Electrical conduit cap and related assemblies and methods
Patent Information
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- MUSCO CORP
- Filing Date
- 2026-01-20
- Publication Date
- 2026-08-06
Smart Images
Figure US2026011825_06082026_PF_FP_ABST
Abstract
Description
Attorney Docket No. 87924.136. WO U1Electrical Conduit Cap and Related Assemblies and MethodsCross-Reference to Related Applications
[0001] This disclosure claims priority to U.S. Provisional Application 63 / 750,806, filed on January 29, 2025, and U.S. Provisional Application 63 / 879,797, filed on September 11, 2025, the entirety of each of which are incorporated herein by reference.Field
[0002] The embodiments herein generally relate to electrical box components.Background
[0003] Underground wires and / or electrical systems can sometimes span large distances and require electrical wires to be positioned in various orientations. Wires and / or hardware associated with such electrical systems can be buried within the ground, and can be accessed at pull boxes. The pull boxes can be designed to be buried into the ground such that pull boxes do not have a floor (or bottom) of the box. The contents of each box can be accessed via a lid. When in use, the lid of the box can be installed at ground level. Within the lid, wires can be positioned via a series of conduits.
[0004] Pull boxes, also referred to herein as junction boxes, can settle once in the ground. That is, the box can move in the ground after being installed and / or positioned. This can cause the box to sink or move to a lower position in the ground. This can cause the lid to come into contact with exposed wires. Electrical wires can become pinched between the lid and conduit surface, applying the weight of the box lid, dirt, and / or foot or equipment traffic onto the wires. This can damage the wires, which can result in current leakage at the area at and / or around the pull box.Summary
[0005] In general, this disclosure relates to systems, devices, and methods for mitigating damage to wires in electrical pull boxes via caps. The cap can be disposed on the conduit and prevent the lid of the box from contacting the wires. The cap can include structures configured to direct the wires in various orientations. The cap can further include structures configured to position the caps on a conduit to reduce movement of the cap during use.
[0006] Systems, devices, and methods described herein can reduce damage caused to wires in pull boxes and / or electrical boxes. The embodiments described herein can prevent and / or reduce damage caused to wires by pinching and / or pressure caused by lids of electrical pull boxes. This can further prevent leakage current at or around said electrical boxes.Attorney Docket No. 87924.136. WO U1
[0007] One embodiment includes an electrical box assembly comprising an electrical box, an electrical conduit, and a cap. The electrical box comprises at least one box wall forming an electrical box cavity. Each wall comprises a first end configured to be positioned within a ground surface and a second end opposite the first end. The electrical box comprises a lid disposed at the second end of the at least one box wall, the lid being configured to cover the electrical box cavity. The electrical conduit is disposed within the electrical box cavity and comprises a wire channel. The cap is configured to receive the electrical conduit. The cap comprises a conduit end, a lid-facing end, a cap wall extending from the conduit end to the lid-facing end and forming the wire channel, and a first opening in the cap wall at the conduit end, the first opening being configured such that at least one electrical wire received by the electrical conduit exits the cap through the first opening. The cap is disposed between the electrical conduit and the lid when in use.
[0008] In a further embodiment, the conduit end of the cap comprises a lip configured to contact the electrical conduit during use. In a further embodiment, the cap comprises a seat and the assembly further comprises a clamp configured to fasten the cap to the electrical conduit at the seat. In a further embodiment, the at least one lip comprises a first lip having a first diameter and a second lip having a second diameter, and the first diameter and the second diameter are different from one another.
[0009] In a further embodiment, the cap comprises a first cap piece and a second cap piece, the first cap piece and the second cap piece being threadably connectable to one another.
[0010] In a further embodiment, the lid-facing end is configured to interface with the lid of the electrical box such that the lid does not apply a pressure on the at least one electrical wire at a surface of the electrical conduit.
[0011] In a further embodiment, the cap wall further comprises a second opening, the second opening being configured such that at least a second electrical wire of the at least one electrical wire received by the electrical conduit exits the cap through the second opening.
[0012] Another embodiment includes an electrical conduit cap. The electrical conduit cap comprises a conduit end configured to be disposed adjacent an electrical conduit, a lid-facing end opposite the conduit end. a wall extending from the conduit end to the lid-facing end, and a first opening in the wall at the conduit end, the first opening being configured to receive a first electrical wire.
[0013] In a further embodiment, the conduit end comprises at least one lip configured to interface with a surface of the electrical conduit. In a further embodiment, the electrical conduit cap comprises a clamp configured to fasten the electrical conduit cap to the electricalAttorney Docket No. 87924.136. WO U1conduit. In a further embodiment, the cap comprises a seat configured to receive the clamp. In a further embodiment, the at least one lip comprises a first lip having a first diameter and a second lip having a second diameter, and the first diameter and the second diameter are different from one another.
[0014] In a further embodiment, the conduit end comprises a skirt structure configured to receive the electrical conduit.
[0015] In a further embodiment, the conduit end comprises a first cap piece and the lid-facing end comprises a second cap piece, and the first cap piece and the second cap piece are configured to be operably connected to one another.
[0016] In a further embodiment, the cap comprises a second opening in the wall at the conduit end.
[0017] Another embodiment includes a method of using an electrical conduit cap. The method includes providing an electrical conduit cap The electrical conduit cap comprises a conduit end, a lid-facing end configured to be disposed adjacent an electrical conduit, a wall extending from the conduit end to the lid-facing end, and a first opening in the wall at the conduit end, the first opening being configured to receive a first electrical wire. The method includes disposing the electrical conduit cap adjacent the electrical conduit within an electrical box having a lid such that the electrical conduit cap is between the electrical conduit and the lid. The method may further include positioning the first electrical wire through the first opening.
[0018] In a further embodiment, the wall comprises a skirt structure configured to receive the electrical conduit. In a further embodiment, the electrical conduit cap comprises a first cap piece and a second cap piece, the first and second cap piece being configured to be threadably attachable to one another.
[0019] In a further embodiment, the electrical conduit cap comprises a lip and a clamp, and wherein disposing the electrical conduit cap over an electrical conduit comprises positioning the lip over the electrical conduit and clamping the electrical conduit cap.
[0020] In a further embodiment, the electrical conduit cap comprises a second opening configured to receive a second electrical wire, and wherein the method further comprises positioning the second electrical wire through the second opening.
[0021] The details of one or more examples of the disclosure are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the disclosure will be apparent from the description and drawings, and from the claims.Attorney Docket No. 87924.136. WO U1Brief Description of the Drawing Figures[00221 The following drawings are illustrative of particular examples of the present invention and therefore do not limit the scope of invention. The drawings are not necessarily to scale, though embodiments can include the scale illustrated, and are intended for use in conjunction with the explanations in the following detailed description wherein like reference characters denote like elements Examples of the present invention will hereinafter be described in conjunction with the appended drawings
[0023] FIG. 1 shows a perspective view of an embodiment of an electrical box. in accordance with one or more examples of this disclosure.
[0024] FIG. 2 shows a perspective view of an embodiment of a lid of an electrical box, in accordance with one or more examples of this disclosure.
[0025] FIG. 3 shows a perspective view of an embodiment of an electrical box body, in accordance with one or more examples of this disclosure.
[0026] FIG. 4 is a close-up top view of an embodiment of the electrical box of FIG. 1.
[0027] FIG. 5 is a perspective view of an embodiment of an electrical conduit having an electrical conduit cap with wires extending from the conduit cap and a clamp, in accordance with one or more examples of this disclosure.
[0028] FIG. 6 is an alternate perspective view of an embodiment of the electrical conduit having an electrical conduit cap with wires extending from the conduit cap and a clamp of FIG. 5.
[0029] FIG. 7 is a perspective view of an embodiment of an electrical conduit having an electrical conduit cap of FIGS. 3 and 4 shown without the wires and the clamp.
[0030] FIG. 8 is a perspective view of the electrical conduit cap of FIG. 7 shown in isolation.
[0031] FIG. 9 is an alternate perspective view of an embodiment of an electrical conduit cap of FIG. 8.
[0032] FIG. 10 is a perspective view of another embodiment of an electrical conduit cap, in accordance with one or more examples of this disclosure.
[0033] FIG. 11 is a bottom view of an electrical conduit cap of FIG. 10.
[0034] FIG. 12 is a perspective view of another embodiment of an electrical conduit cap, in accordance with one or more examples of this disclosure.
[0035] FIG. 13 is a perspective view of yet another embodiment of an electrical conduit cap, in accordance with one or more examples of this disclosure.Attorney Docket No. 87924.136. WO U1
[0036] FIG. 14 is a perspective view of yet another embodiment of an electrical conduit cap, conduit, and wires, in accordance with one or more examples of this disclosure.
[0037] FIG. 15 is a perspective view of an embodiment of an electrical conduit cap of FIG.14 shown in isolation.
[0038] FIG. 16 is a perspective view of an embodiment of a piece of an electrical conduit cap of FIG. 15 shown in isolation.
[0039] FIG. 17 is an alternate perspective view of an embodiment of a piece of an electrical conduit cap of FIG. 16.
[0040] FIG. 18 is a perspective view of an embodiment of another piece of an electrical conduit cap of FIG. 15.
[0041] FIG. 19 is a flow diagram of an embodiment of a method of use of an electrical conduit cap, in accordance with one or more examples of this disclosure.Detailed Description
[0042] The following detailed description is illustrative in nature and is not intended to limit the scope, applicability, or configuration of the techniques or systems described herein in any way. Rather, the following description provides some practical illustrations for implementing examples of the techniques or systems described herein. Those skilled in the art will recognize that many of the noted examples have a variety- of suitable alternatives.
[0043] The embodiments herein can be used in electrical box assemblies to prevent and / or mitigate damage to electrical wires used in such assemblies. FIG. 1 shows an illustrative electrical box assembly 110. An electrical box assembly 110 can include an electrical box 112, an electrical conduit 114, and a cap 120. The electrical box 112 can include at least one box wall 118 forming an electrical box cavity 116. The at least one box wall 118 can include a first end 102 and a second end 104 opposite the first end 102. A lid 106 can be disposed at the second end 104 of the at least one box wall 118. The lid 106 can be configured to cover the electrical box cavity 116. The first end 102 can be configured to be positioned within a ground surface.
[0044] An electrical conduit 114 can be disposed within the electrical box cavity 116 The electrical conduit 114 can have a wire channel (not pictured) and can be configured to receive at least one electrical wire 122. Wire(s) 122 can be disposed within the electrical conduit 114 and extend therefrom and into the electrical box cavity 116. The electrical conduit(s) 114 can direct and / or orient the wires 122 in the electrical box 112.Attorney Docket No. 87924.136. WO U1
[0045] FIG. 2 and FIG. 3 show a lid 106 and body 103 of an electrical box, such as electrical box 112 of FIG. 1. The body 103 can be configured to receive the lid 106. In some examples, the body 103 can include a lip 105. The lip 105 can include a series of openings 107A-107C each configured to receive a fastener (not pictured) and can have a width of about 0.5 inch to about 2 inches. Similarly, the lid 106 can include a senes of openings 109 A, 109B configured to receive a fastener. When the lid 106 is positioned over the body, the lid 106 can be positioned over the lip 105 such that the lid openings 109 A. 109B and lip openings 107B, 107C are aligned with one another. The fasteners can be disposed through each of the sets of openings 107, fastening the lid 106 to the body 103. In some illustrative examples, the electrical box 112 can be a Quazite® pull box, though any pull box having any shape and / or any lid can be used.
[0046] In use. the electrical box 112 is disposed within the ground. In some applications, the ground can be treated to prevent sinking of the box 112 (e.g., disposing the box 112 on a layer of gravel). However, the box 112 may still move over time, causing it to sink. Because the box 112 does not include a base, the box 112 can sink into the ground and around the electrical conduit 114 and wires 122 The box 112 may eventually contact the electrical conduit 114 and / or wires 122, and can apply a downward force thereon. This may damage the wires 122 and / or affect their functioning.
[0047] A cap 120 can be configured to receive the electrical conduit 114 and be disposed between the conduit 114, wires 122, and box lid 106. The cap 120 can include an opening 124. The opening 124 can direct and / or orient a plurality of electrical wires 122. FIG. 4 shows a top-down oriented perspective view of the assembly 110 showing an illustrative example of how the cap 120 can orient wires 122. The cap 120 can include a plurality of openings 124 (see FIGS. 1 and 6) configured to guide wires 122 in different directions within the box 112. For example, in some embodiments, the wires 122 can be directed in generally opposite directions from one another. In other examples, the cap 120 may only include a single instance of openings 124, guiding wires 122 in a single direction within the box 112. In yet another example, the wires 122 can be directed at 30°. 60°, 90°, 120°, 150° angles from one another.
[0048] FIG. 5 and FIG. 6 show the conduit 114 including a cap 120. The cap 120 can include a conduit end 128, a lid-facing end 126, a cap wall 130, and a first opening 124 in the cap wall 130. The cap wall 130 can extend from the conduit end 128 to the lid-facing end 126. The first opening 124 in the cap wall 130 can be at the conduit end 128. The first opening 124 can be configured to receive at least one electrical wire 122. In some embodiments, aAttorney Docket No. 87924.136. WO U1plurality of electrical wires 122 can be disposed within the opening 124. When the cap 120 is disposed on and / or around a conduit 114, the conduit 114 can define a portion of the opening 124. In some embodiments, the cap wall 130 can include a second opening 124 configured to receive a second electrical wire 122. When the cap 120 is in use, the cap 120 can be disposed between the electrical conduit 114 and the lid 106 when the lid 106 is closed (see FIG. 1).
[0049] Looking at FIGS. 5 and 6, the conduit 114 and cap 120 can include a variety of structural features, and the conduit 114 can be configured to have the cap 120 be positioned thereover. In some embodiments, the conduit 114 can be round, and the cap 120 can be round. The top of the cap 120 may be curved or flat and closed so that it can contact the lid 106. The conduit 114 can have a diameter and the cap 120 can have a diameter. The cap diameter may change from the conduit end 128 to the lid-facing end 126. The cap diameter at the conduit end 128 can be larger than the diameter of the conduit 114, such that the cap 120 can fit over the conduit 114. However, the cap 120 and / or conduit 114 can be any shape and or size that facilitates the disposition of the cap 120 between the conduit 114 and the lid 106, as discussed in the preceding paragraph. The cap 120 can be made of plastic; however, in other embodiments, the cap 120 can be made of any material. When made from plastic, the cap 120 may be a custom injection molded part, but not necessarily so.
[0050] The cap 120 can include a variety of features configured to position the cap 120 relative to the electrical conduit 114, as shown in FIG 7. For example, in some embodiments, the conduit end 128 of the cap 120 can include a lip 134. The lip 134 can be configured to contact or interface with a surface 136 of the electrical conduit 114 during use. The lip 134 can protrude a radial distance r from the interior surface of the conduit wall to an inside surface of the lip of about 0.10 inches to about 0.25 inches. In some applications, “about” can mean a plastic molding tolerance of + / -0.005 inches. The lip wall 135 can extend an axial distance a from the top of the opening to the lip 134 measuring about 1 inch to about 3 inches. In a further embodiment, a clamp 138 can be configured to fasten the cap 120 to the electrical conduit 114, The clamp 138 can be any type of clamp 138 configured to go around the conduit 114 and cap 120 and apply pressure to cap 120 such that cap 120 is secured to conduit 114. The clamp 138 can be determined by the size and / or shape of the cap 120.
[0051] FIG. 8 and FIG. 9 each show a cap 120. As discussed elsewhere herein, the cap 120 can include a lip 134. The lip 134 can protrude from the cap wall 130 such that the lip 134 extends over a surface of the conduit 114. The lip 134 can extend a length approximately the same thickness as the thickness of the conduit 114 or a greater thickness. The openings 124 can be generally equidistant (e.g., diametrically opposite) from one another within the capAttorney Docket No. 87924.136. WO U1wall 130. The lip 134 can extend the length of the cap wall 130 between openings 124. The opening 124 can have a width c comprising a portion of the circumference of the cap 120. In some embodiments, the width c can range from about 1 inch to about 3 inches. However, in other embodiments, the lip can be disposed on the conduit, instead of the conduit cap. In applications where the conduit cap is secured to the conduit such that the conduit cap does not slip against the conduit when attached, the lip may be omitted from the conduit and conduit cap entirely.
[0052] FIG. 10 and FIG. 11 show a cap 220 including a plurality of lips 234. In some applications, it can be desirable to provide one cap 220 configured to receive conduits of various diameters. Structural features can be added to the cap 220 such that one cap 220 may¬ be manufactured for use with conduits having different diameters. That is, one cap 220 can be manufactured for use with a conduit having a first diameter or for use with a conduit having a second diameter different from the first diameter.
[0053] Variations in structural features can include variations of the lip 134 described with respect to FIG. 8 and FIG, 9. For example, the cap 220 can have two lips 234A, 234B. Each lip 234 A. 234B can be associated with a change in internal diameter in the conduit cap 220. The inner diameter of the cap 220 can change at the lip 234A, 234B. The inner diameter of cap 220 can increase when measured from the lid-facing end 226 to the conduit-facing end 228,
[0054] The change in inner diameter throughout the cap 220 can be such that the inner diameter decreases from the conduit end 228 to the lid-facing end 226. The first inner diameter Di of the cap 220 can be defined by the inner diameter at the opening 224 toward the lid-facing end 226 of the cap 220 and the second inner diameter D2 of the cap 220 can be defined by the inner diameter at the conduit facing end 228. The first lip 234A can define the first inner diameter Di and the second lip 234B can define the second inner diameter D2. In such embodiments, the second diameter D2 can be closer to the conduit facing end 228 than the first diameter Di In some embodiments, the inner diameter can change from a first diameter D1 of about 1 inch to a second diameter D2 of about 1 ¼ inches. In another embodiment, the inner diameter can change from a first diameter Di of about 1 V2 inches to a second diameter D2 of about 2 inches. In yet another illustrative embodiment, the inner diameter can change from a first diameter D1 of about 2 ½ inches to a second diameter D2 of about 3 inches. In other embodiments, the inner diameter can change from less than 1 inch to about 4, 5, 6, or 7 or more inches.Attorney Docket No. 87924.136. WO U1
[0055] The lip 234 can have a variety of widths depending on the inner diameter of the cap 220, the lip 234 width being defined by the radial protrusion of the lip 234 (e.g., radial protrusion r of FIG. 7). For example, in embodiments, where the first diameter Di is about 1 inch, the diameter can change from 1 inch to 1 1 / 8 inches at the first lip 234A (the first lip 234A protruding a radial distance of about 1 / 8 in.). At the second lip 234B, the diameter can change from 1 1 / 8 inches to 1 ',4 inches, such that the second lip 234B protrudes a radial distance of about 1 / 8 in.
[0056] In another embodiment, the inner diameter can change from about 1 inch to about 1 ½ inches. That is, the radial distance of the protrusion of first lip 234A can be about ¼ inch and the radial distance of the protrusion of the second lip 234B can be about ¼ inch.
[0057] In yet another illustrative embodiment, the diameter can change from 2 ½ inches to 3 inches. In such an embodiment, the inner diameter at the first lip 234A can be about 2 ½ inches and the inner diameter at the second lip 234B can be about 3 inches.
[0058] While the embodiments described herein generally relate to a cap 220 having a diameter between about 1 inch to about 3 inches, some embodiments of the cap 220 may have a diameter of less than 1 inch, or more than 3 inches. In some embodiments, the cap 220 may have three, four, five, six, or seven or more lips 234 such that one cap may be manufactured for use with conduits of varying diameters. The diameter may change in ¼ inch increments, ½ inch increments, or any size increment.
[0059] The cap 220 can also include a seat 240 configured to be in contact with a clamp (e.g., clamp 138 of FIG. 5-6). During use, the cap 220 can be generally upright and the seat 240 can protrude radially outwardly from the cap wall 230. The clamp can contact the seat 240 and / or be disposed above the seat 240 during use. The seat 240 can prevent vertical movement and / or horizontal movement of the clamp relative to the cap wall 230 during use, which can allow for the cap 220 to remain secured over the conduit.
[0060] In some embodiments, the cap 220 can include a first seat 240A and a second seat 240B The wall 230 between first and second seats 240A, 240B can form a skirt structure 242 extending from the first seat 240Ato the second seat 240B. The first seat 240A can be formed by the cap wall 230 generally opposite the second lip 234B. The second seat 240B can be formed at the conduit-facing end 228.
[0061] While the embodiments described herein are described as having two seats, the cap 220 can include more than two seats 240 if, for example, the cap 220 includes more than two lips 234. In such embodiments, the location of the seats 240 can correspond to the location of the lips 234. The seats 240 can radially protrude from the cap wall 230 at the approximateAttorney Docket No. 87924.136. WO U1location of the lips 234. Thus, the lips 234 can protrude radially inwardly from the cap wall 230 and the seats 240 can protrude radially outwardly at a same or similar cap wall 230 location. However, in other embodiments, the lips 234 and seats 240 can be at different locations on the cap wall 230.
[0062] It can be desirable to use a cap 220 configured for use with multiple conduit diameters. For example, only needing to manufacture one conduit cap 220 for use in electrical boxes (such as box 112 of FIG. 1) can reduce manufacturing time and costs associated with the cap 220. Caps configured for use with multiple conduit diameters can reduce the total number of unique caps needed for an assembly. Installation times can also be reduced as well, as it can be easier to locate and install a cap that can be used with multiple conduits; a user may not need to match a cap with a particular conduit diameter.
[0063] FIG. 12 and FIG. 13 each show various embodiments of the cap 320, 420. In some embodiments, such as that of FIG. 12, the openings 324 within the cap wall 330 can be at different distances from one another. In some applications (such as those of FIG. 6 and FIG.7), the openings 324 can be approximately 180 degrees from one another. In other examples, the openings 324 can be approximately 90 degrees from one another on the cap 320. The openings 324 can be any distance, either linearly or angularly, from one another The opening(s) 324 may determine the height and / or shape of the lid-facing structure 326.
[0064] Other embodiments of the cap 420 can include three openings 424 configured to direct electrical wires. For example, FIG. 13 shows a cap 420 having three openings 424. The three openings 424 can be equally spaced from one another; however, in other examples, the openings 424 can be at any distance, either linearly or angularly, from one another. The cap 420 can have one, two, three, four, five or more openings. In some embodiments, the openings 424 can be different sizes and / or heights within the cap 420. As discussed elsewhere herein, the openings 424 can determine the shape of the lid-facing structure 426, as well as in other embodiments.
[0065] FIG. 14 show s another embodiment of the cap 520, In some embodiments, the cap 520 can include a first cap piece 572 and a second cap piece 574. The first cap piece 572 can be at the conduit end 528 and the second cap piece 574 can be at the lid-facing end 526. The first and second cap pieces 572, 574 can be threadably connectable to one another. The first cap piece 572 can include a skirt structure 578 configured to receive the electrical conduit 514. The first cap piece 572 can include at least one opening 524 configured to receive at least one electrical wire (such as electrical wire 122 of FIG. 1).Attorney Docket No. 87924.136. WO U1
[0066] FIG. 15 shows the cap 520 of FIG. 14. The first cap piece 572 can include a skirt structure 578 and a threaded portion 576. In circular caps, the skirt structure 578 can have a larger diameter than the threaded portion 576 of the cap 520, and can increase in diameter. The skirt structure 578 can be larger than the threaded portion 576. The skirt structure 578 can include an opening 524 configured to receive at least one electrical wire (e g., electrical wire 122 of FIG. 1). The opening 524 may extend through the threaded portion 576. Some openings 524 may be at the threaded portion and / or a portion of the skirt structure 578 such that the opening 524 does not extend through the conduit end 128.
[0067] FIG. 16 and FIG. 17 (collectively discussed herein) each show the first cap piece 572 of the conduit cap 520. The wire openings 524 can be within the first cap piece 572. The threaded portion 576 can have a diameter and / or size configured to fit within the second cap piece 574. While not clearly shown in FIGS. 14 and 15, it is to be understood that this embodiment of the cap may include a lip or shoulder that is configured to rest on the conduit as previously described.
[0068] FIG. 18 shows a second cap piece 574 of a conduit cap 520. The second cap piece 574 can include a threaded surface 580 configured to receive the first cap piece 572. In some embodiments, the cap 520 can include a stopper 582. Additionally or alternatively, the cap 520 can include a seal manufactured from elastomer or plastic. The seal can be one piece or alternatively, the seal can be two or more pieces The stopper 582 can be disposed within the cap 520 such that, when in use, the stopper 582 positions the first cap piece 572 relative to the second cap piece 574. The first cap piece 572 can be threadably connected to the second cap piece 574. Unlike various versions of the previously discussed embodiments for the cap that may be purchased, this embodiment of the cap 520 may be manufactured from a commercially available fitting such as a bush fix, but not necessarily so. The second cap piece may have a hole in the top of it since it is made from the commercially available fitting. This may not be present in other embodiments.
[0069] A method 1900 of using the electrical conduit cap can include providing an electrical conduit cap (step 1905), as shown in FIG. 19. The electrical conduit cap can be any of the embodiments described herein. The method can include disposing the electrical conduit cap adjacent an electrical conduit (step 1910). The conduit cap can be disposed between the electrical conduit and the electrical box lid and over the wires. The method can include positioning an electrical w ire through an opening of the electrical conduit cap (step 1195). Some embodiments of the cap can have multiple openings. The method can include positioning multiple electrical wires through a plurality of openings in the cap.Attorney Docket No. 87924.136. WO U1
[0070] In some embodiments, the step of positioning an electrical wire through an opening of the electrical conduit cap adjacent an electrical conduit is performed at the same time as disposing the electrical conduit cap adjacent an electrical conduit. For example, this may be accomplished using the electrical conduit cap shown in FIGS. 4, 5, 6, and 7 allowing wires to pass through multiple openings simultaneously. This may ease retrofitting existing electrical boxes in the field when the wires have already been routed. The openings in such a case may take the form of a slot that extends all the way to the free end of the cap.
[0071] The conduit cap of FIGS 9, 12, and 13 may be able to allow the wires to pass through only a single opening (e.g., a slot that extends to the free end of the cap) when installing the cap while the other opening (e.g., a generally polygonal shaped opening such as rectangular or square that does not extend to the free end of the cap) may allow other wires to be routed only after the cap has been stalled. In other embodiments, the step of positioning an electrical wire through an opening of the electrical conduit cap adjacent an electrical conduit may be accomplished only after the cap has already been installed (e.g., all the openings do not extend to the free end of the cap). It is also possible that this may be accomplished with any of the aforementioned conduit caps. This is suitable when routing the wires on a new electrical box being installed in the field.
[0072] In some embodiments, the cap can be fastened to the electrical conduit. A clamp can be used to fasten the cap to the electrical conduit. The method can include clamping the cap to the electrical conduit (step 1920). The clamp can be fastened via a fastener associated with the clamp. Alternatively, the cap can be attached to the conduit using an adhesive, snaps, threads, pin in slot configurations, or any other fastener configured for use with the cap and electrical conduit.
[0073] Additionally or alternatively, the first cap piece can be positioned over the conduit, and the second cap piece can be attached thereto. The first cap piece skirt can be positioned over the conduit. The wires can be positioned within the opening(s) of the cap. The second cap piece can be attached to the first cap piece. In some embodiments, the second cap piece and first cap piece can be threadably connected to one another.
[0074] Example 1. An electrical box assembly, comprising an electrical box, comprising at least one box wall forming an electrical box cavity, each wall comprising a first end configured to be positioned within a ground surface; and a second end opposite the first end; and a lid disposed at the second end of the at least one box w all, the lid being configured to cover the electrical box cavity; an electrical conduit disposed within the electrical box cavity and comprising a wire channel; and a cap configured to receive the electrical conduit, the capAttorney Docket No. 87924.136. WO U1comprising a conduit end; a lid-facing end; a cap wall extending from the conduit end to the lid-facing end and forming the wire channel; and a first opening in the cap wall at the conduit end, the first opening being configured such that at least one electrical wire received by the electrical conduit exits the cap through the first opening, wherein the cap is disposed between the electrical conduit and the lid when in use.
[0075] Example 2. The assembly of claim 1, wherein the conduit end of the cap comprises a lip configured to contact the electrical conduit during use.
[0076] Example 3. The assembly of claim 2, wherein the cap comprises a seat, and wherein the assembly further comprises a clamp configured to fasten the cap to the electrical conduit at the seat.
[0077] Example 4. The assembly of claim 2, wherein the at least one lip comprises a first lip having a first diameter and a second lip having a second diameter, wherein the first diameter and the second diameter are different from one another.
[0078] Example 5. The assembly of claim 1, wherein the cap comprises a first cap piece and a second cap piece, the first cap piece and the second cap piece being threadably connectable to one another.
[0079] Example 6. The assembly of claim 1, wherein the lid-facing end is configured to interface with the lid of the electrical box such that the lid does not apply a pressure on the at least one electrical wire at a surface of the electrical conduit.
[0080] Example 7. The assembly of claim 1, wherein the cap wall further comprises a second opening, the second opening being configured such that at least a second electrical wire of the at least one electrical wire received by the electrical conduit exits the cap through the second opening.
[0081] Example 8. An electrical conduit cap, comprising a conduit end configured to be disposed adjacent an electrical conduit; a lid-facing end opposite the conduit end; a wall extending from the conduit end to the lid-facing end; and a first opening in the wall at the conduit end, the first opening being configured to receive a first electrical wire.
[0082] Example 9. The electrical conduit cap of claim 8, wherein the conduit end comprises a lip configured to interface with a surface of the electrical conduit.
[0083] Example 10. The electrical conduit cap of claim 9, further comprising a clamp configured to fasten the electrical conduit cap to the electrical conduit.
[0084] Example 11. The electrical conduit cap of claim 10, wherein the electrical conduit cap comprises a seat configured to receive the clamp.Attorney Docket No. 87924.136. WO U1
[0085] Example 12. The electrical conduit cap of claim 9, wherein the at least one lip comprises a first lip having a first diameter and a second lip having a second diameter, wherein the first diameter and the second diameter are different from one another
[0086] Example 13. The electrical conduit cap of claim 8, wherein the conduit end comprises a skirt structure configured to receive the electrical conduit.
[0087] Example 14. The electrical conduit cap of claim 8. wherein the conduit end comprises a first cap piece and the lid-facing end comprises a second cap piece, and wherein the first cap piece and the second cap piece are configured to be operably connected to one another.
[0088] Example 15. The electrical conduit cap of claim 9, further comprising a second opening in the wall at the conduit end.
[0089] Example 16. A method of using an electrical conduit cap, comprising providing an electrical conduit cap, the electrical conduit cap comprising a conduit end; a lid-facing end configured to be disposed adjacent an electrical conduit: a wall extending from the conduit end to the lid-facing end; and a first opening in the wall at the conduit end, the first opening being configured to receive a first electrical wire; disposing the electrical conduit cap adjacent the electrical conduit within an electrical box having a lid such that the electrical conduit cap is disposed between the electrical conduit and the lid; and positioning the first electrical wire through the first opening.
[0090] Example 17, The method of claim 16, wherein the wall comprises a skirt structure configured to receive the electrical conduit.
[0091] Example 18. The method of claim 17, wherein the electrical conduit cap comprises a first cap piece and a second cap piece, the first and second cap piece being configured to be threadably attachable to one another.
[0092] Example 19. The method of claim 18, wherein the electrical conduit cap comprises a lip and a clamp, and wherein disposing the electrical conduit cap over an electrical conduit comprises positioning the lip over the electrical conduit and clamping the electrical conduit cap.
[0093] Example 20. The method of claim 16, wherein the electrical conduit cap comprises a second opening configured to receive a second electrical wire, and wherein the method further comprises positioning the second electrical wire through the second opening.
[0094] Although the various examples have been described with reference to preferred implementations, persons skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope thereof.Attorney Docket No. 87924.136. WO U1
[0095] It is to be recognized that depending on the example, certain acts or events of any of the techniques described herein can be performed in a different sequence, may be added, merged, or left out altogether (e.g., not all described acts or events are necessary for the practice of the techniques). Moreover, in certain examples, acts or events may be performed concurrently, e.g., through multi -threaded processing, interrupt processing, or multiple processors, rather than sequentially.
[0096] While the various systems described above are separate implementations, any of the individual components, mechanisms, or devices, and related features and functionality, within the various system embodiments described in detail above can be incorporated into any of the other system embodiments herein.
[0097] The terms “about” and “substantially,” as used herein, refers to variation that can occur (including in numerical quantity or structure), for example, through typical measuring techniques and equipment, with respect to any quantifiable variable, including, but not limited to, mass, volume, time, distance, wave length, frequency, voltage, current, and electromagnetic field. Further, there is certain inadvertent error and variation in the real world that is likely through differences in the manufacture, source, or precision of the components used to make the various components or carry' out the methods and the like. The terms “about” and “substantially” also encompass these variations. Unless otherwise designated herein, the term “about” and “substantially” can include any variation of 5% or 10%. or any amount - including any integer - between 0% and 10%. Further, whether or not modified by the term “about” or “substantially,” the claims include equivalents to the quantities or amounts.
[0098] Numeric ranges recited within the specification are inclusive of the numbers defining the range and include each integer within the defined range. Throughout this disclosure, various aspects of this disclosure are presented in a range format. It should be understood that the description in range format is merely for convenience and brevity and should not be construed as an inflexible limitation on the scope of the disclosure. Accordingly, the description of a range should be considered to have specifically disclosed all the possible sub¬ ranges. fractions, and individual numerical values within that range For example, description of a range such as from 1 to 6 should be considered to have specifically disclosed sub-ranges such as from 1 to 3, from 1 to 4, from 1 to 5, from 2 to 4, from 2 to 6, from 3 to 6 etc., as well as individual numbers within that range, for example, 1, 2, 3, 4, 5, and 6, and decimals and fractions, for example. 1.2, 3.8, 1½, and 4¾ This applies regardless of the breadth of the range. Although the various embodiments have been described with referenceAttorney Docket No. 87924.136. WO U1to preferred implementations, persons skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope thereof.
[0099] Various examples of the disclosure have been described. Any combination of the described systems, operations, or functions is contemplated. These and other examples are within the scope of the following claims.
Claims
Attorney Docket No. 87924.
136. WO U1ClaimsWhat is claimed is:
1. An electrical box assembly, comprising:(a) an electrical box, comprising:(i) at least one box wall forming an electrical box cavity, each wall comprising:(A) a first end configured to be positioned within a ground surface; and(B) a second end opposite the first end; and(ii) a lid disposed at the second end of the at least one box wall, the lid being configured to cover the electrical box cavity;(b) an electrical conduit disposed within the electrical box cavity and comprising a wire channel; and(c) a cap configured to receive the electrical conduit, the cap comprising:(i) a conduit end;(ii) a lid-facing end;(iii) a cap wall extending from the conduit end to the lid-facing end and forming the wire channel, and(iv) a first opening in the cap wall at the conduit end, the first opening being configured such that at least one electrical wire received by the electrical conduit exits the cap through the first opening,wherein the cap is disposed between the electrical conduit and the lid.
2. The assembly of claim 1, wherein the conduit end of the cap comprises at least one lip configured to contact the electrical conduit during use.
3. The assembly of claim 2, wherein the cap compri ses a seat, and wherein the assembly further comprises a clamp configured to fasten the cap to the electrical conduit at the seat.
4. The assembly of claim 2, wherein the at least one lip comprises a first lip having a first diameter and a second lip having a second diameter, wherein the first diameter and the second diameter are different from one another.Attorney Docket No. 87924.
136. WO U15. The assembly of claim 1, wherein the cap comprises a first cap piece and a second cap piece, the first cap piece and the second cap piece being threadably connectable to one another.
6. The assembly of claim 1, wherein the lid-facing end is configured to interface with the lid of the electrical box such that the lid does not apply a pressure on the at least one electrical wire at a surface of the electrical conduit.
7. The assembly of claim 1, wherein the cap wall further comprises a second opening, the second opening being configured such that at least a second electrical wire of the at least one electrical wire received by the electrical conduit exits the cap through the second opening,8. An electrical conduit cap, comprising:(a) a conduit end configured to be disposed adjacent an electrical conduit: (b) a lid-facing end opposite the conduit end;(c) a wall extending from the conduit end to the lid-facing end; and (d) a first opening in the wall at the conduit end, the first opening being configured to receive a first electrical wire,9. The electrical conduit cap of claim 8, wherein the conduit end comprises at least one lip configured to interface with a surface of the electrical conduit.
10. The electrical conduit cap of claim 9, further comprising a clamp configured to fasten the electrical conduit cap to the electrical conduit.
11. The electrical conduit cap of claim 10, wherein the electrical conduit cap comprises a seat configured to receive the clamp.
12. The electrical conduit cap of claim 9, wherein the at least one lip comprises a first lip having a first diameter and a second lip having a second diameter, wherein the first diameter and the second diameter are different from one another.Attorney Docket No. 87924.
136. WO U113. The electrical conduit cap of claim 8, wherein the conduit end comprises a skirt structure configured to receive the electrical conduit.
14. The electrical conduit cap of claim 8, wherein the conduit end comprises a first cap piece and the lid-facing end comprises a second cap piece, and wherein the first cap piece and the second cap piece are configured to be operably connected to one another.
15. The electrical conduit cap of claim 8, further comprising a second opening in the wall at the conduit end.
16. A method of using an electrical conduit cap, comprising:providing an electrical conduit cap. the electrical conduit cap comprising: (a) a conduit end;(b) a lid-facing end configured to be disposed adjacent an electrical conduit;(c) a wall extending from the conduit end to the lid-facing end; and (d) a first opening in the wall at the conduit end, the first opening being configured to receive a first electrical wire;disposing the electrical conduit cap adjacent the electrical conduit within an electrical box having a lid such that the electrical conduit cap is disposed between the electrical conduit and the lid; andpositioning the first electrical wire through the first opening.
17. The method of claim 16, wherein the wall comprises a skirt structure configured to receive the electrical conduit.
18. The method of claim 17, wherein the electrical conduit cap comprises a first cap piece and a second cap piece, the first cap piece and the second cap piece being configured to be threadably attachable to one another.
19. The method of claim 16, wherein the electrical conduit cap comprises a lip and a clamp, and wherein disposing the electrical conduit cap over an electrical conduit comprises positioning the lip over the electrical conduit and clamping the electrical conduit cap.Attorney Docket No. 87924.
136. WO U120. The method of claim 16, wherein the electrical conduit cap comprises a second opening configured to receive a second electrical wire, and wherein the method further comprises positioning the second electrical wire through the second opening.