Note: Descriptions are shown in the official language in which they were submitted.
Image
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B_ackuround of the Invention
Presently, most buildings are constructed with
interior walls and floors using either metal or wood
support members, i.e., studs or foists, for their frames.
Typically, electrical boxes are mounted on these metal or
wood support members.
Numerous mounting arrangements are known in the prior
art for mounting an electrical box to a metal or wood stud.
Due to the substantial differences between metal and
wood support members, most mounting arrangements are
designed for use with either a metal support member or a
wood support member, but typically not both. Although,
some mounting arrangements have been developed that can be
used on both metal and wood support members. However, ~,
these mounting arrangements have several disadvantages.
For example, U.S. Patent 3,474,994 to Swanquist
discloses an electrical box mounting clip having a pair of
grippers that lock into the inturned flanges on the open
side of a metal stud. Disadvantages of the Swanquist box
mounting clip are that it cannot be mounted onto either
side of the metal stud, it can only be affixed onto the
open side of the metal stud, and the box mounting clip will
not lock onto a wood stud.
Another disadvantage of some prior mounting
arrangements is that they require holding the box to the
support member, then affixing the bracket to the support
member with a fastener such as a screw or nail. Therefore,
two hands are needed to mount an electrical box onto a
support member. Other prior mounting arrangements do not
securely grip the support member.
Examples of some prior electrical boxes with mounting
arrangements are disclosed in the following U.S. Patents:
1,705,768 to Johnson et al; 3,537,698 to Callanan et al;
3,588,019 to Cozeck et al; 3,701,448 to Vadnais; 3,730,466
to Swanquist; 3,780,209 to Schuplin; 4,062,470 to Boteler;
CA 02106801 2002-10-31
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4,135,337 to Medlin; 4,140,293 to Hansen; 4,176,758 to Glick;
4,447,030 to Nattel; 4,747,506 to Stuchlik, III; 4,880,128 to
Jorgensen; 4,892,211 to Jorgensen and 5,025,944 to Rodick.
Thus, there exists a need to provide an improved electrical
box assembly with a mounting bracket which can be used with either
metal or wood support members and is relatively easy to install.
This invention addresses this need in the art, along with other
needs which will become apparent to those skilled in the art once
given this disclosure.
Summary of the Invention
Accordingly, primarily the invention seeks to provide a
mounting bracket coupled to an electrical box for mounting the
electrical box tin a support member by resiliently gripping a
support member in such a manner as to prevent relative movement
between the electrical box and the support member,
Further the invention seeks to provide a mounting bracket
with inwardly angled arms which will grip a support member of any
depth and prevent vertical movement of the electrical box along
the support member.
Still further the invention seeks to provide a mounting
bracket which will grip on either side of a support member.
Further still the invention seeks to provide a mounting
bracket which can be used with either metal or wood support
members.
Yet further the invention seeks to provide a mounting bracket
which can be quickly and easily installed onto a suppart member.
Further still the invention seeks to provide a mounting
bracket which is relatively inexpensive t:o manufacture.
CA 02106801 2002-10-31
t~
Moreover the invention seeks to provide a mounting bracket
that can be mounted on studs or support members with any size
dep th .
Yet further the invention seeks to provide a mounting bracket
that does not require a separate fastener to secure it to either
a metal or wood stud.
The foregoing aspects are basically attained by providing an
electrical box assembly for mounting to a support member, the
combination comprising an electrical housing, a substantially U-
shaped bracket for supporting the housing on the support member,
the bracket including a substantially flat base portion, a first
leg portion coupled substantially perpendicular to the base
portion, a second leg portion coupled substantially
perpendicularly to the base portion to form a space for receiving
the support member between the first and second leg portions and
a first pair of arms coupled to opposite ends of the first leg
portion and angled inwardly into the space formed by the first and
second leg portions for gripping the support member, a second pair
of arms coupled to opposite ends of the second leg portion and
angled inwardly into the space formed by the first and second leg
portions for gripping the support member and coupling elements for
fixedly coupling the bracket to the housing.
The foregoing aspects are also attained by providing a
mounting bracket assembly adapted to be coupled to an electrical
box and mounted on a support member, the combination comprising a
substantially flat base portion, a first leg portion coupled
substantially perpendicularly to the base portion, the first leg
portion having an inwardly facing surface with a gripping portion
lying in a first plane and an outwardly facing surface, a second
leg portion coupled substantially perpendicularly to the base
portion to form a space with the base portion and the leg portion
CA 02106801 2002-10-31
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for receiving a support member between the first and second leg
portions, a first arm coupled to one end of the first l.eg portion
for resiliently gripping the support member, the first arm having
a gripping portion lying in a second plane substantially parallel
to the first plane forming a first slot between the first and
second planes of the gripping portions for receiving a flange of
the support member therein and coupling means for rigidly coupling
the bracket to an electrical box.
The foregoing aspects are further attained by providing a
mounting bracket assembly adapted to be coupled to an electrical
box and mounted on a support member, the combination comprising a
substantially flat base portion with an inwardly facing surface
lying in a first plane for contacting the support surface, a first
leg portion coupled substantially perpendicularly to the base
portion, a second leg portion coupled substantially
perpendicularly to the base to form a space with the base portion
and the first leg portion for receiving a support member between
the first and second leg portions, a first arm coupled to one end
of the first leg portion for resiliently gripping the support
member, the first arm having a gripping portion lying in a second
plane to form a first slot between the first and second planes for
receiving and gripping a flange of the support member and coupling
member for rigidly coupling the bracket to an electrical box.
Other aspects, advantages and salient features of the
invention will become apparent from the following detailed
description, which, taken in conjunction with the annexed drawings
discloses several embodiments of the invention.
Brief Description of_the Drawings
Referring now to the drawings which form part of this
original disclosure:
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Fig. 1 is a front elevational view of a first
embodiment of an electrical box assembly with mounting
bracket in accordance with the present invention;
Fig. 2 is a back elevational view of the electrical
box assembly with mounting bracket shown in Fig. 1;
Fig. 3 is a bottom plan view of the electrical box
assembly with mounting bracket shown in Figs. 1 and 2;
Fig. 4 is a right side elevational view of the
electrical box assembly with mounting bracket shown in
Figs. 1-3;
Fig. 5 is a partial, front elevational view of the
electrical box assembly with mounting bracket shown in
Figs. 1-4 mounted on a conventional metal stud;
Fig. 6 is a partial, bottom plan view of the
electrical box assembly with mounting bracket shown in
Figs. 1-5 mounted on a conventional metal stud;
Fig. 7 is a top plan view of the mounting bracket of
Figs. 1-6 prior to bending;
Fig. 8 is a partial, front elevational view of a
2p second embodiment of an electrical box assembly with
mounting bracket;
Fig. 9 is a partial, front elevational view of the
electrical box assembly with mounting bracket as shown in
Fig. 8, mounted to a conventional wood stud;
z5 Fig. 10 is a perspective view of a third embodiment of
mounting bracket adapted to be coupled to an electrical
box;
Fig. 11 is a side elevational view of the mounting
bracket shown in Fig. 10;
30 Fig. 12 is a partial, bottom plan view of the mounting
bracket shown in Figs. 10 and 11 coupled to an electrical
box;
Fig. 13 is a partial, back elevational view of a
fourth embodiment of an electrical box assembly with a
35 mounting bracket in accordance with the present invention;
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Fig. 14 is a side elevational view of the mounting
bracket shown in Fig. 13 with the electrical box removed;
Fig. 15 is a partial, exploded, back elevational view
of a fifth embodiment of a mounting bracket adapted to be
mounted to an electrical box;
Fig. 16 is a side slsvaflond1 view of the mounting
bracket shown in Fig. 15;
Fig. 17 is a side slsvaflond1 view of a sixth mounting
bracket adapted to be coupled to an electrical box;
Fig. 18 is a back slsvaflond1 view of the mounting
bracket shown in Fig. 17;
Fig. 19 is a bottom end view of the mounting bracket
of Figs. 17 and 18;
Fig. 20 is a top plan view of the mounting bracket of
Figs. 17-19 prior to bending;
Fig. 21 is a partial, bottom plan view of the mounting
bracket shown in Figs. 17--20 mounted on a conventional
metal stud;
Fig. 22 is a partial, side slsvaflond1 view of the
mounting bracket shown in Figs. 17-21 mounted on a
conventional metal stud with the electrical box removed;
and
Fig. 23 is a side slsvaflond1 view of a seventh
mounting bracket in accordance with the present invention. v
25' Detailed Description of the.Invention
As seen in Figs. l, 2 and 6, an electrical box
assembly 10 in accordance with a first embodiment of the
present invention is illustrated, and includes a housing 12
in the form of a wall or junction box, and a mounting
bracket 14 rigidly coupled to housing 12. The mounting
bracket 14 resiliently grips a metal stud or support member
16 for fixedly coupling housing 12 to stud l6.
dousing 12 has four substantially planar side walls
18, 20, 22 and 24, and a rear wall 26. Rear wall 26 and
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side walls 18, 20, 22 and 24 are rigidly coupled together
to form a substantially rectangular box with a top opening
28 for receiving an electrical wiring device therein.
While housing 12 is shown as a square box, it could also be
a round, polygonal, or other shaped box.
Housing 12 is preferably formed as a one-piece member
from a conventional metallic material, such as galvanized
steel or aluminum. Alternatively, housing 12 can be foraged
as a one-piece, unitary, integrally molded member from a
suitable non-metallic material, such as a thermoplastic or
thermoset composition.
As particularly seen in Figs. 1-3, housing 12 has a
plurality of break-out windows 30 and auxiliary holes 32
and 32a. Break-out windows 30 can be removed as necessary
to install electrical wires into housing 12. Auxiliary
holes 32 and 32a can be either used to support housing 12
to a support member with conventional fasteners (not
shown). Auxiliary holes 32 in rear wall 26 can be used to
attach an electrical box support thereto as described in
U~S. Patent 4,898,357 to Jorgensen et al.
Additionally, side walls 18 and 22 have inwardly
extending flanges 34 and 36 with threaded holes 38 and 40,
respectively. Threaded holes 38 and 40 threadedly receive
screws 42 and 44, respectively, for fastening an electrical
wiring device (not shown) or a cover (not shown) to housing
12.
Mounting bracket 14 is preferably formed as a one-
piece, unitary member from spring steel or any other
suitable resilient material. Alternatively, mounting
~~racket 14 can be formed as a one-piece, unitary, ~ .
integrally molded member from a suitable non-metallic
material, such as thermoplastic.
Housing 12 is preferably fixedly and rigidly coupled
to mounting bracket 14 by welding, as seen in Figs. 1-6, or
riveting. As particularly seen in Fig. 3, mounting bracket
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14 is substantially U-shaped with a base portion 46, a
first leg portion 48, and a second leg portion 50.
Preferably, mounting bracket i4 is formed by stamping a
piece of sheet metal into a blank, as seen in Fig. 7, and
then bending the blank along the broken lines to its final
shape as seen in Figs. 1-6.
Base portion 46 is a substantially flat, rectangular
plate with a centrally located mounting or pilot hole 64
and with its four corners removed. heg portions 48 and 50
l0 extend substantially perpendicularly from the two long
sides of base portion 46. Accordingly, leg portions 48 and
50 are substantially parallel to each other and form a
space 51 therebetween for receiving support member 16.
Preferably, the distance between leg portions 48 and 50 is
approximately 1~ inches to accommodate either metal or wood
support members, i.e., studs or joists.
Leg portions 48 and 50 are substantially identical,
except that second leg portion 50 has four embosses 52 and
is a mirror image of first leg portion 48.
As seen in Fig. 4, first leg portion 48 is a
substantially flat, rectangular plate with its four corners
removed. An inwardly angled arm 56 extends from each of
the short ends of first leg portion 48 inwardly into space
51. Each of the inwardly angled arms 56 has upper edge 55
and an outwardly extending wing 60 along the lower portion
of arm 56.
Second leg portion 50 is a substantially flat,
rectangular plate with its four corners removed. An
inwardly angled arm 58 extends from each of the short ends
of second leg portion 50 inwardly into space 51. Each of
the inwardly angled arms 58 has an upper edge 59 and an
outwardly extending wing 62 along the lower portion of arm
58.
As seen in Figs. 5 and 6, each of the upper edges 59
is angled downwardly away from second leg portion 50 to
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form a wedge-shaped space between the plane of base portion
46 and the respective upper edge 59. These wedge-shaped
spaces are sized to receive a portion of metal stud 16.
Upper edges 59 engage metal stud 16 to prevent any relative .
movement therebetween. In particular, edges 59 will dig
into the metal stud 16 upon attempting longitudinal
movement of bracket 14 along stud 16. Contact between
edges 59 and metal stud 16 is maintained by first leg
portion 48 which pulls edges 59 into contact with stud 16
due to the resiliency of bracket 14.
Similarly, upper edges 55 are angled downwardly away
from first leg portion 48 to form wedge-shaped spaces
between the plane of the base portion 46 and upper edges
55. These wedge-shaped spaces are sired to receive a
portion of metal stud 16 when box 10 is mounted on the
opposite side o~ stud 16 from that seen in Figs. 5 and 6.
Upper edges 55 will engage metal stud 16 to prevent any
relative movement therebetween. In particular, edges 55
will dig into the metal stud 16 upon attempting
longitudinal movement.of bracket 14 along stud 16. Contact
between edges 55 and metal stud l6.wi11 be maintained by
the second leg portion 50 which pulls edges 55 into contact
with stud 16 due to the resiliency of bracket 14.
As seen in Figs. 5 and 6, first leg portion 48 , and
second leg portion 50 are resiliently coupled to the base
portion 46 to exert pressure on stud 16 for securely
gripping stud 16. This pressure is accomplished by
ensuring that the space between the free ends of arms 56
and 58 is less than the cross-sectional thickness of metal
stud 16.
Alternatively, bracket 14 can be used by a wood stud
or joist. Upon mounting bracket 14 on a wood stud or
joist, inwardly angled arms 56 and 58 will resiliently grip
the wood stud or joist. Arms 56 and 58 prevent
longitudinal movement of box 10 along the stud or joist,
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since the free end edge will dig into the wood upon
attempting longitudinal movement.
As specifically seen in Figs. 1 and 5, outwardly
extending wings 60 and 62, respectively, extend outwardly
at an angle of approximately 30° from each of the inwardly
angled arms. Outwardly extending wings 60 and 62 serve as
ramps to bias leg portions 48 and 50 outwardly along with
arms 56 and 58 to receive metal stud 16 into space 51.
Second leg portion 50 is rigidly coupled to side wall
~0. As seen in Fig. 7, second leg portion 50 has four
embosses S2, which aid in welding the mounting bracket 14
to housing 12.
As seen in Fig. 5, pilot hole 64 is located in the
center of base portion 46 and can receive an optional
mounting screw 66 or other suitable fastener. The head of
optional mounting screw 66 is slightly larger than pilot
hole 64 to further secure mounting bracket 14 to metal stud
16, if desired.
Installation
20' To install the electrical box assembly 10, mounting
bracket 14 is pressed by one hand either onto side of metal
stud 16, as seen in Figs. 5 and 6, or onto a wood stud (not
shown). The outwardly extending wings 60 and 62 serve as
ramps to bias leg portions 48 and 50 outwardly, upon
engaging metal stud 16. Thus, the mounting bracket 12 is
easily snapped onto metal stud 16. Inwardly angled arms 56
and 58 resiliently grip the metal stud 16 to secure a tight
fit between bracket 14 and metal stud 16. In particular,
inwardly extending arms 56 and 58 engage the metal stud 16
to prevent any relative movement between the box 10 and the
stud 16.
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Second Embodiment of Figs. 8 and 9
Referring now to Figs. 8 and 9, an electrical box
assembly 110 is illustrated in accordance with a second
embodiment of the present invention, and includes a housing
112 rigidly coupled to a mounting bracket 114.
Housing 112 is substantially identical to housing 12
as shown in Figs. 1 and 2. Therefore, housing 112 will not
be discussed or illustrated in detail.
Mounting bracket 114 is substantially U-shaped with a
base portion 146, a first leg portion 148 with arms 156,
and a second leg portion 150 with arms 158.
Haunting bracket 114 is substantially identical to
mounting bracket 14 illustras~ed in Figs. 1-6, except that
the arms 156 and 158 of mounting bracket 114 have been
modified to improve gripping of a wood stud as discussed
below. Therefore, mounting bracket 114 will not be
discussed in detail.
Located at both ends of first leg portion 148 are the
inwardly angled arms 156. Each of the arms 156 includes a
first arm portion 172, a second arm portion 174, and a
third arm portion 176.
The first arm portion 172 extends outwardly at an
angle of approximately 45° from the end of first leg portion
148. The second arm portion 174 extends inwardly at an
angle of approximately 30° from first arm portion 172. The
third arm portion 1?6 is preferably angled slightly
inwardly from second arm portion 174.
The lower portion of each of the third arm portions
176 has an outwardly extending wing 160, which extends
outwardly at an angle of approximately 30° from the
respective third arm portion 176. The upper portion of
each of the third arm portions 176 has an edge 155 with a
pair of inwardly angled gripping teeth 170.
Located at opposite ends of second leg portion 150 are
the inwardly angled arms 158. The lower portion of each of
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the inwardly angled arms 158 has an outwardly extending
wing 162, which extends outwardly at an angle of
approximately 30° from the respective inwardly angled arm
158. The upper portion of each of the inwardly angled arms
158 has an edge 159 with an inwardly angled pair of
gripping teeth 168 for gripping the wood stud 116.
As seen in Fig. 9, inwardly angled gripping teeth 168
and 170 slightly penetrate the wood stud 116, thereby
insuring a secure fit. For the purpose of illustration,
the penetration of gripping teeth 168 and 170 into the wood
stud 116 has been exaggerated.
Gripping teeth 168 and 170 are sufficient by
themselves to securely fasten the mounting bracket 214 to
the wood stud 116. However, mounting bracket 214 may be
further secured to the wood stud by an optional nail, if
desired. In particular, a mounting or pilot hole 164 is
located in the center of second member 148 and can receive
an optional nail 166 or other suitable fastener. The head
of nail 166 is slightly larger than mounting hole 164 to
further secure mounting bracket 114 to wood stud 116, if
desired.
When bracket 114 is mounted on a metal support member,
edges 155 or 159 will engage the metal support member in
substantially the same manner as edges 55 and 59 of bracket
14 engage stud 16 discussed above. Accordingly, bracket
114 can be used with either metal or wood support members.
Third Embodiment of Fius. 10-12
Referring now to Figs. 10-12, an electrical box
assembly 210 is illustrated in accordance with a third
~odiment of the present invention. As seen in Fig. 12,
electrical box assembly 210 includes a housing or
conventional electrical box 212 rigidly coupled to a
mounting bracket 214. This embodiment permits mounting
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.: ,; '; x ,r' '' . .: ; . :y. .
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bracket 214 to be mounted on any conventional electrical
box without the need of any tools or additional fasteners.
Housing 212 is substantially identical to housing 12
as shown in Figs. 1 and 2. Therefore, housing 212 will not
be discussed or illustrated in detail.
Mounting bracket 214 is substantially U-shaped with a
base portion 246, a first leg portion 248 with arms 256,
and a second leg portion 250 with arms 258. Mounting
bracket 214 is substantially identical to mounting bracket
14 illustrated in Figs. 1-6, except that mounting bracket
214 has been modified to be rigidly coupled to a
conventional electrical box or housing 212 by clamping tabs
282, as discussed below, rather than by welds or rivets.
Therefore, only the differences between mounting bracket
214 and mounting bracket 14 will be discussed in detail.
Mounting bracket 214 is preferably stamped and folded
from a single sheet of metal to form an integral, unitary,
one-piece bracket.
Second leg portion 250 has a pair of openings 280
st~Ped out of leg 250 to form a pair of clamping tabs 282.
Clamping tabs 282 are resiliently coupled to leg 250 by
connecting portions 284. Connecting portions 284 extend
outwardly and downwardly from leg 250 to space clamping
tabs 282 from leg 250 for receiving a side wall of housing
212 between the inner surfaces of the clamping tabs 282 and
the outer surface of leg 250.
Each of the clamping tabs includes a base portion 286
extending downwardly from connecting portion 284 and
inwardly towards leg 250, and a gripping portion 288
extending downwardly and outwardly from base portion 286.
Each base portion 286 is substantially planar and
forms a space 290 between its inner surface and the outer
surface of leg 250 to receive a side wall of housing 212
therein.
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Gripping portion 288 has a pair of angled barbs 292
extending upwardly and inwardly from gripping portion 288
for engaging a side wall of an electrical box.
ors seen in Fig. 12, mounting bracket 214 is rigidly
5 coupled to housing 212 by clamping tabs 282. In
particular, side wall 220 of housing 212 is slid into , ~.
spaces 290 formed between leg 250 and clamping tabs 282
thereby causing clamping tabs 282 to be deflected outwardly
from leg 250. The resiliency of connecting portions 284
10 and clamping tabs 282 cause clamping tabs 2B2 to apply a
force inwardly against the side wall 220. Specifically,
side wall 220 is clamped between leg 250 and clamping tabs
282 with angle barbs 292 engaging and digging into side
wall 220. Thus, mounting bracket 214 is rigidly coupled to
15 housing 214. Next, mounting bracket 214 can be mounted
onto a support member 216 in substantially the same manner
that mounting bracket 14 is coupled to support member 16 as
discussed above.
Fourth Embodiment of Figs. 13 and 14
Referring now to Figs. 13 and 14, an electrical box
assembly 310 is illustrated in accordance with a fourth
embodiment of the present invention. As seen in Fig. 13,
electrical box assembly 310 includes a housing: or
conventional electrical box 312 rigidly coupled to a
mounting bracket 314.
Housing 312 is substantially identical to housing 12
as shown in Figs. 1 and 2. Therefore, housing 312 will not
be discussed or illustrated in detail.
Mounting bracket 314 is substantially U-shaped with a
base Portion 346, a first leg portion 348 with arms 356,
and a second leg portion 350 with arms 358. Mounting
bracket 314 is substantially identical to mounting bracket
14 illustrated in Figs. 1-6, except that mounting bracket
314 has been modified to be rigidly coupled to an
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electrical box or housing 312 by rivets 382, as discussed
below, rather than by welds, and second leg portion 350 has
been modified to have an offset portion 392. Therefore,
only the differences between mounting bracket 314 and
mounting bracket 14 will be discussed in detail.
Second leg portion 350 has an offset portion 392 bent
outwardly from a main portion 394 of second leg portion
350. A transition portion 396 connects offset portion 392 .
to main portion 394 of second leg portion 350. Offset
portion 392 is substantially flat and parallel to main
portion 394. Preferably, offset portion 392 is spaced
about 1/16 of an inch outwardly from main portion 394, and
spaced about 9/64 of an inch away from the outer surface of
base portion 346, to provide clearance for an outlet cover
which is slightly larger than the outside dimensions of the
electrical box.
Offset portion 392 can be provided with holes 398 for
coupling mounting bracket 314 to electrical box 312 via
rivets 382 or other suitable fasteners. Of course, offset
potion 392 could be Welded to electrical box 312.
~=f~ Embodiment of FicZs . 15 and 16
Referring now to Figs. 15 and 16, an electrical box
assembly 410 is illustrated in accordance with a fifth
embodiment of the present invention. As seen'in Fig. 15,
electrical box assembly 410 includes ~a housing or
electrical box 412 adapted to be rigidly coupled to a
mounting bracket 414. This embodiment permits mounting
bracket 414 to be mounted on any conventional electrical
box without the need of any tools,or additional fasteners.
Housing 412 is substantially identical to housing 12
as shown in Figs. 1 and 2. Therefore, housing 412 will not
be discussed or illustrated in detail.
Mounting bracket 414 is substantially U-shaped with a
base portion 446, a first leg portion 448 with arms 456,
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and a second leg portion 450 with arms 458. Mounting
bracket 414 is substantially identical to mounting bracket
214 illustrated in Figs. 10-12, except that second leg
portion 450 of mounting bracket 414 has been modified to
have an offset portion 492 as discussed below. Therefore,
only the differences between mounting bracket 414 and
mounting bracket 214 will be discussed in detail.
Second leg portion 450 has an offset portion 492 bent
outwardly from a main portion 494 of second leg portion
450. A transition portion 496 connects offset portion 492
to main portion 494 of second leg portion 450. Offset
portion 492 is substantially flat and parallel to main
portion 494. Preferably, offset portion 492 is spaced
about 1/16 of an inch outwardly from main portion 494, and
spaced about 9/64 of an inch away from the outer surface of
base portion 446 to provide clearance for an outlet cover
which is slightly larger than the outside dimensions of the
electrical box.
Offset portion 492 is provided with a pair of clamping
tabs 482 for securely coupling mounting bracket 414 to
electrical box 412. Clamping tabs 482 are substantially
identical to clamping tabs 282, and thus will not be
discussed in detail herein.
Sixth Embodiment of Fias. 17-22
Mounting bracket 514 is preferably formed as a one
piece, unitary member from spring steel or any other
suitable resilient material. Alternatively, mounting
bracket 514 can be formed as a one-piece, unitary,
integrally molded member from a suitable non-metallic
material, such as thermoplastic.
Housing 512 is preferably fixedly and rigidly coupled
to mounting bracket 514 by riveting, as seen in Fig. 21, or
by other suitable fastening means. As particularly seen in
Fig. 19, mounting bracket 514 is substantially U-shaped
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with a base portion 546, a first leg portion 548, and a
second leg portion 550. Preferably, mounting bracket 514
is formed by stamping a piece of sheet metal into a blank,
as seen in Fig. 20, and then bending the blank along the
broken lines to its final shape as particularly seen in
Figs. 17-19.
Base portion 546 is a substantially flat, rectangular
plate with a centrally located mounting or pilot hole 564
and with its four corners removed. Leg portions 548 and
550 extend substantially perpendicularly from the two long,
longitudinal sides of base portion 546. Accordingly, leg
portions 548 and 550 are substantially parallel to each
other and form a space 551 therebetween for receiving
support member 516. Preferably, the distance between leg
Portions 548 and 550 is approximately 1~ inches to
accommodate either metal or wood support mesabers, i.e.,
studs or joists.
Leg portions 548 and 550 are substantially identical
in construction, except that second leg portion 550 has a
raised portion 552 and is a mirror image of first leg
portion 548.
As seen in Figs. 17- .21, first leg portion 548 is a
substantially flat, rectangular plate with an inwardly
surface and an outwardly facing surface. An inwardly,
ogled arm 556 extends inwardly from each of the short ends
of first leg portion 548 into space 551. Each of the
inwardly angled arms 556 has upper edge 555 and an
outwardly extending wing 560 along the lower portion of arm
556.
A slot or notch 561 is formed between each of the
short ends of first leg portion 548 and upper edges 555 of
arms 556 for receiving flange 516a of support member 516.
In particular, slots 561 is sufficiently larger in depth
than the length of Flange 516a of support member 516 to
allow flange 516a to easily enter slots 561. Each of the
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slots 561 is preferably substantially U-shaped with a pair
of gripping edges or portions 561a and 561b. Gripping
edges 561a are formed along the inner surface or edge of
the respective short ends of first leg portion 548, while
gripping edges 561b are formed along the outer surface or
edge of arms 556.
Gripping edges 561b are spaced laterally inwardly from
gripping edges 561a towards the center of space 551 since
gripping edges 561b are formed on the inwardly angled arms
556. In other words, gripping edges 561a lie in a first
plane formed along the inner surface of first leg portion
548, while gripping edges 561b lie in a second plane which
is parallel to the first plane of gripping edges 561x. The
distance between the first plane of gripping edges 561a and
the second plane of gripping edges 561b is slightly less
than the thickness of flange 516a of support member 516,
i.e., about one-sixty fourth of an inch. ,.
P~ccordingly, when mounting bracket 514 is mounted on
support member 516, flange 516a o~ support member 516 will
be positioned in slots 561 with gripping forces being
applied to flange 516a by gripping edges 561a and 561b. In
particular, the resiliency of the material of bracket 514
will cause gripping edges 561a and gripping edges 561b to
apply oppositely directed forces on flange 516a to firmly
secure bracket 514 to support member 516. Depending on the
material, i.e., thickness and hardness, of support member ,
516, the forces applied by gripping edges 561a and gripping
edges 561b may cause flange 516a to bend or crimp.
Arms 556 may also be provided with a sharp gripping
tooth 563 to provide additional gripping strength. Teeth
563 are particularly useful when bracket 514 is mounted on
a wood stud. Each tooth 563 is located along upper edge
555 at the free end of the respective arm 556. Tooth 563
is angled inwardly towards space 551 to engage the side of
support member 516.
210681
-20-
Second leg portion 550 is a substantially flat,
rectangular plate with an inwardly facing surface and an
outwardly facing surface. An inwardly angled arm 558
extends inwardly from each of the short ends of second leg
portion 550 into space 551. each of the inwardly angled
arms 558 has an upper edge 559 and an outwardly extending
wing 562 along the lower portion of arm 558.
Second leg 550 and arms 558 will not be discussed in
detail, since second leg portion 550 and arms 558 axe
substantially identical in construction to first leg
portion 548 and arms 556, respectively.
As particularly seen in Figs. 21 and 22, a slot or
notch 561' is formed between each of the short ends of
second leg portion 550 and upper edges 559 of arms 558 for
receiving flange 516a of support member 516. In
particular, slots 561' is sufficiently larger in depth than
the length of flange 516a of support member 516 to allow
flange 516a to easily enter slots 561'. Each of the slots
561' is preferably substantially U-shaped with a pair of
gripping edges or portions 561c and 561d. Gripping edges
561c are formed along the inner surface or edge of the
respective short ends of second leg portion 550, while
gripping edges 561d are formed along the outer surface or
edge of arms 558.
Gripping edges 561d are spaced laterally inwardly from
gripping edges 561c towards the center of space 551 since
gripping edges 561d are formed on the inwardly angled arms
558. In other words, gripping edges 561c lie in a third
plane formed along the inner surface of first leg portion
550, while gripping edges 561d lie in a fourth plane which
is parallel to the third plane of gripping edges 561c. The
distance between the first plane of gripping edges 561c and
the second plane of gripping edges 5614 is slightly less
than the thickness of flange 516a of support member 516,
i.e., about one-sixty fourth of an inch.
21~68~1
- 21 -
Accordingly, when mounting bracket 514 is mounted on
support member 516, flange 516a of support member 516 will
be positioned in slots 561' with gripping forces being
applied to flange 516a by gripping edges 561c and 561d. In
particular, the resiliency of the material of bracket 514
will cause gripping edges 561c and gripping edges 561d to
apply oppositely directed forces on flange 516a to firmly
secure bracket 514 to support member 516. Depending on the
material, i.e>, thickness and hardness, of support member
516, the forces applied by gripping edges 561c and gripping
edges 561d may cause flange 516a to bend or crimp.
As seen in Fig. 21, first leg portion 548 and second
leg portion 550 are resiliently coupled to the base portion
546 to exert pressure on support member 516 for securely
gripping support member 516. This pressure is accomplished
by ensuring that the space between the free ends of arms
556 and 558 is less than the cross-sectional thickness of
metal stud 516.
As specifically seen in Figs. 17-19, outwardly
extending wings 560 and 562, respectively, extend outwardly ~,
at an angle of approximately 30° from each of the inwardly
angled arms. Outwardly extending wings 560 and 562 serve
as ramps to bias leg portions 548 and 550 outwardly along
with arms 556 and 558 to receive metal stud 516 into space
551.
As seen in Fig. 18, pilot hole 564 is located in the
center of base portion 546 which can receive an optional
mounting screw or other suitable fastener to further secure
mounting bracket 514 to metal stud 516, if desired.
As mentioned above, bracket 514 can be used on a wood
stud or joist. Upon mounting bracket 514 on a wood stud or
joist, inwardly angled arms 556 and 558 will resiliently
grip the wood stud or joist. Arms 556 and 558 prevent
longitudinal movement of box 510 along the stud or joist,
2106~~1
- 22 -
since the teeth 563 will dig into the wood upon attempting
longitudinal movement.
Seventh Embodiment of Fia. 23
Referring now to Fig. 23, a mounting bracket 614 in
accordance with a seventh embodiment of the invention is
~s.llustrated and includes a base portion 646, a first leg
portion with arms (not illustrated,), and a second leg .
portion 650 with arms 658.
Mounting bracket 614 is substantially identical to
mounting bracket 514 illustrated in Figs. 17-22, except
that mounting bracket 614 has been modified to be rigidly
coupled to a conventional electrical box or housing by
clamping tabs 682, as discussed below, rather than by
rivets. Therefore, only the differences between mounting
bracket 614 and mounting bracket 514 will be discussed in
detail.
Mounting bracket 614 is preferably stamped and folded
from a single sheet of metal to form an integral, unitary,
one-piece bracket. , This embodiment permits mounting
bracket 614 to be mounted on any conventional electrical
box without the need of any tools or additional fasteners.
Second leg portion 650 has a pair of openings 680
stamped out of leg 650 to form a pair of clamping tabs 682.
Clamping tabs 682 are resiliently coupled to,leg 650 by
connecting portions 684. Connecting port~.ons 684 extend
outwardly and downwardly from leg 650 to space clamping
tabs 682 from leg 650 for receiving a side wall of housing
(not shown) between the inner surfaces of the clamping tabs
682 and the outer surface of leg 650.
Each'of the clamping tabs includes a base portion 686
extending downwardly from connecting portion 684 and
inwardly towards leg 650, and a gripping portion 688
extending downwardly and outwardly from base portion 686.
~1a68~1.
_ 23 _
Each base portion 686 is substantially planar and
forms a space between its inner surface and the outer
surface of leg 650 to receive a side wall of a housing or
electrical box (not shown) therein.
dripping portion 688 has a pair of angled barbs 692
extending upwardly and inwardly from gripping portion 688
for engaging a side wall of an electrical box.
While several embodiments have been chosen to -
illustrate the invention, it will be understood by those
skilled in the art that various changes and modifications
can be made herein without departing from the scope of the
invention as defined in the appended claims.
