AU2021221417A1 - Wall box conduit connection system and method - Google Patents

Abstract

Disclosed is an electrical wall box for receiving at least one conduit, the wall box comprising: a base for mounting to a surface; and a cover for covering at least a portion of the base; wherein the base comprises at least one base conduit entry for receiving the at least one conduit, the base conduit entry comprising a removable base conduit entry cover for covering the base conduit entry; and wherein, the cover comprises at least one cover conduit entry for also receiving the at least one conduit when the cover is covering the at least a portion of the base. Also disclosed are a base, a base conduit entry insert and a method of connecting a conduit to an electrical wall box. 3/15 -/"200 281 280 Fig. 4 - "200 200 281..... . ,280 280 K~mI~~281 Fig. 5A Fig. 5B

Description

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WALL BOX CONDUIT CONNECTION SYSTEM AND METHOD TECHNICAL FIELD

[0001] The present application relates to electrical housings, and in particular, electrical housings for receiving one or more conduits.

INCORPORATION BY REFERENCE

[0002] The entire content of each of the following Australian Provisional Patent Applications filed on 25 September 2020:

- "Wall Box Cable Connection" No. 2020903469

- "Wall Box With Socket Cover" No. 2020903468

- "Electrical Wall Box and Cover" No. 2020903464

is hereby incorporated by reference.

PRIORITY

[0003] This application claims priority from Australian Provisional Patent Application No 2020903465 entitled "Wall Box Conduit Connection System and Method" filed on September 2020. The entire content of this Provisional Patent Application is hereby incorporated by reference.

BACKGROUND

[0004] In the electrical industry, it is often necessary to provide electrical power to one or more components housed within a housing. In such cases, the housing requires an entry through which a conduit carrying electrically-conductive wires can be passed to allow the electrical wires to be connected to the components therein.

[0005] A particular example of such a scenario is in the use of mounting blocks to provide a power socket/outlet at a new location. In such situations, the power-carrying wires are provided from a power source such as mains or supply power (e.g. from a wall outlet) encased in a non conductive conduit, and directed towards a mounting block which is an electrical housing which can be mounted to a new surface (e.g. within a cupboard). The conduit is received within the mounting block through a conduit entry and the wires connected to respective terminals of the socket, before the socket plate is mounted to the mounting block.

SUMMARY

[0006] According to a first aspect, there is provided an electrical wall box for receiving at least one conduit, the wall box comprising: a base for mounting to a surface; and a cover for covering at least a portion of the base; wherein the base comprises at least one base conduit entry for receiving the at least one conduit, the base conduit entry comprising a removable base conduit entry cover for covering the base conduit entry; and wherein, the cover comprises at least one cover conduit entry for also receiving the at least one conduit when the cover is covering the at least a portion of the base.

[0007] According to a second aspect, there is provided a base for an electrical wall box, the base comprising at least one base conduit entry for receiving at least one conduit, the base conduit entry comprising a removable base conduit entry cover for covering the base conduit entry, and the base conduit entry also for receiving a base conduit entry insert when the base conduit entry cover is removed, for engaging with at least a portion of a cover conduit entry of a cover for covering at least a portion of the base.

[0008] According to a third aspect, there is provided a cover for an electrical wall box, the cover comprising at least one cover conduit entry cover that is able to be removed to expose the cover conduit entry.

[0009] According to a fourth aspect, there is provided a base conduit entry insert for covering the at least one base conduit entry of the base of the second aspect, the base conduit entry insert comprising: a body; an aperture for receiving the conduit; and a base conduit entry connector for connecting to the base conduit entry.

[0010] According to a fifth aspect, there is provided a method of connecting a conduit to an electrical wall box, the method comprising: removing a, or part of a, base conduit entry cover from a base conduit entry of a base of the electrical wall box; inserting a base conduit entry insert into or over the base conduit entry; and inserting the conduit into the base conduit entry via an aperture in the base conduit entry insert.

BRIEF DESCRIPTION OF DRAWINGS

[0011] Embodiments of the various aspects described herein will be detailed with reference to the accompanying drawings in which:

[0012] Figure 1 - shows an example of an electrical device, such as a wall box, comprising a cover and a base according to some aspects;

[0013] Figure 2 - shows a side view of the wall box of Figure 1 with the cover connected to the base;

[0014] Figure 3A - shows a side view of the base of the wall box of Figure 1 showing a base conduit entry cover being removed according to one embodiment;

[0015] Figure 3B - shows a side view of the base of the wall box of Figure 1 showing a base conduit entry cover being removed according to another embodiment;

[0016] Figure 4 -shows aside view ofthe cover of the wallbox of Figure 1 withthe cover conduit entry cover;

[0017] Figure 5A- shows aside view of the cover of Figure 4 showing the cover conduit entry cover being removed according to one embodiment;

[0018] Figure 5B - shows a side view of the cover of Figure 4 showing the cover conduit entry cover being removed according to another embodiment;

[0019] Figure 6 - shows a side view of the base of the wall box of Figure 3A with the base conduit entry insert in place;

[0020] Figure 7A - shows an underside view of the wall box with base and cover showing the engagement of the cover with the base conduit entry insert according to one embodiment;

[0021] Figure 7B- shows an underside view of the wall box with base and cover showing the engagement of the cover with the base conduit entry insert according to another embodiment;

[0022] Figure 8A - shows a front perspective view of a general embodiment of a base unit according to one aspect described herein;

[0023] Figure 8B - shows a rear view of the base unit of Figure 8A;

[0024] Figure 9 - shows a side view of an electrical system with base and cover according to an aspect described herein;

[0025] Figure 1OA- shows an embodiment of abase unit or grid plate according to an aspect described herein;

[0026] Figure 1OB- shows an embodiment of a cover unit or faceplate according to an aspect described herein;

[0027] Figure 11- shows an example of the base unit or gridplate for Figure 10A and exchangeable cover units or face plates according to an aspect described herein;

[0028] Figure 12 - shows an embodiment of an electrical device, in the form of a wall box, according to another aspect;

[0029] Figure 13- shows an embodiment of the base of the wall box of Figure 10;

[0030] Figure 14 - shows an underside view of the base of Figure 13;

[0031] Figure 15 - shows an embodiment of the base of Figure 13 in which the base is made up of a base part and a frame or grid;

[0032] Figure 16 - shows an example of a base conduit entry insert according to one embodiment;

[0033] Figure 17 - shows an embodiment of a cover for use with the base of Figure 13;

[0034] Figure 18A - shows a close up view of the base of Figure 15 with the base conduit entry covers in place;

[0035] Figure 18B - shows a view of the cover of Figure 17 with a cover conduit entry cover removed to expose the cover conduit entry;

[0036] Figure 18C - shows the base of Figure 18A with one of the base conduit entry covers removed;

[0037] Figure 18D - shows the base of Figure 18C with a base conduit entry insert in place;

[0038] Figure 18E - shows the base of Figure 18D with a conduit inserted into the aperture of the base conduit entry insert;

[0039] Figure 18F - shows a close up of the wall box with the cover of Figure 18B covering the base of Figure 18E;

[0040] Figure 19 - shows an example of a base with a base conduit entry cover according to another embodiment;

[0041] Figure 20 - shows an exploded view of the base of Figure 19;

[0042] Figure 21 shows an example of a base conduit entry insert according to another embodiment;

[0043] Figure 22A - shows a close up top perspective view of the base part of Figure 19 with the base conduit entry covers in place;

[0044] Figure 22B - shows a view of the cover of Figure 17 with a cover conduit entry cover removed to expose the cover conduit entry;

[0045] Figure 22C - shows the base part of Figure 22A with a portion of one of the base conduit entry cover removed to provide a formed base conduit entry;

[0046] Figure 22D - shows the base part of Figure 22C with a base conduit entry insert in place;

[0047] Figure 22E - shows the base part of Figure 22D with the conduit in place;

[0048] Figure 22F - shows a close up of the wall box with the cover of Figure 22B covering the base of Figure 22E;

[0049] Figure 23 - shows an example of a base with a base conduit entry cover according to another embodiment in which the entire base conduit entry cover is overmolded over the base conduit entry;

[0050] Figure 24 - shows an exploded view of the base of Figure 23;

[0051] Figure 25A- shows a close up top perspective view of the base part of Figure 24 with the base conduit entry cover in place;

[0052] Figure 25B - shows a view of the cover of Figure 17 with a cover conduit entry cover removed to expose the cover conduit entry;

[0053] Figure 25C - shows the base part of Figure 25A with a portion of the base conduit entry cover removed to provide a formed base conduit entry;

[0054] Figure 25D - shows the base part of Figure 25C with a base conduit entry insert in place;

[0055] Figure 25E - shows the base part of Figure 25D with the conduit in place;

[0056] Figure 25F - shows a close up of the wall box with the cover of Figure 25B covering the base of Figure 25E;

[0057] Figure 26A - shows a flowchart of a method of connecting a conduit to a base of an electrical wall box according to one aspect; and

[0058] Figure 26B - shows a flowchart of additional steps of the method of Figure 26A.

DESCRIPTION OF EMBODIMENTS

[0059] Figure 1 shows an embodiment of an electrical device 300 to which aspects described herein may be applied. In some embodiments, electrical device 300 is a wall box. In some aspects, the wall box 300 comprises a base 100 and a cover 200 which in use, is slid over the base 100 to enclose the arrangement. As will be understood by the person skilled in the art, wall box 300 is used to receive one or more conduits (not shown in this view) to connect one or more terminals of the wall box 300 to a source of electrical power.

[0060] Figure 1 also shows the provision of a base conduit entry 180 on base 100 for receiving a conduit 400 (not shown in this view). In some embodiments, such as shown in Figure 1, base conduit entry 180 is covered by a removable base conduit entry cover 181.

[0061] Figure 1 also shows a corresponding cover conduit entry 280 on cover 200 for receiving the conduit 400 when the cover 200 is covering the base 100, as shown in Figure 2.

[0062] In a broad aspect then, there is provided an electrical wall box for receiving at least one conduit, the wall box comprising: a base for mounting to a surface; and a cover for covering at least a portion of the base; wherein the base comprises at least one base conduit entry for receiving the at least one conduit, the base conduit entry comprising a removable base conduit entry cover for covering the base conduit entry; and wherein, the cover comprises at least one cover conduit entry for also receiving the at least one conduit when the cover is covering the at least a portion of the base.

[0063] Figure 3A shows an embodiment of base 100 with base conduit entry 180 with the base conduit entry cover 181being removed. In the embodiment shown in Figure 3A, base conduit entry cover 181 is removed by sliding it out of base conduit entry 180. In some embodiments of this aspect, base conduit entry cover 181 may be replaced by sliding it back in when desired.

[0064] In another embodiment, as shown in Figure 3B, base conduit entry cover 181 is only partially removed by removing a part or portion 181' of base conduit entry cover 181. In some embodiments, this is accomplished by having the part 181' of base conduit entry cover 181 being a frangible portion that is able to be torn, pulled, or otherwise separated from the remainder of base conduit entry cover 181.

[0065] In a broad aspect then, there is provided a base for an electrical wall box, the base comprising at least one base conduit entry for receiving at least one conduit, the base conduit entry comprising a removable base conduit entry cover for covering the base conduit entry, and the base conduit entry also for receiving a base conduit entry insert when the base conduit entry cover is removed, for engaging with at least a portion of a cover conduit entry of a cover for covering at least a portion of the base.

[0066] Figure 4 shows an embodiment of cover 200 with cover conduit entry 280 covered by cover conduit entry cover 281.

[0067] Figure 5A shows an embodiment in which cover conduit entry cover 281 is removed from cover conduit entry 280 by sliding out and may be replaced again as required.

[0068] In other embodiments, cover conduit entry cover 281 is removed from cover conduit entry 280 by tearing, cutting or otherwise separating from the cover 200, as will be understood by the person skilled in the art.

[0069] Figure 6 shows an embodiment of base 100 with a base conduit entry insert 182 inserted into the exposed base conduit entry 180 after having removed the, or part of the, base conduit entry cover 181 as previously described. Base conduit entry insert 182 comprises an aperture 182a, which provides a formed base conduit entry for receiving the conduit as will be described in more detail below.

[0070] In some embodiments, the aperture 182a is sized so as to provide a tight fit around the conduit 400 so as to reduce the instance of moisture and/or dust ingress from the environment in which the wall box 300 is installed. It will be appreciated that, in some applications, the environments in which the wall boxes are installed may increase the chances of moisture and/or dust ingress into the wall box, which can affect the integrity of the wall box components and electrical connections over time.

[0071] In some embodiments, the base conduit entry insert 182 is made of, or partly of, a soft or resilient material such as a rubber, which can further enhance the sealing of the engagement with the conduit 400. Any suitable material can be used including thermoplastic elastomer (TPE).

[0072] In other embodiments, aperture 182a need not be in tight engagement with the periphery of the conduit 400, with the arrangement described merely providing a convenient method of providing a conduit entry point into the wall box.

[0073] Figure 7A shows a bottom representational view of the wall box 300 formed by the base 100 of Figure 6 and the cover 200 of Figures 5A or 5B connected thereto. In this embodiment, it can be seen that the edge of the cover conduit entry 280 simply abuts against a surface of the base conduit entry insert 182. In another embodiment, as shown in Figure 7B, it can be seen that the edge of the cover conduit entry 280 is received within a recess of the base conduit entry insert 182, to provide for a tighter and more highly-sealed engagement.

[0074] This arrangement also covers any jagged or rough edges of the cover conduit entry that may be left after tearing, cutting or otherwise separating the cover conduit entry cover from the cover to expose the cover conduit entry.

[0075] A general embodiment of electrical device 300, of which a wall box is one embodiment will now be described with reference to Figures 8A to 11.

[0076] Figure 8A shows a front perspective view of a general embodiment of a base or base unit 100 and Figure 8B shows a rear perspective view of the base unit 100 of Figure 8A. In one aspect, the base unit 100 comprises a mounting region 110 for mounting the base unit 100 to the surface. In some embodiments, the surface is a wall. In some other embodiments, the surface is a floor. In some other embodiments, the surface is a wall of a box or other enclosure. In other embodiments, the surface is a frame for supporting the base unit.

[0077] In some embodiments, the mounting region 110 is itself a surface which will come into contact with the surface to which the base unit 100 is to be mounted. In other embodiments, the mounting region 110 is a pin, tab or other connector.

[0078] As shown in Figure 8A, base unit 100 also comprises a base connector 120 for connecting the base unit to a cover unit 200 as will be described in more detail below. The base connector is shown generically in Figure 8A but can take on any form that allows connection of the cover unit to the base unit 100. Such forms include a recess for receiving a protrusion from the cover unit, a protrusion for being received in a corresponding recess in the cover unit, a clipping arrangement, or a magnet for attracting and retaining a region of the cover unit. In other embodiments, the base connector is an adhesive, or a loop-hook connector such as a product sold under the trade mark Velcro@ by Velcro Industries B.V. In this embodiment, base connector 120 can be either the loop component of the connector or the hook component.

[0079] Base unit 100 also comprises abase supply power input 130 for electrically connecting the base unit 100 to a supply or mains power supply (see Figure 8A). In some countries, the mains, or supply power, is provided as an alternating current (AC) electrical signal of about 240V (for example between about 220V and 260V) and about 50Hz frequency. In other countries, mains or supply power is provided as an AC signal of between about 100V and 130V. Some systems use a frequency of about 50Hz while others use a frequency of about 60Hz. Some supply power systems are single phase and others may be three-phase. It will be understood that any electrical power that would be considered to be supply or mains power can be used.

[0080] In some embodiments, base unit 100 will also comprise abase power output 150 (see Figure 8A) for providing output power to the cover unit 200 when cover unit 200 is connected to base unit 100.

[0081] Base power output 150 can be provided by any suitable means including a direct plug/socket arrangement with a recess provided in base unit 100 leading to conductive elements which make electrical connection with a corresponding electrically conductive element of a cover unit power input 210 (see below), or can be provided by a radiating element that transfers power from base unit 100 to cover unit 200 by induction or other means. An example of this embodiment is described in more detail below. Any other form of power transfer can also be used.

[0082] In some embodiments, base power output 150 and base connector 120 can be provided by the same element. In one such embodiment, the connection of cover power input to the base power output 150 will also provide sufficient support to retain cover unit 200 to base unit 100 without a further additional base connector 120 or other connection arrangement.

[0083] In some embodiments, base unit 100 will also comprise a power converter 140 which converts the supply input power received at the base supply power 130 input to the output power provided by the base power output 150 to provide useable power to the cover unit 200 when in use.

[0084] In some embodiments, the base power output will be shielded or otherwise protected so that no electrically-live element is easily accessible by a user when the base unit 100 is installed. In some embodiments, the default state of the base power output is to an OFF state and is electrically isolated from the mains or supply power, and/or from the output of the power converter 140. In such an embodiment, only when the cover unit 200 is in place will the base power outlet be electrically connected to the mains or supply power and/or the output of the power converter 140.

[0085] Figure 9 shows an embodiment of base unit 100 and cover unit 200 connected together, with base unit 100 mounted to a surface 40 (e.g. a wall), and mains or source power 50 connected to the base supply power 130 input.

[0086] In other embodiments, base unit 100 also comprises a base switch interface 160 for interfacing with a switch element of the cover unit 200, to allow actuation of a switch on the cover unit 200 to be effected on the base unit 100. Figure 1OA shows a base unit 100 with base switch interface 160. In some embodiments, base switch interface 160 is an electrical interface such as a radio frequency (RF) receiver for receiving RF signals from a switch on the cover unit 200 (Figure 10B) when actuated. In some embodiments, base switch interface 160 is an infrared (IR) receiver for receiving IR signals from a switch of cover unit 200. In other embodiments, base switch interface 160 is a component of a touch switch which actuates upon a user touching or near-touching a corresponding switch element on the cover unit 200. An example of such a touch switch arrangement is described in PCT Patent Application No. PCT/AU2011/001675 (published as WO 2012/083380) entitled "Touch Switch" incorporated by reference in its entirety.

[0087] In other embodiments, base switch interface 160 is a mechanical interface for engaging with a switch element or a cover switch interface of cover unit 200 as is described in more detail in Australian Patent Application No. 2015275225 hereby incorporated by reference.

[0088] Figure 10A shows a general representation of the components of an embodiment of a switch assembly, connected to base unit 100 according to one aspect. Broadly, in this aspect, switch assembly 500 comprises two sub-assemblies, being base unit switch part 510 and operational part 1200. As shown in Figure 1OA, base unit switch part 510 comprises a functional part 1000 and a base switch interface 160. Operational part 1200 is for actuation by a user and for controlling the functional part 1000, via the base switch interface 160, for interfacing the functional part 1000 and the operational part 1200.

[0089] It will be noted that the operational part 1200 is not fixed to the base switch interface 160 or the functional part 1000 and is able to move freely with respect thereto as discussed in more detail in Australian Patent Application No. 2015275225 previously referred to, as well as Australian Patent Application No. 2015275227 entitled "Switch Assembly, System and Method", Australian Patent Application No. 2015275234 entitled "Push Button Switch Assembly, and Operational Part"; and Australian Patent Application No. 2015275233 entitled "Switch Assembly with Rotatable Operational Part", all incorporated by reference.

[0090] It will be understood that there can be any combination of different operational parts 1200 and plates or cover units 200. For example, a switch assembly 500 with a small dolly 1201B might be converted to a switch assembly with a big dolly 1201B by replacing the operational part 1200 with a small dolly as described above. In another example, a switch assembly with a round push-button switch might be converted to a switch assembly with a square push-button/rocker switch by changing the operational part and the plate. In another combination, as shown in Figure 11, the appearance of system 300 may be changed completely by changing the existing plate or cover unit 200 with a plate or cover unit 200' of a different type. In one embodiment, the user interface 1201 can be used, or a different user interface 1201 can be used. In the example of Figure 11, the switch interface 1201 is changed from a round dolly 1201B to a square dolly 1201B'.

[0091] Figure 12 shows an embodiment of electrical device 300 as a wall box 300, with cover 200 and switches 1201B and sockets 111.

[0092] Figure 13 shows an embodiment of the base 100 in which the base 100 comprises a base part 110 for mounting to a surface, and a frame or grid 155. In these embodiments, the frame or grid 155 supports the sockets 111 and switch interfaces 160 previously described with reference to Figure 10A for example. In other embodiments, the base 100 is provided as a unitary piece.

[0093] Also shown in Figure 13 is a plurality of base conduit entry covers 181 (three visible in this view - one on the side and two at the top). It will be appreciated that the base 100 can have at least one base conduit entry cover 181, including 1, 2, 3, 4, 5, 6, 7, 8, 9, and 10 or more.

[0094] Figure 14 shows the two top base conduit entry covers 181.

[0095] Figure 15 shows an exploded view of base 100, in this embodiment, comprising base part 110, frame or grid 155, and six base conduit entry covers 181 which, in this embodiment, comprise plastic tabs that are able to be slid in and out of respective base conduit entries 180. In some embodiments, a rubber seal may be overmolded over these pieces to enhance sealing between the base conduit entry covers 181 and the base conduit entry 180 when in place. Any suitable material may be used for the conduit entry cover, including polycarbonate. Any suitable material may be used for the overmoulded seal, including thermoplastic elastomer.

[0096] In practice, this allows a base conduit entry 180 to be created in one or more of a range of areas on the base 100 to suit the particular application and environment, and may allow 1, 2, 3, 4, 5, 6, 7, 8, 9 and 10 or more conduits to be connected, as may be required.

[0097] As previously described, once a base conduit entry cover 181 is removed, a base conduit entry insert 182 can be inserted into the space created in the base conduit entry 180 to provide a formed base conduit entry via the aperture 182a for receiving the conduit 400.

[0098] Figure 16 shows an embodiment of a base conduit entry insert 182, comprising a body; and an aperture 182a (providing the formed base conduit entry within the base conduit entry 180). In some embodiments, base conduit entry insert 182 also comprises a base connector 182b, which in some embodiments, is a recess in the body of the base conduit entry insert 182. The function of the base connector 182b is to engage with the base 100 and, in some embodiments, the cover 200 the wall box 300 as previously described with reference to Figures 7A and 7B.

[0099] Figure 17 shows an embodiment of cover 200 for covering base 100.

[00100] Figures 18A to 18F show an example of steps in connecting a conduit 400 to a wall box 300 according to one aspect. Figure 18A shows the base 100 with two base conduit entry covers 181. In Figure 18B, which shows a part of cover 200, it can be seen that a portion, being cover conduit entry cover 281 of cover 200, has been removed to provide cover conduit entry 280. In Figure 18C, one of the base conduit entry covers 181 has been removed from its respective base conduit entry 180. In Figure 18D, base conduit entry insert 182 is slid into base conduit entry 180 with aperture 182a, to provide a formed base conduit entry. In Figure 18E, conduit 400 has been inserted into the aperture/formed base conduit entry 182a to provide, in some embodiments, a sealed engagement with the periphery of the conduit 400. In Figure 18F, cover 200 is slid over base 100 to cover the base and form wall box 300, with conduit 400 connected thereto. It will be appreciated that, in some embodiments, the cover conduit entry 280 exposed in the step of Figure 18B, comes into engagement with a part of the base conduit entry insert 182 to provide, in some embodiments, a sealing engagement, providing further protection against ingress of moisture and/or dust as previously described with reference to Figures 7A and 7B.

[00101] It will be appreciated that, in some embodiments, cover 200 is provided with at least one cover conduit entry 280, including 1, 2, 3, 4, 5, 6, 7, 8, 9 or 10 or more, to provide cover conduit entries 280 to align with corresponding base conduit entries 180 of the base 100. One or more, including all of the cover conduit entries 280, may be covered by corresponding removable cover conduit entry covers 281 as previously described.

[00102] Figure 19 shows an example of a base 100 according to another aspect, in which base conduit entry covers 181 are provided by base conduit entry covers that themselves have a removable portion 181' which may be frangibly connected thereto. In these embodiments, base conduit entry cover 181 may be slid into the respective base conduit entry 180, and may be stuck in place such as by adhering, bonding or otherwise attaching to, base 100. In some embodiments, the base conduit entry cover 181 of these embodiments may be left removable to slide out at a later time as desired.

[00103] Figure 20 shows an exploded view of base 100, in this embodiment, comprising base part 110, frame or grid 155, and six base conduit entry covers 181 which, in this embodiment, comprise rubber tabs that are able to be slid in and out of respective base conduit entries 180. In these embodiments, base conduit entry covers 181 comprise the removable portions 181'.

[00104] In practice, this allows a base conduit entry 180 to be created in one or more of a range of areas on the base 100 to suit the particular application and environment, and may allow 1, 2, 3, 4, 5, 6, 7, 8, 9 and 10 or more conduits to be connected, as may be required.

[00105] Once a removable portion 181' of a base conduit entry cover 181 is removed, a base conduit entry insert 182 can be inserted into the space created in the base conduit entry cover 181 to provide a formed base conduit entry 182a for receiving the conduit 400.

[00106] Figure 21 shows an embodiment of a base conduit entry insert 182 which, in these embodiments, comprises a body; and an aperture 182a (providing the formed base conduit entry within the base conduit entry 180). In some embodiments, base conduit entry insert 182 also comprises a base connector 182b which, in some embodiments, forms a plug for allowing the base conduit entry insert to be pushed or plugged into the hole formed in the base conduit entry cover 181 when the removable portion 181' is removed.

[00107] Figures 22A to 22F show an example of steps in connecting a conduit 400 to a wall box 300 according to these embodiments. Figure 22A shows the base 100 with two base conduit entry covers 181. In Figure 22B, which shows a part of cover 200, it can be seen that a portion, being cover conduit entry cover 281 of cover 200, has been removed to provide cover conduit entry 280. In Figure 22C, the removable portion 181' of one of the base conduit entry covers 181 has been removed from its respective base conduit entry 180. In Figure 22D, base conduit entry insert 182 of Figure 21 is plugged or pushed into the remaining part of base conduit entry cover 181, with aperture 182a, providing a formed base conduit entry. In Figure 22E, conduit 400 has been inserted into the aperture/formed base conduit entry 182a to provide, in some embodiments, a sealed engagement with the periphery of the conduit 400. In Figure 22F, cover 200 is slid over base 100 to cover the base and form wall box 300, with conduit 400 connected thereto. It will be appreciated that, in some embodiments, the cover conduit entry 280 exposed in the step of Figure

22B, comes into engagement with a part of the base conduit entry insert 182 to provide, in some embodiments, a sealing engagement, providing further protection against ingress of moisture and/or dust.

[00108] Figure 23 shows an example of a base 100 according to another embodiment, in which base conduit entry covers 181 are provided by base conduit entry covers that have been overmolded over base conduit entry 180 and that themselves have a removable portion 181' which may be frangibly connected thereto as described in relation to the embodiments of Figures 19 to 22F.

[00109] Figure 24 shows an exploded view of base 100, in this embodiment, comprising base part 110, frame or grid 155, and various overmolded base conduit entry covers 181 which, in this embodiment, comprise rubber sheets overmolded over base conduit entries 180. In these embodiments, base conduit entry covers 181 comprise the removable portions 181'.

[00110] In practice, this allows a base conduit entry 180 to be created in one or more of a range of areas on the base 100 to suit the particular application and environment, and may allow 1, 2, 3, 4, 5, 6, 7, 8, 9 and 10 or more conduits to be connected, as may be required.

[00111] Once a removable portion 181' of a base conduit entry cover 181 is removed, a base conduit entry insert 182 can be inserted into the space created in the base conduit entry cover 181 to provide a formed base conduit entry 182a for receiving the conduit 400.

[00112] The base conduit entry insert 182 of Figure 21 may be used in these embodiments.

[00113] Figures 25A to 25F show an example of steps in connecting a conduit 400 to a wall box 300 according to these embodiments. Figure 25A shows the base 100 with base conduit entry cover 181, which itself has two removable portions 181'. In Figure 25B, which shows a part of cover 200, it can be seen that a portion, being cover conduit entry cover 281 of cover 200, has been removed to provide cover conduit entry 280. In Figure 25C, one of the removable portions 181' of one of the base conduit entry cover 181 has been removed from its respective base conduit entry 180. In Figure 25D, base conduit entry insert 182 of Figure 21 is plugged or pushed into the remaining part of base conduit entry cover 181, with aperture 182a, providing a formed base conduit entry. In Figure 22E, conduit 400 has been inserted into the aperture/formed base conduit entry 182a to provide, in some embodiments, a sealed engagement with the periphery of the conduit 400. In Figure 22F, cover 200 is slid over base 100 to cover the base and form wall box 300, with conduit 400 connected thereto. It will be appreciated that, in some embodiments, the cover conduit entry 280 exposed in the step of Figure 22B, comes into engagement with a part of the base conduit entry insert 182 to provide, in some embodiments, a sealing engagement, providing further protection against ingress of moisture and/or dust.

[00114] It will be appreciated that some of the various steps described above for the different embodiments may be carried out in different orders, and some omitted entirely. For example, in some embodiments, a method of connecting a conduit to a wall box may in fact be a method of connecting a conduit to a base of a wall box, and that method may be provided by carrying out the steps of Figures 25A, 25C, 25D and 25E only.

[00115] In other aspects, the steps of Figures 25B and 25F relating to the cover can be performed separately if at all. Similarly with the embodiments of Figures 18A-18F and Figure 22A- 22F.

[00116] Figure 26A shows a flowchart of steps according to one embodiment, of connecting a conduit 400 to an electrical wall box 300. In step 600, the base conduit entry cover 181, or a part 181' of the base conduit entry cover, is removed from the base conduit entry 180 of the base 100, as previously described.

[00117] In step 601, the base conduit entry insert 182 is inserted into or over the base conduit entry 180.

[00118] In step 602, the conduit 400 is inserted into the base through the base conduit entry 180 via the aperture 182a of the base conduit entry insert 182.

[00119] As will be understood by the person skilled in the art, the electrical conductors within the conduit 400 can then be electrically connected to respective terminals of the wall box 300, to provide electrical power to the sockets 111, with the other end of the electrical conductors of the conduit 400 being connected to a source of electrical power such as mains or supply power.

[00120] It will be understood that the term "connecting a conduit to a wall box" and the like does not necessarily require the connection of the electrical conductors to the terminals of the wall box, but merely requires the inserting of the conduit through the aperture of the base conduit entry insert to thereby retain the conduit to the wall box. The connection of the electrical conductors to the terminals is an optional step that may be carried out as a separate action at a later time.

[00121] In a broad aspect then, there is provided a method of connecting a conduit 400 to an electrical wall box 300, the method comprising: removing a, or part of a, base conduit entry cover 181 from a base conduit entry 180 of a base 100 of the electrical wall box 300; inserting a base conduit entry insert 182 into or over the base conduit entry 180; and inserting the conduit 400 into the base conduit entry 180 via an aperture 182a in the base conduit entry insert 182.

[00122] In some embodiments, the step of removing the base conduit entry cover 181 comprises sliding out the base conduit entry cover 181 from the base conduit entry 180.

[00123] In some embodiments, the step of removing a part of the base conduit entry cover 181 comprises tearing away a portion 181' of the base conduit entry cover 181.

[00124] A method of connecting a conduit to an electrical wall box as claimed in any one of claims 19 and 20, wherein the step of removing a part of the base conduit entry cover comprises tearing away a portion of the base conduit entry cover.

[00125] In a further aspect of connecting the conduit 400 to the wall box 300, the method further comprises removing a cover conduit cover 281 from a cover conduit entry 280 of a cover 200; and covering at least a portion of the base 100 with the cover 200 such that at least a portion of the cover conduit entry 280 engages with the base conduit entry insert 182.

[00126] It will be appreciated that the wall box 300 may be of a wide range of configurations. In some embodiments, the wall box 300 need not have any sockets 111, and may simply have one or more switches. In some embodiments, wall box 300 may only have one socket and no switches. According to some aspects as previously described with reference to Figures 8A to 11, these various embodiments may be provided simply by replacing the cover 200 according to a required configuration.

[00127] Throughout the specification and the claims that follow, unless the context requires otherwise, the words "comprise" and "include" and variations such as "comprising" and "including" will be understood to imply the inclusion of a stated integer or group of integers, but not the exclusion of any other integer or group of integers.

[00128] The reference to any prior art in this specification is not, and should not be taken as, an acknowledgement of any form of suggestion that such prior art forms part of the common general knowledge.

[00129] It will be appreciated by those skilled in the art that the invention is not restricted in its use to the particular application described. Neither is the present invention restricted in its preferred embodiment with regard to the particular elements and/or features described or depicted herein. It will be appreciated that the invention is not limited to the embodiment or embodiments disclosed, but is capable of numerous rearrangements, modifications and substitutions without departing from the scope of the invention as set forth and defined by the following claims.

Claims (22)

1. An electrical wall box for receiving at least one conduit, the wall box comprising: a base for mounting to a surface; and a cover for covering at least a portion of the base; wherein the base comprises at least one base conduit entry for receiving the at least one conduit, the base conduit entry comprising a removable base conduit entry cover for covering the base conduit entry; and wherein, the cover comprises at least one cover conduit entry for also receiving the at least one conduit when the cover is covering the at least a portion of the base.

2. An electrical wall box as claimed in claim 1 wherein the base conduit entry cover is provided by a removable base conduit entry insert inserted into the base conduit entry.

3. An electrical wall box as claimed in claim 1 wherein the base conduit entry cover is provided by a frangible portion.

4. An electrical wall box as claimed in claim 3 wherein the frangible portion is overmolded over the base conduit entry.

5. An electrical wall box as claimed in any one of claims 1 to 4 wherein the cover conduit entry is covered by a removable conduit entry cover.

6. An electrical wall box as claimed in claim 5 wherein the cover conduit entry cover is provided by a removable cover conduit entry insert.

7. An electrical wall box as claimed in claim 5 wherein the cover conduit entry cover is provided by a frangible portion.

8. An electrical wall box as claimed in any one of clams I to 7 wherein an edge of the cover is received within a corresponding recess of the base conduit entry insert when the cover is covering the at least a portion of the base.

9. A base for an electrical wall box, the base comprising at least one base conduit entry for receiving at least one conduit, the base conduit entry comprising a removable base conduit entry cover for covering the base conduit entry, and the base conduit entry also for receiving a base conduit entry insert when the base conduit entry cover is removed, for engaging with at least a portion of a cover conduit entry of a cover for covering at least a portion of the base.

10. A base as claimed in claim 9 comprising the base conduit entry insert inserted into the base conduit entry when the base conduit entry cover is removed, the base conduit entry insert comprising: a body, an aperture for receiving the conduit; and a base conduit entry connector for connecting to the base conduit entry.

11. A base as claimed in claim 10 wherein the base conduit entry insert further comprises a cover connector for engaging with a portion of the cover.

12. A cover for an electrical wall box, the cover comprising at least one cover conduit entry cover that is able to be removed to expose the cover conduit entry.

13. A cover as claimed in claim 12 wherein the cover conduit entry cover is a frangible part of the cover which is able to be torn away to expose the cover conduit entry.

14. A base conduit entry insert for covering the at least one base conduit entry of the base of any one of claims 9 to Ithe base conduit entry insert comprising: a body; an aperture for receiving the conduit; and a base conduit entry connector for connecting to the base conduit entry.

15. A base conduit entry insert as claimed in claim 14 further comprising a cover connector for engaging with a portion of the cover.

16. A base conduit entry insert as claimed in any one of claims 14 or 15 wherein the base conduit entry connector is a recess in a periphery of the base conduit entry insert for receiving a portion of the base.

17. A base conduit entry insert as claimed in claim 14 wherein the cover connector is provided by a recess in the periphery of the base conduit entry insert.

18. A base conduit entry insert as claimed in claims 15 and 16 wherein the base conduit entry connector and the cover connector are provided by the same recess.

19. A method of connecting a conduit to an electrical wall box, the method comprising: removing a, or part of a, base conduit entry cover from a base conduit entry of a base of the electrical wall box; inserting a base conduit entry insert into or over the base conduit entry; and inserting the conduit into the base conduit entry via an aperture in the base conduit entry insert.

20. A method of connecting a conduit to an electrical wall box as claimed in claim 19 further comprising: removing a cover conduit cover from a cover conduit entry of a cover; and covering at least a portion of the base with the cover such that at least a portion of the cover conduit entry engages with the base conduit entry insert.

21. A method of connecting a conduit to an electrical wall box as claimed in any one of claims 19 and 20, wherein the step of removing the base conduit entry cover comprises sliding out the base conduit entry cover from the base conduit entry.

22. A method of connecting a conduit to an electrical wall box as claimed in any one of claims 19 and 20, wherein the step of removing a part of the base conduit entry cover comprises tearing away a portion of the base conduit entry cover.