, an angled upper panel 129, a horizontal top panel 130, a long side panel 131, a horizontal bottom panel 132, an angled lower panel 135, and portions 136, 71, 72 and 73 of the discontinuous side panel 134. The following panels and panel portions extend perpendicularly from the plane containing the rear panel 128: a portion 135 of a discontinuous side panel 134, an angled upper panel 129, a horizontal top panel 130, a long side panel 131, a horizontal bottom panel 132, an angled lower panel 135, and portions 136, 71, 72 and 73 of the discontinuous side panel 134. As shown in FIG15A , all of the following panels and panel portions extend from the rear panel 128 the same distance as the rear panel 128: the portion 135 of the discontinuous side panel 134, the angled upper panel 129, the horizontal top panel 130, the long side panel 131, the horizontal bottom panel 132, the angled lower panel 135, and the portions 136 and 72 of the discontinuous side panel 134. The unmodified panel portions 71 and 73 of the discontinuous side panel 134 extend a short distance from the rear panel 128, as shown in FIG15A . Fig. 12A As shown, this is consistent with the first embodiment of the present invention. The panels 129, 130, 132 and 133 of the structural core 127 include various cable entry holes 68. The long side panel 131 of the structural core 127 also includes two cover fixing tabs 69, such as Fig. 12A shown.

[0083] The cover 138 of the structural core 127 is also Fig. 12A The cover 138 includes a front cover plate 139, a hanging extension 61 of the front cover plate 139, a cover lip plate 140, a cover lip plate 141, a cover lip plate 142, a cover lip plate 143, a cover lip plate 144, a cover lip plate 145, a cover lip plate 146 and a hanging extension lip 62. The front cover plate 139 and the hanging extension 61 of the front cover plate are coplanar. Fig. 12A As shown, the cover lip 140 begins at the location where it meets the cover plate 139 and as shown in FIG. Fig. 12AThe core 127 is shown extending a short distance toward the core 127. Fig. 12A As shown, the cover lip 141 begins at the location where it meets the cover plate 139 and as shown in FIG. Fig. 12A The core 127 shown in FIG. 1 extends a short distance toward the structural core 127. Fig. 12A As shown, the cover lip 142 begins at the location where it meets the cover plate 139 and as shown in FIG. Fig. 12A The core 127 shown in FIG. 1 extends a short distance toward the structural core 127. Fig. 12A As shown, the cover lip 143 begins at the location where it meets the cover plate 139 and as shown in FIG. Fig. 12A The core 127 shown in FIG. 1 extends a short distance toward the structural core 127. Fig. 12A As shown, the cover lip 144 begins at the location where it meets the cover plate 139 and as shown in FIG. Fig. 12A The core 127 shown in FIG. 1 extends a short distance toward the structural core 127. Fig. 12A As shown, the cover lip 145 begins at the location where it meets the cover plate 139 and as shown in FIG. Fig. 12A The core 127 shown in FIG. 1 extends a short distance toward the structural core 127. Fig. 12A As shown, the cover lip 146 begins at the location where it meets the cover plate 139 and as shown in FIG. Fig. 12A The cover lips 140, 141, 142, 143, 144, 145 and 146 all extend the same short distance from the cover front plate 139 and together form an abutting lip that runs around the periphery of the cover front plate 139, as shown. Fig. 12A The overhang extension 61, overhang extension lip 62 and non-threaded hole 76 in cover 138 are the same as the first preferred embodiment and operate as described. Cover plate 139 includes two non-threaded holes 75 which are arranged to align with two cover fixing tabs, as shown. Fig. 12A shown.

[0084] Now refer to Fig. 12B , showing the Fig. 12A 147 is a three-dimensional perspective view of the assembly of the novel component 147 viewed from the same perspective. The assembly of the novel component includes the structural core 127 and the cover 138, which are assembled together as if they were installed into the existing shell 78, but without the shell 78. The assembly 147 is installed into the existing shell 78 in the same manner as the first preferred embodiment of the present invention was installed into the existing shell 78. In particular, components 61, 62, 64, 65, 66, 71, 72 and 73 are the same as the first embodiment and function as described above. Although the portion 135 of the discontinuous side panel 134 of the structural core 127 has been modified from the first embodiment of the present invention, the side panel 81 of the shell 78 (such as Figure 2B2C ) is identical to portion 70 of discontinuous side 56 (shown as 56 in FIG. 2C ). Similarly, although portion 136 of discontinuous side panel 134 of structural core 127 has been modified from the first embodiment of the present invention, it is identical to side panel 81 (shown as 56 in FIG. 2C ) of shell 78. Figure 3B The upper portion of the portion 136 adjacent to the bottom of the plate 81 shown in FIG. Figure 2A The same as portion 74 of 56) shown.

[0085] Now special reference Fig.13A , shows a three-dimensional front perspective view of a complete assembly 148 of a fifth preferred embodiment of the present invention. The complete assembly 148 includes an assembly of the novel component 147, the existing shell 78, and the existing cover assembly 96. It can be seen that the novel structural core 127 and the novel cover 138 are incorporated into the complete assembly 148. A portion of the modified portion 135 of the discontinuous side 134 is shown in FIG. Fig.13A It is visible in the figure that the portion is the modified portion 135. As described above, the unmodified portion 135 is connected to the discontinuous side plate 56 (such as Figure 2A The portion 70 of the side panel 56 shown is identical, so the unmodified portion 135 is hidden within the overall assembly 148.

[0086] Now special reference Fig. 13B , showing a three-dimensional rear perspective view of the complete assembly 148 of the fifth preferred embodiment of the present invention. When assembled into the complete assembly 148, the holes 66 in the rear plate portion 64 and the rear plate portion 65 are aligned with the housing 78 (such as Figure 3B All four holes 93 in the rear plate 79 of FIG. 78) are aligned.

[0087] The novel components of the present invention may be constructed of any material that provides standard structural integrity in the electrical enclosure field. Some examples of materials include sheet steel that can be bent or otherwise formed into the novel components of the present invention using standard methods and practices known in the art; or, alternatively, non-conductive rigid plastics that can be formed using existing methods known in the art.

[0088] The novel component of the present invention can be constructed of sheet steel in the manner of sheet steel electrical enclosures known in the prior art. The sides can be formed by bending an initially flat sheet of metal that is shaped so that the bends at preferred locations will result in any or all of the electrical enclosures described above. Typically, electrical enclosures are designed to be safe and effective only inside a building, where it is not desirable for the electrical enclosure to be exposed to outdoor elements or otherwise exposed to large amounts of water that may cause electrical failures. Therefore, in the field of sheet steel electrical enclosures, some plate intersections or corners are created by adjacent sides that are bent into place from a flat plate, and the resulting corner is the intersection of two sides, but the corner may contain a small gap that is not closed between the two otherwise intersecting sides. In other applications of sheet steel formed enclosures, these adjacent side panels that meet to form a corner can be welded together, which will provide increased structural integrity and a continuous seal between the two sides that meet at the corner. However, as described above, any two plates or sides that meet to form a corner in a preferred embodiment of the present invention can be the terminals of the two plates at the location where the corner is formed as described above, rather than being joined together with continuous welding or other joining techniques known in these technologies. As an alternative to the above-described embodiment of the invention where the corner between two plates is the intersection of the two plates without joining, the corner where two plates meet as described in the present invention can be produced by bending of a flat plate having portions that when bent using methods known in the art of steel sheet forming produce one or more of the above-described plates. Due to the bending, such a corner produced by bending will be a continuous corner and will also include a small radius, which is a standard result of existing steel sheet forming methods. All plate intersections of the abutting elements of the present invention are formed in accordance with existing standards and practices for interior dry location installation of electrical enclosures.

[0089] Each of the preferred embodiments of the present invention described above may be adapted for installation where exposure to wet conditions is anticipated. Any modification to the configuration for wet locations (such as the exterior of a building) will be an application of standard methods and practices for modifying electrical enclosures to accommodate such exposure.

[0090] These preferred embodiments of the present invention include at least one angled cable entry plate. The angle is defined herein as the angle between the cable entry plate in question and a horizontal line that intersects the angled plate at its edge closest to any portion of the discontinuous side plate 56 or discontinuous plate 134, and the angle of the angled plate is defined as the angle between the angled plate and the portion of the horizontal line that is also between the long side plates 54 or side plates 121 or long sides 131. For example, Figure 1As shown, the angle of the angled plate 53 with the horizontal plane is 45 degrees. Similarly, the angle of the angled plate 133 is estimated to be 70 degrees. In these figures, between the angled plate and the horizontal plane, the only two different angles shown in the figures are 45 degrees and about 70 degrees. These two angles are selected from many angles and should not limit the scope of the present invention. Any angle between the angled plate and the horizontal line that also extends through the side plate 54, 121 or 131 (where the angle is greater than zero degrees) will provide some utility and at least slightly reduce the required length of the branch circuit cable, which will be rearranged from the existing housing such as housing 78 by the angled plate included in the present invention. Similarly, the angle of 90 degrees will appear as a vertical cable entry plate extending from a portion of the discontinuous side plate 56 or 134 in the same plane as the plane containing the plate 56 or 34. This can also be used to enable the branch circuit cable to reach the angled cable entry plate. However, the present invention does not include any angle greater than 90 degrees, because the utility will decrease with an angle greater than 90 degrees.

[0091] The foregoing description has been given for the purpose of illustration and description, and the foregoing description is not exhaustive or limits the invention to the precise form disclosed. These descriptions are selected to explain the principles of the present invention and its practical application, so that other technicians in the field can utilize the present invention in various embodiments and various modifications to suit the specific purposes envisioned. Although the specific structure of the present invention has been shown and described, other optional structures are obvious to those skilled in the art and are within the intended scope of the present invention.

Claims

1. An electrical enclosure assembly for attachment to an existing electrical enclosure, comprising: A shell structural core having a rear panel, a top side panel, a bottom side panel, long side panels, discontinuous short side panels, and a front opening; the back plate having an inner portion and an extension portion, the extension portion extending from the inner portion beyond the discontinuous side plate and configured to be secured to the existing electrical enclosure; at least one of the top side panel and the bottom side panel having one or more cable entry points defined therein and advantageously angled and arranged to receive branch circuit cables rerouted from the existing electrical enclosure without requiring additional cable length; the discontinuous side panels having openings arranged to align with one or more cable entry points in the existing electrical enclosure when the structural core is secured to the existing electrical enclosure; an openable cover securable over the top opening for providing access to the interior of the structural core, the cover having an extended overhang extending outwardly over the discontinuous side panels and abutting and securable to the existing shell; Wherein, when the housing structural core is secured to the existing electrical housing, the structural core comprises an additional electrical housing.

2. The electrical enclosure assembly of claim 1, further comprising surface mounting holes in the extended portion of the back plate, the surface mounting holes being arranged to align with corresponding mounting holes in the existing electrical enclosure.

3. The electrical enclosure assembly of claim 1, wherein: The discontinuous side panel also includes a coplanar main portion, a short end portion, a narrow portion located between the main portion and the short end portion, and an opening in the discontinuous side panel located between the main portion and the short end portion, wherein the discontinuous side panel is configured to abut against a side panel of the existing electrical enclosure, the side panel of the existing electrical enclosure having one or more cable entry points in the side panel, wherein the opening is arranged to be aligned with at least one of the cable entry points.

4. The electrical enclosure assembly of claim 1, wherein: Both the top side panel and the bottom side panel are angled and configured to be adjacent to a corresponding top panel or bottom panel in the existing electrical enclosure and to receive branch circuit cables that are relocated from the existing electrical enclosure.

5. The electrical enclosure assembly of claim 1, wherein: The back plate also includes another extension portion connected to the main portion and extending outwardly from the main portion and configured to be connected to the existing electrical enclosure.

6. The electrical enclosure assembly of claim 5, further comprising rear surface mounting holes in the two extended portions of the rear plate, the rear surface mounting holes being positioned to align with corresponding mounting holes in the existing electrical enclosure.

7. The electrical enclosure assembly of claim 6, further comprising rear key holes in the extended portion of the rear plate, the rear key holes being arranged to align with upper and lower key holes in the existing electrical enclosure.

8. The electrical enclosure assembly of claim 3, wherein: When the structural core is secured to the side panels of the existing electrical enclosure, the side panels of the existing electrical enclosure extend over the openings in the discontinuous short side walls of the structural core such that the electrical enclosure assembly is adapted to accommodate electrical cables.

9. The electrical enclosure assembly of claim 1, further comprising at least two threaded holes in the long side panels of the junction box, the at least two threaded holes being arranged to align with corresponding holes in the cover for securing the cover to the top opening of the structural core.

10. The electrical enclosure assembly of claim 4, wherein: When the structural core is installed to the existing electrical enclosure, the top angled panels and the bottom angled panels meet the linear corners of the existing electrical enclosure.

11. The electrical enclosure assembly of claim 1 , wherein: The shell structural core is formed from a single piece of bent steel plate.

12. The electrical enclosure assembly of claim 1 further comprising a knockout in a cable entry aperture of the enclosure structural core.

13. The electrical enclosure assembly of claim 1, wherein: The cover also includes a narrow inwardly directed lip that extends through a narrow cover attachment plate and then inwardly toward the interior of the shell structural core.

14. The junction box assembly according to claim 1, wherein: The plurality of cable entry holes have variable sizes.

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