Field of invention:

The present invention relates to a surface mounting box comprising a base member and a cover member. The surface mounting box is provided with snap fit arrangements for pre-clipping the cover member with the base member; and subsequently when required final clipping the cover member with the base member. Advantageously, surface mounting box is provided with disengaging lugs for disengaging the base member from the cover member. Although the invented surface mounting box generally finds its application electrical and telecommunication industries, the invention is equally applicable to any other fields where surface mounting boxes with an arrangement for pre-clipping and final clipping might be required.

Background of the invention:

The surface mounting box, typically, is a hollow box mounted on the wall, ceilings of a plenum space and includes ports for establishing connection between electrical conductors, communication cables and like. The wall of the box protects the connections contained inside. The primary purpose of the surface mounting box is to establish connection between electrical, telecommunication components and the same time to prevent inadvertent contact with the components housed therein that would cause damage or a safety hazard.

Surface mounting boxes of various types are currently available in the market catering to specific requirements. One of such conventional plenum-rated surface mounting box has been disclosed in US patent publication 20080003871. The box comprises a main panel and a pair of side walls attached to opposite ends of the main panel wherein at least one W

of the side walls includes a recess configured to receive a connector adapter. The main panel and side walls are formed as a unitary structure and comprise a polymeric material. US 2008003871 also discloses surface mounting box, comprising a main panel having a plurality of apertures sized and configured to receive communications cables and a pair of side walls attached to opposite ends of the main panel; at least one of the side walls includes a recess configured to receive a connector adapter. The main panel and side walls are formed as a unitary structure and comprise a polymeric material selected from the group consisting of: polyetherimide, polysulfone, fluoropolymers, vinyl polymers, and non-halogenated polymers.

US patent document US5632656 discloses a surface mount box which includes a substrate and a cover member. The substrate has four side walls on a rectangular base. The surface mount box can be expanded by directly connecting with other surface mounted boxes to have a desired number of connector ports. The cover has a number of coupling elements and a plug on a base plate and the cover is fastened to the substrate by the coupling elements.

US patent document US5091826 discloses a printed wiring board connector comprises a rigid, dielectric surface with an opening therein. Various components and conductive paths are mounted on the rigid surface. The components include jumper wires that span the opening and are mechanically attached to the rigid surface on opposite sides of the opening. The printed wiring board connector is joined with a base unit which comprises a rigid, dielectric structure having connector housing molded therein that extends through the opening in the printed wiring board and includes wire-receiving slots for supporting the jumper wires. However, the disadvantage associated with conventional surface mounting boxes is that the cover member cannot be easily disengaged from corresponding base member or the substrate. Once the surface mounting box is assembled on a rigid surface such wall or a floor, it is very difficult to remove the cover from the base since the engaging means which secures the cover member with the base are not accessible from outside of the surface mounting box.

Another disadvantage associated with conventional surface mounting boxes is that they do not have any pre-clipping arrangement to cater to the requirement of shipment and delivery of the product.

In order to address to the above-mentioned problem, the inventors felt the need to develop a surface mounted box provided with a pre-clipping arrangement and in which the cover member can to disengaged from the cover member from outside of the housing.

Summary of the invention;

Accordingly the present invention provides, a surface mounting box comprising a cover member and a base member, said cover member and base member are removably secured to each other by a snap fit arrangement, said snap fit arrangement being formed by at least a pair of pre-clipping lugs, at least pair of final clipping lugs and at least pair of corresponding engaging arrangement, when the lugs are provided with the cover member, the engaging arrangements are provided with the base member and vice-versa, each said engaging arrangement is configured to engage with one of said pre-clipping lugs and subsequently, when required, with one of said final clipping lugs to releasably secure said cover member with said base, wherein each of said lugs has a entrance side and a retraction side and wherein each of said pre-clipping lugs has a gentle ramp on its retraction side, while each of said final-clipping lugs has a sharper ramp on its retraction side. The base member and the cover member pre-clips with each other by means of said pre-clipping lugs and corresponding engaging arrangement and when desired final clips with each other by means of said final clipping lugs and corresponding engaging arrangement.

Advantageously, the pre-clipping arrangement as provided in the present invention, helps to assemble the cover with the base member partially during delivery and shipment of the surface mounting box and at the same time defining the exact look of the product.

Each of said engaging attachments may comprise at least of a recess or at least an engaging undulation.

According to a particular embodiment of the invention, said engaging attachments are provided on the inner surface of said cover member. Preferably, said base member is provided with atleast two resilient members, each resilient member is disposed on either side of said base member, and wherein each of said resilient members is provided with at least a pre-clipping lug and a final clipping lug.

According to a another embodiment of the invented surface mounting box, base member is provided with four resilient members, a pair of pre-clipping resilient members and a pair of final clipping resilient members, each of said pre-clipping resilient member is provided with a pre-clipping lug for pre-clipping the cover member and the base member, while each of said final clipping resilient member is provided with a final clipping lug for final clipping the base member and the cover member and wherein each of said resilient members are disposed on a side of said base member. Preferably, one end of said resilient members is in contact with said base member while its other end remains free.

According to a preferred embodiment of the invented surface mounting box, said base member is provided with disengaging lugs for disengaging said cover member from said base member , each of said disengaging lugs is disposed on the free end of said resilient member and is adapted to unsnap the snap fit between an engaging attachment and corresponding pre- clipping lug or final clipping lug when the disengaging lug is actuated, and wherein said cover member is provided with peripheral notches for accessing said disengaging lugs from the outside of said surface mounting box. Preferably, said resilient member has a U shaped profile and comprises:

- an inner limb attached with said base member, and

- an open ended outer limb,

said outer limb being provided with a disengaging lug, a pre-clipping lug and/ or a final clippings lug.

Preferably, said outer limb is outwardly biased.

According to a further embodiment of the invented surface mounting box, said pre-clipping lugs and said final clipping lugs are provided on the inner surface of said cover member, and corresponding engaging attachments are provided with the base member. Preferably, said base member is provided with at least two resilient attachments, each of said resilient attachments is provided with at least an engaging attachment and each of said resilient attachments is disposed on a side of said base member. One of said resilient attachment is in contact with said base member end while its other end remains free. Advantageously, said base member may be provided with disengaging lugs for disengaging said cover member from said base member , each of said disengaging lugs is disposed on the free end of said resilient attachment and is adapted to unsnap the snap fit between an engaging attachment and corresponding pre-clipping lug or final clipping lug when the disengaging lug is actuated, and wherein said cover member is provided with peripheral notches for accessing said disengaging lugs from the outside of said surface mounting box.

The resilient attachment may have a U shaped profile and comprises:

- an inner limb attached with said base member, and

- an open ended outer limb,

said outer limb being provided with a disengaging lug and an engaging attachment.

According to yet another embodiment of the present invention, said base member of the surface mounting box has a quadrangular profile and said cover member is configured to match the profile of the base member.

According to a still further embodiment of the invented surface mounting box said cover member is provided with openings for accommodating at least one electrical device, such as a switch or a receptacle. The invented surface mounting box can be adopted to accommodate telecommunication devices.

According to yet another embodiment of the present invention said base member are provided with at least an outwardly protruding lip shaped locator, said lip shaped locater is configured to provide space for a user to snap and unsnap said base member with said cover member.

According to yet another embodiment of the invented surface mounting box, said base member is provided with upstanding members, each of said upstanding members is disposed adjacent to an edge of the base member; the base member together with said upstanding members constitute a frontally opened quadrangular enclosure, said quadrangular enclosure being configured to removably retain at least an electrical device.

Advantageously, in the present invention the overlapping of said pre- clipping lugs with corresponding engaging attachments is less than the overlapping of the final clipping lugs with corresponding engaging attachments. This ensures that lesser force is required to disengage the pre-clipping at the time of installation of the surface mounting box.

Brief Description of the Drawings;

For better understanding, illustrative embodiments of the invention will be described with reference to the accompanying drawings. It will however be appreciated that the embodiments exemplified in the drawings are merely illustrative and not limitative to the scope of the invention, because it is quite possible, indeed often desirable, to introduce a number of variations in the particular embodiments that have been shown in the drawings.

Figure 1 schematically shows the cover member and the base member of a surface mounting box according to a particular embodiment of the invention.

Figure 2 schematically shows the assembling of the cover member and the base member together with electrical devices according to a particular embodiment of invention.

Figure 3 schematically shows an assembled surface mounting box according to a particular embodiment of the invention. Figure 4 is a schematic cut-away view of the inner wall of the cover member showing an engaging undulation according to a particular embodiment invention.

Figure 5 is a schematic cut-away view of the base member showing the U shaped resilient member according to a particular embodiment of the invention.

Figure 6 is a schematic cut-away view of a surface mounting box showing the pre-clipping of the base member with the cover member according to a particular embodiment of the invention.

Figure 7 is a schematic cut-away view a surface mounting box showing the final clipping of the base member with the cover member according to a particular embodiment of the invention.

Figure 8 is a schematic sectional view of the particular embodiment of the invention.

Figure 9 is a schematic front view of the base member according to a particular embodiment of the invention.

Figure 10 schematically shows the cover member and the base member of a surface mounting box another embodiment of the invention.

Figure 11 schematically shows the assembling of the cover member and the base member together with electrical devices according to another embodiment of the invention.

Figure 12 an assembled surface mounting box according to another embodiment of the invention. Figure 13 is a schematic cut-away view of the base member showing the U shaped resilient member according to another embodiment of invention.

Figure 14 is a schematic cut-away view of the inner wall of the cover member showing an engaging undulation according to another embodiment of the invention.

Figure 15 is a schematic cut-away view of a surface mounting box showing the pre-clipping of the base member with the cover member according to another embodiment of the invention.

Figure 16 is a schematic cut-away view a surface mounting box showing the final clipping of the base member with the cover member according to another embodiment of the invention.

Figure 17 schematically shows the cover member and the base member of a surface mounting box according to a further embodiment of the invention.

Figure 18 is a schematic cut-away view of the inner wall of the cover member showing a pre-clipping lug and a final clipping lug according to a further embodiment invention.

Figure 19 is a schematic cut-away view of the base member showing the U shaped resilient attachment according to a further embodiment of the invention.

Figure 20 is a schematic cut-away view of a surface mounting box showing the final of the base member with the cover member according to a further embodiment of the invention. Figure 21 is a schematic cut-away view of a surface mounting box showing the pre-clipping of the base member with the cover member according to a further embodiment of the invention.

Figure 22 schematically shows the cover member and the base member of a surface mounting box according to yet another embodiment of the invention.

Figure 23 is a schematic cut-away view of the base member showing a U shaped resilient member with a final clipping lug according to yet another embodiment invention.

Figure 24 is a schematic cut-away view of the base member showing a U shaped resilient member with a pre-clipping clipping lug according to yet another embodiment invention.

Figure 25 is a schematic cut-away view of the inner wall of a cover member showing an engaging undulation according to yet another embodiment of the invention.

Figure 26 is a schematic cut-away view of a surface mounting box showing the final clipping of the base member with the cover member according to yet another embodiment of the invention.

Figure 27 is a schematic cut-away view of a surface mounting box showing the pre-clipping clipping of the base member with the cover member according to yet another embodiment of the invention. Figure 28 is a schematic view of the entrance and retraction sides of pre- clipping and final clipping lugs according to a particular embodiment of the present invention.

Figure 29 and 30 schematically shows the method of unsnapping the cover member from the base member by actuating the disengaging lugs of the surface mounting box according to a particular embodiment of the invention.

Detailed description of the Drawings:

According to a particular embodiment of the invention, as illustrated in figures 1 to 9 of the accompanying drawing, the invented surface mounting box (101) (shown in figure 3) comprises of a cover member (102} and a base member (103) (not shown in figures 3 and 4). The cover member (102) and the base member (103) are removably secured to each other by means of a snap fit arrangement (104) as seen in figures 6 to 8 of the accompanying drawings. Each snap fit arrangement (104) comprises a pre-clipping lug (105) a final clipping lug (106) and an engaging undulation (107). The lugs (105, 106) are provided on the base member (103) as seen in figures 1 , 2, and 5 to 8; while the engaging undulations (107) are provided on the inner surface of the cover member (102), as seen in figures 6 to 8 of the accompanying drawings.

Referring to figure 1 of the accompanying drawings, the base member (103) has a quadrangular profile and is provided with four V shaped resilient members (108), each disposed at a corner of the base member (103). Each resilient member (108), has an inner limb (109) connected to said base member (103), and an outer limb (110) which remains free, as seen in figure 1, 2, 5 to 8 of the accompanying drawings. The outer limb (109) has a pre-clipping lug (105) and a final clipping lug (106) disposed thereon. As seen in figure 1 to 3, of the accompanying drawings, the cover member (102) has been adapted to match the quadrangular profile of the base member (103). The inner surface of the cover member (102) is provided with engaging undulations (107), as seen in figure 4. The inner surface of the cover member (102) is provided with four engaging undulations (107) at appropriate positions (not shown) to removably engage with the corresponding the lugs (105, 106) provided on the resilient members (108). Thus, the surface mounting box (101), according to this particular embodiment is provided with four snap-fit arrangements (104). The engaging undulations (107) also aids in correct mounting of the cover member (102) on to the base member (103).

According to another embodiment of the invention, as illustrated in figure 10 to 16 of the accompanying drawings, the surface mounting box (202) is provided with a pair of snap fit arrangements (204) (shown in figures 15 and 16). The base member (203) has a quadrangular profile and is provided with two U shaped resilient members (208); one of said resilient members (208) is disposed on one side of said base member (203) and the other resilient member is disposed on the other side of said base member (203), as seen in figure 10. The pre-clipping lug (205) and the final clipping lug (206) are disposed on the outer limb ( 10) of the resilient member (208), as seen in figures 10, 1 1, 13, 15 and 16 of the accompanying drawings, and the corresponding engaging undulation (207) (as shown in figure 14) is provided on the inner surface of the cover member (202).

Figures 17 to 21 of the accompanying drawings illustrate a further embodiment of the invention. As shown in figures 20 and 21, the pre- clipping lug (305) and the final clipping lug (306) of the snap fit arrangement (304) are provided on the inner wall of the cover member (302). The corresponding engaging undulations (307) are provided with the base member (303), as seen in figures 17 and 19. The base member (303) has a quadrangular profile, as seen in figure 17, and is provided with four U shaped resilient attachments (311), each disposed at a corner of the base member (303). Referring to figures 17 and 19, each of the U shaped resilient attachments (311) has an inner arm (312) connected to said base member (303), and a free outer arm (313), The outer arm (313) is outwardly biased. The engaging attachment of each snap fit arrangement (304) is in the form of an engaging undulation (307,) and is provided on the outer arm (313) of the resilient attachment (311), as seen in figures 17 and 19 of the accompanying drawings.

Yet another embodiment of the invention has been illustrated in figures 22 to 27 of the accompanying drawings. The base member (403) is provided with four U shaped resilient members, each disposed at a corner of the base member (403). Two of these resilient members are provided only with a pre-clipping lug each, while the other two of these resilient members are provided only with final clipping lug each. Referring to figure 22 of the accompanying drawings, two resilient members 408a and 408c, which are disposed diagonally opposite to each other, are provided with only a final clipping lug (406) each. While the resilient members 408b is provided with only with the final clipping lugs (406). A resilient member similar to 408b is disposed diagonally opposite to 408b, which is not visible in figure 22. The inner surface of the cover member (402) is provided corresponding engaging undulations (407), as seen in figure 27, at appropriate places to engage with the pre-clipping lugs (405) and the final clipping lugs (406), as seen in ftgure 27. According to this embodiment of the invention, the surface mounting box is provided with four snap-fit arrangements (404), two for pre-clipping and the other two for final clipping the cover member (402) with the base member (403). When required the engaging undulation (407) snap fits with the final clipping lug (406) as shown by the snap fit arrangement (404c) in figure 26, and when required the undulation (407) snap fits with the pre-clipping lug (405) as shown by the snap fit arrangement (404b) in figure 27.

Referring to figure 28 of the accompanying drawings, the pre-clipping lug (105) has an entrance side (114), and a retraction side (115) and the final clippings lug (106), too has an entrance side (116) and a retraction side (117). The pre-clipping lug (105) has a gentle ramp on its retraction side (115); while the final clipping lug (106) has a shaper ramp on their respective retraction sides (117). Similarly, the pre-clipping lugs (205,305,405) have a gentle ramp on their respective retraction sides while the final clipping lug (206,306,406) has a shaper ramp on their respective retraction sides.

When the surface mounting box (101, 201,....) is shipped or delivered, it is pre-clipped. The pre-clipping lugs (105,205,305, 405) snap fits with the corresponding engaging undulations , (107,207,307, 407) to releasably secure the cover member (102,202,302,402) with its respective base member (103, 203,303 and 403). The gentle ramp on the retraction side of the pre-clipping lugs (105,205,305,405) ensures that cover member (102,202,302,402) is easily unsnapped from the its respective base member (103, 203, 303, 403) by applying gentle pull force. The surface mounting box (101, 201,...) has robust design to withstand the pull force. The pre- clipping of the cover member (102,202,302,402) with the corresponding base member (103,203,303,403) according to different embodiments of the invention, have been shown in figure 6, 15, 21 and 27 of the accompanying drawings.

When required, the final clipping lugs (106, 206, 306 , 406) snap fits with corresponding engaging undulations (107,207,307, 407) to releasably engage the cover members (102, 202, 302, 402) with each of their respective the base members (103, 203, 303 and 403). The shaper ramp on the retraction sides of the final clipping lugs (103 _} 206, 306 and 406) ensures that the cover members (102, 202, 302, 402) does not unsnap from their respective the base members (103, 203, 303 and 403) easily. The final clipping of the cover member (102,202,302,402) with the corresponding base member (103,203,303,403), according to different embodiments of the invention, have been illustrated in figure 7, 8, 16, 20 and 26 of the accompanying drawings. Thus the invention provides a provision for pre- clipping during shipment or delivery of the surface mounting box (101, 201, ... ), and a provision for final clipping of the cover member (102, 202, 302, 402) with the corresponding base member (103,203,303,403) when the surface mounting box (101, 201, ...) is to be mounted on a plenum surface.

As shown in figures 1 to 13, 15 to 17, 19 to 24, 26 to 30 of the accompanying drawings each of the base members 103,203, 303, and 403 is provided with disengaging lugs 1 18, 218, 318 and 418 respectively. The disengaging lugs (118, 218, 318, 418) are provided for desirably disengaging the cover member (102,202,302, 402) from its respective base member (103, 203, 303, 403). The disengaging lugs 118,218, 418 are provided on the outer limbs 110,210, 410 respectively; as seen in figures 1 to 13, 15 to 17, 26 and 27; while the disengaging lugs 318 are provided on the outer arm 313 as seen in figure 17, 1 to 24. The cover members (102,202,302,402) are provided with peripheral notches (119,219,319,419) for accessing the disengaging lugs (118, 218, 318, 418). When a disengaging lug (118,218,318,418) is actuated the corresponding snap fit arrangement (104,204,304,404) shifts to pre-clipping stage from final clipping stage. This shift to the pre-clipping stage ensures that once the snap fit arrangement (104,204,304,404) is unsnapped from its final clipping stage, it does not slip back again to the final clipping stage, when other snap fit arrangements are being unsnapped. W

When the snap fit between the final clipping lugs (106,206, 306, 406) and its corresponding engaging undulation (107,207, 307, 407) is to be unsnapped, the disengaging lugs (118, 218, 318, 418) are to be actuated. Advantageously, in the present invention the disengaging lugs

(118.218.318.418) are accessible from outside. The peripheral notches

(119.219.319.419) allows the disengaging lugs (118,218,318,418) to be accessed from outside. Referring to figures 29 and 30 of the accompanying drawings, when the disengaging lug (119) is pushed by means of a tool (120), the outer limb (110) (not shown in figures 29 and 30) moves inwardly; and upon said outer limb (1 10) being pushed inwardly upto a predetermined distance, the final clipping lugs (106,206, 306, 406) unsnaps from the corresponding (107,207, 307, 407). Thus the present invention provides an aesthetic method for removing the cover members (102, 202, 302, 402) from its corresponding base member (103, 203, 303, 403).

Referring to figures 6, 7, 8, 15, 16, 20, 21, 26 and 27 of the accompanying drawings, the base members (103, 203, 303, 403) are provided with recesses (121,221,321,421) to the allow movement of the outer limbs (110,210,410) and of the outer arm (313).

Referring to figure 1, 2, 10, 11, 17 and 22 of the accompanying drawings the cover members (102, 202, 302, 402) are provided with openings (122,222,322,422) for accommodating electrical or telecommunication devices such as switches (123,223) and receptacles (124).

Referring to figures 1, 2, 8, 10, 11, 17 and 22, of the accompanying drawings the base member (103,203,303,403) is provided with four upstanding members (125, 225, 325, 425) disposed at its edges. The upstanding member (125, 225, 325 _t 425 is attached to its adjoining upstanding members on its either side. The base member (103,203,303,403) together with its respective upstanding members (125, 225, 325,425) constitute quadrangular encloses (126,226,326,426 respectively), each having a frontal opening. The quadrangular enclosures (126,226,326,426) provide support for the electrical or telecommunication devices which are housed in the surface mounting box (101, 201, ..,). The switches (123) and the receptacle (124) snap fits with the quadrangular enclosures (126), while the switch (226) snap fits with the quadrangular enclosure (226).

Referring to figures 1, 2, 9, 17 and 22 of the accompanying drawings , the base members 103,303, and 403 are provided with outwardly protruding lip shaped locators 127,327 and 427 respectively for providing adequate space for an user to snap and unsnap said base members 103,303, and 403 from respective cover members 102, 302 and 402.

As seen in figures 1, 2, 9, 10, 17 and 22 of the accompanying drawings the base member (103, 203, 303, 403) is provided with open spaces (128,228,328,428) for fastening hardware.

As already mentioned, the foregoing description is illustrative of the invention and not limitative to its scope, because it will be apparent to persons skilled in the art to devise other alternative embodiments without departing from the broad ambit of the disclosures made herein.