Plumbing outlet box

Abstract

Plumbing outlet boxes, such as for connecting washing machines, ice makers, and other plumbed appliances to plumbing systems, are provided that increase the energy efficiency of a building thermal envelope. In particular, plumbing outlet boxes are described that include a continuous flange and a compressible seal contacting the flange. The plumbing outlet boxes are designed to be mounted within a cutout in a drywall panel such that, when a faceplate is engaged with the housing, the seal creates a sealing effect between the plumbing outlet box and the wall, thereby maximizing the energy efficiency of the installation by reducing the air leakage between the interior side of the wall and the exterior side of the wall.

What is claimed is: 
     
         1 . A plumbing outlet box configured for mounting within a cutout in a drywall panel having an interior surface and an exterior surface, said plumbing outlet box comprising:
 a housing including a top wall and a bottom wall and an opening providing access into an interior of the housing;   a substantially planar and continuous flange extending proximate to and surrounding the opening;   a compressible seal having a front surface and a rear surface, the rear surface of the seal contacting the flange; and   a faceplate configured to mount to the housing,   wherein in a mounted position, the faceplate contacts a portion of the front surface of the drywall panel and compresses the seal such that the front surface of the seal contacts the rear surface of the drywall panel to create a seal around the drywall panel cutout.   
     
     
         2 . The plumbing outlet box of  claim 1 , wherein the flange is integral with the housing. 
     
     
         3 . The plumbing outlet box of  claim 1 , wherein the flange is separate from the housing and wherein the flange is configured to be attached to the housing. 
     
     
         4 . The plumbing outlet box of  claim 3 , wherein the flange is configured to be attached to the housing via at least one of a snap-fit attachment, an adhesive attachment, or a sonic weld attachment. 
     
     
         5 . The plumbing outlet box of  claim 1 , wherein the faceplate is configured to mount to the housing via at least one of a snap-fit mounting and a screw mounting. 
     
     
         6 . The plumbing outlet box of  claim 1 , wherein the seal comprises a single piece. 
     
     
         7 . The plumbing outlet box of  claim 1 , wherein the seal comprises two or more pieces. 
     
     
         8 . The plumbing outlet box of  claim 1 , wherein the rear surface of the seal is affixed to the flange. 
     
     
         9 . The plumbing outlet box of  claim 1 , wherein the outlet box is configured for use as a washing machine outlet box. 
     
     
         10 . The plumbing outlet box of  claim 1 , wherein the outlet box is configured for use as an ice maker outlet box. 
     
     
         11 . A method of installing a plumbing outlet box within a cutout in a drywall panel having an interior surface and an exterior surface, said method comprising:
 providing a plumbing outlet box housing that includes a top wall, a bottom wall, and an opening providing access into an interior of the housing;   providing a substantially planar and continuous flange extending proximate and surrounding the opening;   applying a compressible seal having a front surface and a rear surface to the flange such that the rear surface of the seal contacts the flange;   positioning the plumbing outlet box proximate the cutout of the drywall panel; and   mounting a faceplate to the housing so that the faceplate contacts a portion of the front surface of the drywall panel and compresses the seal such that the front surface of the seal contacts the rear surface of the drywall panel to create a seal around the drywall panel cutout.   
     
     
         12 . The method of installing a plumbing outlet box of  claim 11 , wherein providing a substantially planar and continuous flange comprises attaching a flange to the plumbing outlet box housing. 
     
     
         13 . The method of installing a plumbing outlet box of  claim 11 , wherein providing a compressible seal comprises attaching the compressible seal to the flange. 
     
     
         14 . The method of installing a plumbing outlet box of  claim 11 , wherein the plumbing outlet box is configured for use as a washing machine outlet box. 
     
     
         15 . The method of installing a plumbing outlet box of  claim 11 , wherein the plumbing outlet box is configured for use as an ice maker outlet box.