AU2025238102A1

AU2025238102A1 - A waterproofing recessed electrical junction box

Info

Publication number: AU2025238102A1
Application number: AU2025238102A
Authority: AU
Inventors: Benjamin Byron Lynam
Original assignee: Individual
Current assignee: Individual
Priority date: 2020-06-23
Filing date: 2025-09-26
Publication date: 2025-10-16
Also published as: AU2023248140B2; AU2021204226A1; AU2023248140A1

Abstract

14 A recessed electrical junction box designed to house electrical apparatus within walls and ceilings consists of a container with an integrated flange that interfaces with the container’s rim. The container and flange are one piece, often plastic injection- moulded, and create a flush surface with the interior wall when installed. The flange can be sealed to the wall or a waterproof barrier, forming a watertight seal meeting codes and standards related to internal wet area waterproofing. Installation may involve inserting the container through a wall opening, allowing the flange to interface with a waterproof membrane to prevent water ingress. Holes for electrical cabling can be made and sealed, or the container may have destructible tabs for creating these holes. The junction box may also include angled sides to allow for stacking and prevention of water collection. The container may have interior side projections which serve as attachment holes for the electrical apparatus and through which electrical wiring may be run.

Description

A waterproofing A waterproofing recessed recessed electrical electrical junction junction box box

Field of the Field of theInvention Invention

[0001]

[0001] This invention relates This invention relates generally generallytotoelectrical electricaljunction junctionboxes boxes and,and, more more

particularly, particularly, to to a a waterproofing recessed waterproofing recessed electrical electrical junction junction box.box.

Background Background of of theInvention the Invention 2025238102

[0002] Anelectrical

[0002] An electricaloutlet outletenclosure enclosureis is a protective a protective housing housing designed designed to encase to encase and and

safeguard electricaloutlets safeguard electrical outlets andand apparatus apparatus installed installed withinwithin a wall.a This wall.enclosure This enclosure is is

typically made typically made ofofdurable durable materials materials suchsuch as plastic as plastic or metal or metal and and may may afeature feature cover a cover

that can that besecurely can be securelysealed sealed to to prevent prevent dust, dust, moisture, moisture, or contaminants or contaminants from infiltrating from infiltrating

the electrical the electrical components. components.

[0003]

[0003] These enclosuresnot These enclosures notonly onlyenhance enhance safety safety butbut also also ensure ensure compliance compliance with with

electrical electrical codes andstandards, codes and standards, including including codes codes and standards and standards related related to internal to internal wet wet

area waterproofing. area waterproofing.

[0004]

[0004]Various Various types types of of enclosures enclosures exist existincluding includingUS6239365B1 (2001-05-29) US6239365B1 (2001-05-29)

McEvers whichdiscloses McEvers which discloses a one-piece, a one-piece, unitary unitary sealable sealable electricaljunction electrical junctionbox boxwith with

built-in built-in sealing sealing chambers chambers forfor electricalwires. electrical wires.The The wires wires passpass through through these these chambers chambers

before before entering entering the the main main box, box, and and they they can can be be sealed sealed with with expandable foamto expandable foam to create create

an airtight barrier. an airtight barrier. The Thebox boxhashas an an outer outer flange flange that that allows allows for a for a vapor vapor barrierbarrier to be to be

securely attached, securely attached, ensuring ensuring an airtight an airtight sealseal around around the outside. the outside.

[0005] Thejunction

[0005] The junction box box includes includes a front a front flange flange that that protrudes protrudes outwardoutward from itsfrom outerits outer

wall. This wall. front flange This front flange is is positioned positionedparallel paralleltotothe thebox's box'sfront frontopening openingandand set set backback to to

accommodate a wall accommodate a wall lining lining such such as sheetrock, as sheetrock, It features It features attachment attachment holes for holes for

securing thebox securing the box to to a stud a stud using using nails, nails, screws, screws, or similar or similar means.means. The flange's The flange's width width

allows for the allows for the attachment attachmentof of a vapor a vapor barrier barrier using using adhesive. adhesive.

[0006]

[0006] US4757158A (1988-07-12) US4757158A (1988-07-12) Lentz Lentz discloses discloses a five-sided a five-sided air-vapor air-vapor barrier barrier box box

used toseal used to sealananelectrical electricaloutlet outletbox box within within a building's a building's wall. wall. TheThe barrier barrier box box features features

outwardly extending outwardly extendingreinforced reinforcedflanges flangesaround around its its open open side, side, withwith these these flanges flanges

secured secured totoa a wallstud. wall stud. TheThe electrical electrical outlet outlet box box an d barrier and barrier box box are are attached attached to the to the

stud, stud, and a moisture-proof and a moisture-proof sheet sheet is is placed over them, placed over them, with with an an opening openingcut cutto to match match

1 the barrier barrier box's box'sopen open side. Caulk is applied toflanges, the flanges, and the is film is pressed 26 Sep 2025 the side. Caulk is applied to the and the film pressed against them to against them to create create an anairtight airtight and moisture-proof seal. and moisture-proof seal. The Theentire entire assembly assemblyisis then covered then covered with with the the finalwall final wallfinish. finish.The Thebarrier barrierbox box walls walls have have varying varying thicknesses , thicknesses, with thicker with thicker portions portions near near the the flanges flanges for foradded added strength strength and thinner sections and thinner near sections near the back the backwall wallfor foreasier easierwire wire insertion. insertion.

[0007]

[0007]US4673097A (1987-06-16) Schuldt US4673097A (1987-06-16) Schuldt discloses discloses an an electrical electrical box which is box which is 2025238102

designedforforwall designed wall andand ceiling ceiling installation installation to enclose to enclose the of the ends ends of sheathed sheathed electrical electrical

conductors connected conductors connected to ato a switch switch or socket or socket within within the box's the box's hollowhollow interior. interior. It features It features

an integrally moulded an integrally moulded flange flange thatthat surrounds surrounds the box's the box's exterior exterior walls walls and is and is pato parallel rallel to

its its open front face. open front face. The Theflange flange is is setback set back from from the the openopen face face to to ensure ensure it aligns it aligns with with

the interior the interior wall's wall'ssurface surfacewhen installed. This when installed. This flange flange can be secured can be securedtotothe thewall wall

material or aavapor material or vapor and and airair barrier barrier using using adhesive, adhesive, preventing preventing moisture moisture and air from and air from

passing throughthe passing through thebox. box.Additionally, Additionally, alignment alignmentspacers spacersareare included included forfor precise precise

installation installation on on aa rigid rigid building wall surface. building wall surface.

[0008] Thepresent

[0008] The present invention invention seeks seeks to provide to provide a recessed a recessed electrical electrical junction junction box which box which

will overcome will overcome oror substantially substantially ameliorate ameliorate at least at least somesome ofdeficiencies of the the deficiencies of theof the prior prior

art, art, or or to to at at least least provide an alternative. provide an alternative.

[0009] It is

[0009] It isto tobe be understood that,if understood that, if any prior art any prior art information is referred information is referred to to herein, herein, such such

reference doesnot reference does notconstitute constitute an anadmission admission thatthe that theinformation informationforms forms part part of of thethe

common general common general knowledge knowledge in the in theinart, art, in Australia Australia or any or anycountry. other other country.

Summary Summary ofofthe the Disclosure Disclosure

[0010] According

[0010] According to to oneone aspect, aspect, therethere is provided is provided a recessed a recessed electrical electrical junction junction box box

comprising comprising aa container container defining defining an an interior interior for for accommodating electrical apparatus accommodating electrical apparatus

and and aasurrounding surrounding flange flange interfacing interfacing a rim a rim of the of the container, container, wherein wherein the container the container and and

the flange the flangeare areintegrally integrallyformed formedas as oneone piece, piece, an intersection an intersection of container of the the container and and the the

flange defining flange definingananopening, opening,andand wherein wherein the container the container defines defines interior interior side projections side projections

for reticulation for reticulation of of electrical electricalwiring wiring therethrough which therethrough which define define interior interior attachment attachment hole s holes

and exteriorside and exterior siderecesses. recesses.

[0011] In some

[0011] In some embodiments, embodiments, the junction the junction box further box further definesdefines a lip projecting a lip projecting forward forward

of of the the flange flange surrounding surrounding the the opening. The flange opening. The flange may maybebeinstallable installable against against aa rear rear

2 surface of aawall walllining, lining, with with the thelip lip projecting projecting through throughanan opening in the wallwall lining to to 26 Sep 2025 surface of opening in the lining cover interior edges cover interior edges thereof. thereof. The The lip lipmay may be be rectangular rectangular with with opposed longstraight opposed long straight edges andopposed edges and opposed short short straight straight edges, edges, optionally optionally joined joined by by rounded rounded corners. corners. A A height of the height of the lip lip may correspond may correspond to atothickness a thickness of wall of the the wall lining, lining, for for example example 10 mm,10 mm,

13 13 mm, 16mm mm, 16 mmor or 2525 mmmm plasterboard, plasterboard, andand in some in some embodiments embodiments theislipfrangible the lip is frangible

or cuttable to or cuttable to permit permitadjustment adjustment of its of its height height during during installation. installation. Faces Faces of interior of the the interior 2025238102

side side projections projections defining definingthe theattachment attachment holes holes may may be recessedbehind be recessed behindedges edgesofofthe the

lip lip such that aa cover such that coverplate plateofofthe theelectrical electricalapparatus apparatus is recessed is recessed within within the lip. the lip.

[0012]

[0012] In In other otherembodiments, openingsto embodiments, openings to the the attachment attachmentholes holesare are coplanar coplanarwith with the the

opening opening soso that that cover cover plates plates of the of the electrical electrical apparatus apparatus are flush are flush with awith a face front frontofface of

the flange. the flange. The The attachment holes may attachment holes maybebeblind blindholes holes formed formedininthickened thickenedportions portions of of

the projections. the projections.The The container container may compriseangled may comprise angledsides sidessuch suchthat thatwhen whenthe theflange flange

is is installed installed vertically vertically aa bottom oneofofthe bottom one the sides sides is is angled angled downdown towards towards the opening, the opening,

thereby directing thereby directing water out of water out of the the container. container. The The angled angledsides sidesmay may further further permit permit

stacking of multiple stacking of multiple containers. containers. The container may The container maybebedefined defined by by four four planar planar side side

walls and walls anda aplanar planar floor, floor, andand the the interior interior projections projections may define may define raised surfaces raised surfaces to to

direct direct water away water away from from wiring wiring passing passing therethrough. therethrough. Exterior Exterior surfaces surfaces of the exterior of the exterior

recesses may recesses may be be angled angled with with respect respect to thetoflange the flange sowater so that that drains water drains away away from the from the

container when container when installed. installed.

[0013]

[0013] According to another According to another aspect, aspect,there thereisis provided provideda asystem system comprising comprising a wall a wall

lining lining defining an opening defining an openingandand a recessed a recessed electrical electrical junction junction box asbox as described described above above

installed therein, wherein installed therein, wherein the the liplip projects projects through through the opening the opening of the of thelining wall wall lining and and

conceals interioredges conceals interior edgesof of thethe opening. opening. In some In some embodiments, embodiments, thelies the flange flange lies against against

a a rear surfaceofof the rear surface thewall wall lining lining and andinterfaces interfaceswith witha awaterproofing waterproofing membrane membrane appliedapplied

across thewall across the walllining. lining.

[0014]

[0014] According to aafurther According to further aspect, aspect,there thereisisprovided provided a method a method of installation of installation

comprising formingananopening comprising forming opening in wall in a a wall lining, lining, insertingthethe inserting recessed recessed electrical electrical

junction box junction boxsosothat thatthe the flange flange is is positioned positioned against against the wall the wall lining, lining, passing passing theoflip the lip of

the junction the junction box box through throughthe theopening, opening, andand mounting mounting electrical electrical apparatus apparatus to theto the

3 junction box boxsosothat thata acover cover plate of of thethe electrical apparatus is recessed withinwithin the lip 26 Sep 2025 junction plate electrical apparatus is recessed the lip and substantiallyflush and substantially flushwith witha afront frontsurface surface of of thethe wall wall lining. lining.

[0015] Otheraspects

[0015] Other aspectsof of thethe invention invention are are also also disclosed. disclosed.

Brief Brief Description of the Description of the Drawings Drawings

[0016] Notwithstanding

[0016] Notwithstanding anyany other other forms forms whichwhich may may fall fall within within the of the scope scope of the present the present

invention, invention, preferred preferred embodiments of the embodiments of the disclosure disclosure will will now now be described, by be described, by way way of of 2025238102

example only, with example only, with reference reference to to the the accompanying drawings accompanying drawings ininwhich: which:

[0017] Figure1 1shows

[0017] Figure shows a front a front view view of aofrecessed a recessed electrical electrical junction junction box box in in accordance accordance

with aa first with first embodiment. embodiment.

[0018] Figure2 2shows

[0018] Figure shows a rear a rear perspective perspective view view of theofjunction the junction box of box of Figure Figure 1. 1.

[0019] Figure3 3shows

[0019] Figure shows a side a side cross-sectional cross-sectional view view of theof the junction junction box of box of 1. Figure Figure 1.

[0020] Figure4 4shows

[0020] Figure shows a front a front view view of aofrecessed a recessed electrical electrical junction junction box box in in accordance accordance

with aa second with second embodiment embodiment including including a projecting a projecting lip. lip.

[0021] Figure5 5shows

[0021] Figure shows a rear a rear viewview of junction of the the junction box box of of Figure Figure 4. 4.

[0022] Figure6 6shows

[0022] Figure shows a rear a rear perspective perspective view view of theofjunction the junction box of box of Figure Figure 4. 4.

[0023] Figure7 7shows

[0023] Figure shows a front a front perspective perspective view view of theofjunction the junction box ofbox of Figure Figure 4. 4.

[0024] Figure8 8shows

[0024] Figure shows a side a side cross-sectional cross-sectional view view of theof the junction junction box of box of 4. Figure Figure 4.

Description Description of ofEmbodiments Embodiments

[0025]

[0025] A A recessed electrical junction recessed electrical junctionbox box100 100 is isdesigned designed to toaccommodate electrical accommodate electrical

apparatus such apparatus such as as nurse nurse call call points, points, electrical electrical outlets, outlets, and and the like. the like.

[0026]

[0026] The junction box The junction box 100 comprisesaacontainer 100 comprises container 101 101recessed recessedwithin withina awall wall cavity cavity

in use. The in use. Thecontainer container 101101 defines defines an interior an interior 103receiving 103 for for receiving the electrical the electrical

apparatus. apparatus. The junction box The junction 100 further box 100 further comprises comprises aa surrounding surrounding flange flange 102 102

interfacing with aa rim interfacing with rim116 116ofofthe the container container 101. 101.

[0027] Thecontainer

[0027] The container 101101 and and the flange the flange 102 102 are are integrally integrally formed formed as apiece. as a single single piece.

In embodiments, the In embodiments, the junction junction box box 100 100may may be plastic be plastic injection -moulded.AnAn injection-moulded.

intersection intersection of ofthe thecontainer container101 101 and and the the flange flange 102 102 defines defines an opening 104 an opening 104that that is is

coplanar withthe coplanar with theflange flange 102. 102. According According to embodiment to the the embodiment of Figures of Figures 1–3,ofno part of 1-3, no part

the junction the junction box box 100 protrudes beyond 100 protrudes beyonda afront frontface face105 105ofofthe theflange flange102. 102.InInother other

4 words,when whenthethe junction box box 100 is installed, the junction box 100box 100 terminates flush 26 Sep 2025 words, junction 100 is installed, the junction terminates flush with the with the front front face face105 105ofofthe theflange flange 102. 102.

[0028]

[0028] The container 101 The container has interior 101 has interior attachment attachment holes holes 106 recessedwith 106 recessed with respect respect to to

the opening the opening104. 104. These These attachment attachment holes holes 106 106 are are to spaced spaced align to align with with fixation fixation screws screws

of the electrical of the electrical apparatus. apparatus. ForFor installation, installation, an an aperture aperture is through is cut cut through a wall alining wall lining

into into the the wall wall cavity cavity therebehind. Thecontainer therebehind. The container101 101 is is then then inserted inserted through through the the 2025238102

aperture untilthe aperture until theflange flange 102102 lieslies flatflat against against an outer an outer face face of the of the wall wall lining. lining. The The

surface areaofofthe surface area theflange flange102 102 interfaces interfaces with with a waterproofing a waterproofing membrane membrane applied over applied over

the wall the wall lining lining so that the so that the junction junctionbox box100 100 forms forms a watertight a watertight barrier barrier to prevent to prevent waterwater

ingress ingress or or egress, egress, thereby thereby complying with applicable complying with applicable codes codesoror standards standardsrelating relating to to

internal wet-areawaterproofing. internal wet-area waterproofing.

[0029]

[0029] AAhole holemay may be drilled be drilled through through the container the container 101 for101 for electrical electrical cabling,cabling, which which

may besealed may be sealedwith withaaplug plug or or sealant. sealant. Alternatively, Alternatively,the thecontainer container101 101may may comprise comprise

destructible tabswhich destructible tabs whichareare displaced displaced to form to form holesholes for electrical for electrical cabling. cabling.

[0030] In an

[0030] In analternative alternativeinstallation, installation,the thejunction junction boxbox 101 101 is mounted is mounted with with the the flange flange

102 against aarear 102 against rearsurface surfaceofofthe thewall walllining, lining, and anda acover cover plate plate of of the the electrical electrical

apparatus apparatus isisselected selected so that so that its its front front surface surface lies lies substantially substantially flush flush withfront with the the front

surface ofthe surface of thewall walllining. lining.InInthis thisway, way,thethe thickness thickness of cover of the the cover plate plate is chosen is chosen to to

correspond correspond to to thethe thickness thickness of the of the wall wall lining, lining, thereby thereby allowing allowing the junction the junction box 101box 101

to be to be used usedwith with wall wall linings linings of different of different thicknesses. thicknesses. In this In this installation, installation, the the

waterproofing waterproofing barrier barrier is is applied applied behind behind the the wallwall lining. lining.

[0031]

[0031] As best shown As best shownininFigure Figure3,3,openings openings 107107 to the to the attachment attachment holesholes 106 are 106 are

preferably coplanar with preferably coplanar with the theopening opening 104. 104. Thus, Thus, the faceplate the faceplate of electrical of the the electrical

apparatus can apparatus can be be mounted mounted flush flush acrossacross theface the front front105 face 105flange of the of the102. flange 102.

[0032] At least

[0032] At least one oneside side108108 of of thethe container container 101 101 is preferably is preferably angledangled with respect with respect to to

the flange the flange 102 102 so so that, that, when whenthe thejunction junctionbox box100 100 is isinstalled installed with with the the flange flange 102 102

vertical and vertical and the the angled side 108 angled side 108 positioned positionedatat the the bottom bottomofofthe thecontainer container101 101 as as

shown in Figure shown in Figure 3, 3, an an interior interior surface surface 109 109 of of that thatside side108 108slopes slopesdownward toward downward toward

the opening the 104. Consequently, opening 104. Consequently,any any water water collected collected withinthe within thecontainer container101 101 flows flows

downtotothe down theopening opening 104 104 rather rather than than pooling pooling insideinside the container. the container.

5

[0033]

[0033] Preferably, Preferably, the the container container101 101 has has angled sides 108 108 so so that that the the container container 101 26 Sep 2025

angled sides 101

can bestacked can be stackedwith withadjacent adjacent similar similar containers. containers. In In thethe embodiment embodiment shown, shown, the the

container 101has container 101 has a generally a generally rectangular rectangular cross-section cross-section defined defined by fourby four planar planar angled angled

side walls 108, side walls 108,and and may may further further comprise comprise a planar a planar floorbetween floor 117 117 between the sides. the sides.

[0034]

[0034] The container 101 The container 101 may maycomprise comprise interiorside interior sideprojections projections110 110disposed disposed with with

respect to a respect to frontal plane a frontal plane as as shown in Figure shown in Figure 1. 1. The Thesides sides108 108may may be be of uniform of uniform 2025238102

thicknesssosothat thickness thatthe thecontainer container 101101 defines defines exterior exterior side side recesses recesses 111 corresponding 111 corresponding

to respective to respectiveinterior interiorside sideprojections projections 110.110. TheseThese interior interior side projections side projections 110 are 110 are

preferably sufficientlywide preferably sufficiently wide (i.e.substantially (i.e. substantially wider wider than than the attachment the attachment aperturesapertures

106) to allow 106) to allowelectrical electricalwiring wiringtotopass pass through through holes holes formed formed therein. therein. Any Any such such wiring wiring

may betucked may be tuckedaway away withinthe within thecorresponding correspondingexterior exteriorside siderecesses recesses111. 111.

[0035] Preferably,exterior

[0035] Preferably, exteriorsurfaces surfaces 112112 of the of the recesses recesses 111 111 are are with angled angled with respect respect

to the to flange102. the flange 102.With With reference reference to Figure to Figure 3, when 3, when the junction the junction box 100 box 100 is installed is installed

with the with the flange flange102 102 vertical,a atoptop vertical, oneone of the of the exterior exterior surfaces surfaces 112 slopes 112 slopes downward downward

away fromthe away from theflange flange102. 102.Thus, Thus,any any water water collectedininthe collected therecess recess111 111 flows flows away away

from the from theflange flange102 102 andand fromfrom the rear the rear of container of the the container 101, instead 101, instead of pooling of pooling in the in the

recess 111. recess 111.

[0036]

[0036] The interior side The interior side projections projections 110 110 may definethe may define theattachment attachment holes holes 106. 106. As As

shown shown ininFigure Figure3, 3, the the interiorside interior side projections projections 110110 may may comprise comprise a thickasection thick section 113 113

at at the the opening 104, opening 104, with with thethe attachment attachment holesholes 106 formed 106 formed as blindas blindwithin holes holesthese within these

thick sections thick sections 113. 113. Such blind holes Such blind holes 106 do not 106 do not compromise compromise the the watertightintegrity watertight integrity

of of the junction box the junction box100. 100.

[0037] Withreference

[0037] With referenceto to Figure Figure 1, the 1, the container container 101bemay 101 may be elongate, elongate, with with a pair of a pair of

interior interior side projections110 side projections 110 provided provided at respective at respective ends ends of the of the container container 101. With 101. With

further reference further referencetotoFigure Figure 1, 1, when when the junction the junction box box 101 is 101 is installed installed with thewith the flange flange

102 vertical, a 102 vertical, a bottom interior side bottom interior sideprojection projection110 110 defines defines a raised a raised surface surface 114 114 relative relative

to adjacent to adjacent surfaces 115. As surfaces 115. As noted noted above, above,electrical electrical wiring wiring may passthrough may pass throughholes holes

in in the the interior interior side side projections 110. Thus, projections 110. Thus,any any water water collected collected within within the the container container 101 101

pools pools against against the the adjacent adjacent surfaces surfaces 115, 115, away from wiring away from wiring routed routed through through the the bottom bottom

projection 110. projection 110.

6

[0038] Theinterior interiorside sideprojections projections110110 preferably alsoalso have have angledangled sides that so thethat the 26 Sep 2025

[0038] The preferably sides so

container 101cancan container 101 be be stacked stacked with with adjacent adjacent similar similar containers. containers.

[0039]

[0039] The flange 102 The flange 102may may define define attachment attachment apertures apertures 121 therethrough. 121 therethrough. In theIn the

embodiment shown, embodiment shown, the the flange flange 102 102 defines defines apertures apertures 121 at121 at respective respective corners corners

thereof.Figures thereof. 4–8illustrate Figures 4-8 illustrate aa second second embodiment embodiment ofrecessed of the the recessed electrical electrical junction junction

box 100ininwhich box 100 which the the box box further further defines defines a lipa118 lip projecting 118 projecting forwardforward of the of the 2025238102

surrounding flange surrounding flange 102102 at the at the opening opening 104 defined 104 defined at the at the intersection intersection of the of the container container

103 andthe 103 and theflange flange 102. 102. Figures Figures 4 and 4 and 5 respectively 5 respectively showand show front front and rear rearofviews views the of the

junction box junction box 100, while Figures 100, while 6 and Figures 6 and 77 show showrear rearand andfront frontperspective perspectiveviews, views,and and

Figure Figure 88shows shows a side a side cross-sectional cross-sectional view view of theofjunction the junction box 100. box 100.

[0040] Asisis evident

[0040] As evidentininparticular particularfrom from Figure Figure 7, the 7, the lip lip 118 118 is preferably is preferably of generally of generally

rectangular form and rectangular form andcomprises comprises planar planar walls walls 119119 defining defining a pair a pair of of opposed opposed long long

straight straight edges 120a and edges 120a anda apair pairofof opposed opposed shortstraight short straightedges edges120b. 120b. TheThe corners corners

between the planar between the planar walls walls 119 119maymay be rounded be rounded in order in order to reduce to reduce stress stress

concentrations and concentrations and to to ease ease insertion insertion of lip of the the 118 lip 118 through through a corresponding a corresponding aperture aperture

in thewall in the walllining. lining.

[0041]

[0041] In In accordance withthis accordance with thisembodiment, embodiment,the the surrounding surrounding flange flange 102bemay be 102 may

installed againsta arear installed against rearsurface surface of aofwall a wall lining, lining, withwith a rectangular a rectangular aperture aperture formed formed

throughthe through thewall walllining liningdimensioned dimensioned to receive to receive the118. the lip lip 118. In this In this manner, manner, the lipthe 118lip 118

extends forwardly extends forwardly through through the the aperture aperture and overlies and overlies the the raw raw interior interior edges edges of of the wall the wall

lining, lining, thereby concealing thereby concealing those those edges edges and and at same at the the same time maintaining time maintaining a waterproof a waterproof

barrier acrossthe barrier across thejunction junction between between the and the box boxthe and the wall wall lining. lining. By covering By covering the cut the cut

edges edges ofofthe thewall walllining, lining,the thelip lip118 118 also also reduces reduces the likelihood the likelihood of water of water ingress ingress into into

the wall the wall cavity cavity and andassists assistsininpreserving preservingthethe integrity integrity of of anyany waterproofing waterproofing membrane membrane

applied applied in in thethe vicinity vicinity of the of the wall wall lining. lining.

[0042] Theheight

[0042] The height of of thethe liplip 118 118 is preferably is preferably selected selected to match to match the thickness the thickness of the of the

wall lining wall lining into into which thejunction which the junctionbox box100100 is installed. is installed. In In thethe embodiment embodiment shown,shown, the the

lip lip 118 118 projects forwardofofthe projects forward theflange flange102 102by by approximately approximately 13which 13 mm, mm, corresponds which corresponds

to the to the nominal nominalthickness thicknessofofa astandard standard plasterboard plasterboard or drywall or drywall lining lining commonly commonly

employed employed ininresidential residential and andcommercial commercial building building construction construction in Australia. in Australia. Other Other

7 versionsofofthe thejunction junctionbox box 100100 may may be provided with118lips of 118 of alternative heights 26 Sep 2025 versions be provided with lips alternative heights suitable suitable for forother othercommonly available lining commonly available liningthicknesses, thicknesses,for example for example10 10mm, mm, 16 16 mm mm or or 25 mm.InInfurther 25 mm. further alternatives, alternatives, the lip 118 the lip 118 may bemanufactured may be manufacturedin in a range a range of of standard depths, standard depths, or or maymay be formed be formed with awith a frangible frangible or cuttable or cuttable extension extension that allows that allows an installertotoadjust an installer adjust its its height height attime at the theoftime of installation installation to suit ato suit a particular particular wall lining wall lining thickness. thickness. 2025238102

[0043] Asfurther

[0043] As furtherevident evident from from Figure Figure 7, interior 7, the the interior side side projections projections 110define 110 that that define

the attachment the attachmentholes holes106106 are are arranged arranged so their so that that their front front faces, faces, including including the the

openings 107 openings 107totothe theattachment attachmentholes, holes,are arerecessed recessed slightlyrearward slightly rearwardofofthe theedges edges

120a, 120bofofthe 120a, 120b thelip lip118. 118.InInthis thisconfiguration, configuration, the thecover coverplate plateofofthe theinstalled installed

electrical apparatuscancan electrical apparatus be received be received entirely entirely withinwithin the the lip 118lip 118that such such the that outerthe outer

surface of the surface of thecover coverplate platelies liesflush flushwith, with,ororslightly slightly recessed recessed relativeto, relative to,the thefrontmost frontmost

plane of the plane of the lip lip 118. 118. This This arrangement providesa aneat arrangement provides neat andand aesthetically aesthetically pleasing pleasing

finish, while finish, while maintaining thewaterproof maintaining the waterproof barrier barrier created created by flange by the the flange 102lipand 102 and lip 118. 118.

[0044] Forinstallation

[0044] For installation according accordingto to the the firstembodiment, first embodiment, an aperture an aperture is cutisthrough cut through a a

wall lining wall lining into into aa wall wallcavity cavitylocated located behind thelining. behind the lining. The Thecontainer container101 101 of of thethe junction junction

box 100isis inserted box 100 inserted through throughthe theaperture apertureuntil until the the surrounding surroundingflange flange102 102lies liesflat flat

against the outer against the outersurface surfaceofofthethe wall wall lining.TheThe lining. flange flange 102 102 interfaces interfaces with with a a

waterproofing membrane waterproofing membrane applied applied across across thethe wall wall liningsosothat lining thatthe thejunction junction box box 100 100

formsa awatertight forms watertight barrier. barrier. TheThe installer installer may may then then drill drill a holea through hole through the container the container

101, or alternatively 101, or alternativelydisplace displace a destructible a destructible tab,tab, to provide to provide a passage a passage for electrical for electrical

cabling. Thecabling cabling. The cabling cancan be sealed be sealed with with a pluga or plug or sealant sealant to maintain to maintain the watertight the watertight

integrity. integrity. The electricalapparatus The electrical apparatus is secured is secured tointerior to the the interior attachment attachment holes 106, holes 106,

with the with the cover coverplate plateapplied applied flush flush across across the the frontfront face face 105 105 of theofflange the flange 102. In102. this In this

manner, the junction manner, the junction box box 100 100isis fixed fixed in in place, place, provides provides aa recessed housingfor recessed housing for the the

apparatus, and maintains apparatus, and maintains waterproofing waterproofingcompliance. compliance.

[0045]

[0045] For installation according For installation to the according to the second second embodiment, embodiment, the flange the flange 102 is102 is

positioned against aa rear positioned against rear surface surface of of the the wall wall lining. lining. A rectangular aperture A rectangular aperture is is cut cut

throughthe through thewall walllining liningcorresponding corresponding to lip to the the118. lip 118. The The lip 118lipprojects 118 projects forward forward of of

the flange the flange102 102and and extends extends through through the aperture the aperture such such that that the the planar planar walls walls 119 119 of the of the

8 lip lip 118 118 overlie overlie and conceal the theraw rawinterior interior edges edgesofofthe thewall walllining. lining. The Thelip lip 118 118 26 Sep 2025 and conceal therebyassists thereby assistsininmaintaining maintaining the the waterproof waterproof barrier barrier by preventing by preventing water at water ingress ingress at the cut the cut edge edgeofofthethe wall wall lining. lining. The The height height of the of the lip 118 lip 118 is chosen is chosen to correspond to correspond to to the thickness the thickness ofofthe thewall walllining—for example, lining-for 10 10 example, mm,mm, 1313 mm, mm,16 16mm or 25 mm or 25 mm mm plasterboard commonly plasterboard commonly employed employed in Australian in Australian construction. construction. In In some some forms, forms, the the lip lip

118 may 118 may be be frangible frangible or cuttable or cuttable to allow to allow trimming trimming to thetoappropriate the appropriate height.height. 2025238102

[0046]

[0046] Once installed, the Once installed, interior side the interior side projections projections 110 110 with with openings 107for openings 107 forthe the

attachment holes 106 attachment holes 106preferably preferably remain remainrecessed recessedrelative relative to to the the forward forward edges edges 120a, 120a,

120b of the 120b of thelip lip 118. 118.This Thisarrangement arrangement allows allows the cover the cover plate plate of theofelectrical the electrical

apparatus apparatus toto bebe positioned positioned within within the 118 the lip lip so 118 so the that thatouter the surface outer surface of the cover of the cover

plate lies flush plate lies with, or flush with, or slightly slightly recessed recessedrelative relative to,thethe to, plane plane defined defined by edges by the the edges

120a, 120b. The 120a, 120b. Thewiring wiringmay may be be passed passed through through holesholes formedformed in the in the interior interior side side

projections projections 110 and, as 110 and, as previously previously described, described, may maybebe tucked tucked intothe into theexterior exteriorside side

recesses 111 recesses 111 to to facilitateinsertion facilitate insertion andand removal removal of theofjunction the junction box 100box 100 the through through the

wall aperture. wall aperture. The Theraised raisedsurface surface114114 of of thethe bottom bottom projection projection 110 directs 110 directs any any

incidental wateraway incidental water away fromfrom electrical electrical wiring, wiring, thereby thereby furtherfurther reducing reducing risk of water risk of water

ingress into live ingress into live connections. connections.

[0047]

[0047] Following Following installation installationinineither embodiment, either embodiment, the the junction junctionbox box 100 100 provides a provides a

recessed housingthat recessed housing that satisfies satisfies both both functional functionaland and waterproofing waterproofing requirements. requirements. The The

electrical electrical apparatus apparatus isissecured securedin in thethe interior interior 103, 103, wiring wiring is is protected protected and and directed directed by by

the interior the interior projections 110,and projections 110, and water water drainage drainage is promoted is promoted by the by the angled angled sides sides 108 108

and interior surface and interior surface109. 109. The The cover cover plate plate is mounted is mounted either either flushthe flush with with the 102 flange flange 102

in in the the first firstembodiment, embodiment, or or recessed recessed within within the 118 the lip lip 118 in second in the the second embodiment, embodiment, to to

present present aaneat neatfinish finishininline linewith withthe thefront frontsurface surfaceof of the the wall wall lining. lining.

[0048]

[0048] The foregoingdescription, The foregoing description,forfor purposes purposes of explanation, of explanation, used specific used specific

nomenclature toprovide nomenclature to provideaathorough thoroughunderstanding understandingof of theinvention. the invention.However, However,it itwill will

be apparent be apparent to to one one skilled skilled in in thethe art art that that specific specific details details are are not not required required in order in order to to

practise practise the the invention. invention. Thus, Thus, the the foregoing foregoing descriptions descriptions of of specific specificembodiments of embodiments of

the invention the inventionare arepresented presentedfor for purposes purposes of illustration of illustration and description. and description. They They are notare not

intended intended totobebe exhaustive exhaustive orlimit or to to limit the the invention invention to precise to the the precise forms forms disclosed disclosed as as

9 obviously many manymodifications modifications andand variations are are possible in view of above the above 26 Sep 2025 obviously variations possible in view of the teachings. The teachings. embodiments The embodiments were were chosen chosen and and described described in order in order to best to best explain explain thethe principles principles of of the the invention invention and its practical and its practical applications, applications, thereby thereby enabling others enabling others skilled skilled in in the art to the art to best best utilize utilize the the invention inventionand and various various embodiments embodiments with various with various modifications modifications asas are are suited suited to to thethe particular particular useuse contemplated. contemplated. It is intended It is intended that the that the following claims following claimsand and their their equivalents equivalents define define the scope the scope of theofinvention. the invention. 2025238102

10

Claims

Claims 26 Sep 2025

Claims 1. 1. A A recessed electricaljunction recessed electrical junctionbox box comprising: comprising:

a containerdefining a container definingananinterior interiorfor for accommodating accommodating electrical electrical apparatus; apparatus; and and

a surroundingflange a surrounding flange interfacing interfacing a rim a rim of of thethe container, container, wherein: wherein:

the container the containerand andthe the flange flange areare integrally integrally formed formed as piece; as one one piece;

an intersectionof an intersection of the the container containerand and thethe flange flange defines defines an opening, an opening, wherein wherein the the 2025238102

container definesinterior container defines interiorside sideprojections projectionsfor forreticulation reticulationofofelectrical electrical wiring wiring

therethroughwhich therethrough which define define interior interior attachment attachment holesholes and exterior and exterior side recesses. side recesses.
2. 2. The recessed The recessed electricaljunction electrical junction boxbox of of claim claim 1, wherein 1, wherein the junction the junction box defines box defines a a

lip lip projecting projecting forward of the forward of the flange flangesurrounding surroundingthethe opening opening defined defined atintersection at the the intersection

of of the the container andthe container and theflange. flange.
3. 3. The recessed The recessed electricaljunction electrical junction box box of of claim claim 2, wherein 2, wherein the flange the flange is installable is installable

against against aa rear rearsurface surfaceofofa awall walllining liningand andwherein wherein the the lip lip projects projects through through an opening an opening

in in the walllining. the wall lining.
4. The 4. recessed The recessed electrical electrical junction junction boxbox of of claim claim 2, wherein 2, wherein the defines the lip lip defines a a

rectangular rectangular configuration configurationcomprising comprisingopposed long straight opposed long straightedges edges and and opposed short opposed short

straight straight edges. edges.
5. 5. The recessed The recessed electricaljunction electrical junction box box of of claim claim 4, wherein 4, wherein the long the long straight straight edgesedges

and shortstraight and short straightedges edgesareare joined joined by by rounded rounded corners. corners.
6. 6. The recessed The recessed electricaljunction electrical junction boxbox of of claim claim 3, wherein 3, wherein a height a height of lip of the the lip

corresponds corresponds to to a a thickness thickness of the of the wall wall lining. lining.
7. 7. The recessed The recessed electricaljunction electrical junction box box of of claim claim 6, wherein 6, wherein the projects the lip lip projects forward forward of of

the flange the flange by by approximately approximately 13 13 mm. mm.

11
8. 8. The recessed electricaljunction junction box of of claim 6, wherein the is lip frangible is frangible or or 26 Sep 2025

The recessed electrical box claim 6, wherein the lip

cuttable to permit cuttable to permit adjustment adjustmentof of itsitsheight heightduring during installation. installation.
9. 9. The recessed The recessed electricaljunction electrical junction box box of of claim claim 2, wherein 2, wherein facesfaces of interior of the the interior side side

projections definingthe projections defining theattachment attachment holes holes are are recessed recessed behindbehind edges edges of of the the lip suchlip such

that a that a cover plateof cover plate of the theelectrical electrical apparatus apparatusisisrecessed recessed within within the the lip.lip. 2025238102
10. 10. The recessed The recessed electrical electrical junction junction boxbox of claim of claim 1, wherein 1, wherein the attachment the attachment holes are holes are

blind blind holes. holes.
11. 11. The recessed The recessed electrical electrical junction junction boxbox of claim of claim 1, wherein 1, wherein sidessides of container of the the container are are

angled withrespect angled with respecttotothe theflange flange so so that that when when the flange the flange is installed is installed vertically vertically in use, in use,

a bottomone a bottom oneofof thesides the sides is is angled angled down down toward toward the opening. the opening.
12. 12. The recessed The recessed electrical electrical junction junction boxbox of claim of claim 1, wherein 1, wherein the container the container has angled has angled

sides sothat sides so that the thecontainer containercan can be be stacked stacked withwith an adjacent an adjacent similar similar container. container.
13. 13. The recessed The recessed electrical electrical junction junction boxbox of claim of claim 12, 12, wherein wherein the container the container has four has four

planar angledside planar angled sidewalls walls and and a planar a planar floor floor between between the walls. the side side walls.
14. 14. The recessed The recessed electrical electrical junction junction boxbox of claim of claim 1, wherein 1, wherein exterior exterior surfaces surfaces of theof the

exterior exterior side recessesare side recesses are angled angled with with respect respect to the to the flange. flange.
15. 15. The recessed The recessed electrical electrical junction junction boxbox of claim of claim 14, 14, wherein, wherein, when when the flange the flange is is

installed installed vertically vertically in inuse, use, aa top top one of the one of the exterior exterior surfaces surfacesisisangled angleddown down awayaway from from

the flange. the flange.
16. 16. The recessed The recessed electrical electrical junction junction boxbox of claim of claim 1, wherein 1, wherein a bottom a bottom interior interior side side

projection definesaaraised projection defines raisedsurface surface relative relative to to adjacent adjacent surfaces surfaces so that so that water water is is

directed awayfrom directed away from wiring wiring extending extending therethrough. therethrough.

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17. 17. A A system comprising: system comprising:

a wall lining a wall lining defining defining an opening;and an opening; and

the recessed the recessedelectrical electricaljunction junctionbox box of of claim claim 2 installed 2 installed therein, therein, wherein wherein the the lip lip

projects throughthe projects through theopening opening of of thethe wall wall lining lining andand conceals conceals interior interior edgesedges of theof the

opening. opening. 2025238102
18. 18. The system The system of of claim claim 17,17, wherein wherein the flange the flange lies lies against against a rear a rear surface surface of theofwall the wall

lining lining and interfaceswith and interfaces withaawaterproofing waterproofing membrane membrane applied applied across across the wallthe wall lining. lining.
19. 19. A method A method of of installationcomprising: installation comprising:

formingananopening forming openingin in a wall a wall lining; lining;

inserting the recessed inserting the recessedelectrical electricaljunction junctionbox box of of claim claim 2 such 2 such thatthat the the flange flange is is

positioned againstthe positioned against thewall walllining; lining;

passing passing a alip lip of of the the junction junction box boxthrough throughthethe opening opening of the of the wallwall lining; lining; and and

mounting electricalapparatus mounting electrical apparatusto to thethe junction junction box box so that so that a cover a cover plateplate of the of the

electrical electrical apparatus apparatus isis recessed recessed within within thethe liplip and and substantially substantially flush flush with with a front a front

surface of the surface of the wall wall lining. lining.

13