Note: Descriptions are shown in the official language in which they were submitted.
CA 02606647 2007-10-12
INSTALLATION BRACKET FOR ELECTRICAL BOX, ELECTRICAL BOX
ASSEMBLY, AND METHOD OF USE
CROSS-REFERENCE TO RELATED APPLICATION
This application claims the priority right of applicant's prior co-pending
provisional application Serial No. 60/829,991 filed October 18, 2006.
FIELD OF THE INVENTION
The invention relates to the field of electrical boxes, and brackets to
position
and retain such electrical boxes in a partition or on a wall.
BACKGROUND TO THE INVENTION
During building construction or maintenance electrical outlets or switches, as
well as other electrical devices, are positioned in or adjacent a partition or
wall so
that they are reachable by occupants of the building. These electrical devices
are
typically positioned in, or wired into, electrical boxes which are themselves
be
mounted in a cavity between two walls of a partition. The mounting process has
often presented challenges to the building industry, and can be the cause of
delay
during constructiQn.
Electrical box mounting is generally facilitated by the use of an installation
bracket to position the electrical box at a desired position adjacent or near
a rear face
of a front wall of a partition. Several electrical box installation brackets
are known
in the art, and most share a number of common features. These include a
mounting
plate to which an electrical box can be mounted, the mounting plate generally
defining an aperture therethrough or other opening to allow access to an
internal
cavity of any electrical box mounted to the bracket, and any electrical device
retained therein. Importantly, the installation bracket may further include
means to
rigidly fix the bracket to a wall stud or a floor member, thereby to provide a
secure
mounting place for the electrical box immediately behind the front wall of the
partition. In this way, the mounting plate may be located flush with or at
least near
to a rear surface of the front wall, with the electrical box extending back
into the
ca.vity. Access may be gained to the electrical box by a hole in the wall in
line with
the aperture of the mounting plate.
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CA 02606647 2007-10-12
The complete electrical box assembly may further include a box ring or mud
ring of a type that is well known in the art. Typically, a box ring or mud
ring may
be mounted to the installation bracket on a side opposite to the electrical
box so as to
pass though a hole in the wall which is cut (for example by a router) to
accommodate the ring.. The box ring may. include an aperture that is
continuous
with an aperture in the mounting plate of the installation bracket once the
box ring is
secured thereto, so as to provide access an internal recess within an
electrical box
from the front exterior of the partition.
The size and depth of the required electrical box, the depth of the recess
extending from the installation bracket into the electrical box, and the depth
of the
cavity of the partition, may vary according to the building project and the
electrical
devices to be installed in the partition. Selected electrical devices, such as
for
example speaker or horn devices, may be wider and / or deeper than other
electrical
devices such as electrical switches or sockets. Such larger electrical devices
may
require a significant mounting depth within a partition cavity, or may further
require
the use of a larger electrical box to accommodate their bulk. For this reason,
an
electrician installing such electrical box assemblies may be required to have
numerous types and sizes of electrical boxes to hand, as well as numerous
types and
sizes of installation brackets correspond.ing to such electrical boxes.
Importantly,
the electrician must use'skill and careful judgment to select an electrical
box and
associated components suitable to accommodate a particular electrical device
before
securing the electrical box and associated components in position in the
partition
cavity.
At times, it may not even be possible for the electrician to procure an
electrical box having a size or depth sufficient to accommodate certain
electrical
devices. Under these circumstances, an electrician may be obliged to resort to
the
fashioning or combining of various components to achieve an electrical box
assembly suitable to contain the required device in the partition cavity. For
example, extension rings, plates or spacers may be located between the
electrical
box and the mounting plate of the installation bracket thereby to increase the
overall
depth of the recess extending from the mounting plate back into the electrical
box,
sufficient to accommodate the electrical device.
The selection of electrical boxes and corresponding electrical box
components, as well as the possible manipulation of such components to make
them
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CA 02606647 2007-10-12
'fit' to required size or depth requirements of an electrical device, can be a
rather
haphazard and time-consuming procedure. Even an experienced electrician may
require both skill and luck to select an electrical box and corresponding
components
to construct an electrical box assembly suitable for each application, and to
successfully install such components in a partition cavity. It follows that
there
remains a continuing need to develop electrical box assemblies, and associated
components thereof, that facilitate their installation and use. In particular,
there
remains a need for electrical box assemblies, and components thereof, that
reduce
the time or effort required by an electrician to select and install such
components
during building construction and maintenance.
SUMMARY OF THE INVENTION
It is an object of the present invention, at least in preferred embodiments,
to
provide an electrical box assembly, or a component thereof, that is able to
accommodate electrical boxes of more than one depth, for example in a cavity
of a
partition.
It is another object of the present invention, at least in preferred
embodiments, to provide an electrical box assembly, or a component thereof,
that is
able to accommodate electrical boxes of more than one size, for example in a
cavity
of a partition..
It is another object of the invention, at least in preferred embodiments, to
provide an installation bracket upon which can be mounted electrical boxes
having a
range of sizes and / or depths.
It is another object of the present invention, at least in preferred
embodiments, to provide an improved method of installing or retaining an
electrical
box in or on a partition.
In one aspect of the present invention there is provided an installation
bracket for mounting an electrical box to a partition comprising a front wall
and a
rear wall defining therebetween an interior space, the installation bracket
comprising:
a mounting plate having an openirig of sufficient size to receive therethrough
an electrical device;
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CA 02606647 2007-10-12
at least one stud or floor attachment means each for securing the installation
bracket to a stud or a floor, thereby to position the mounting plate alongside
a rear
face of the front wall in the interior space; and
at least one mounting flange on at least one side of the opening in the
mounting plate, each mounting flange extending from the mounting plate toward
the
rear wall, for mounting thereupon an electrical box, each mounting flange
defining
at least two electrical box anchor positions located at different distances
toward the
rear wall from a plane of the mounting plate, the installation bracket thereby
accommodating electrical boxes of varying depths within the interior space of
the
partition.
In another aspect of the present invention there is provided an electrical box
assembly comprising:
(1) the installation bracket as described above;
(2) an electrical box for mounting to the mounting flange(s) of the
installation bracket; and
(3) a plurality of fasteners to fasten components (1), and (2) together.
In another aspect of the present invention there is provided a method of
securing an electrical box within an interior space of a partition including a
front
wall and a rear wall to define the interior space, the method comprising the
steps of:
mounting the installation bracket as described above to a stud or floor; and
mounting the electrical box to the mounting flange(s) of the installation
bracket.
In another aspect of the present invention there is provided a kit for
mounting
an electrical box to a partition comprising a front wall and a rear wall
defining
therebetween an interior space, the kit comprising a first and second mounting
bracket, each comprising:
a plate portion;
a stud or floor attachment means for securing the mounting bracket to a stud
or a floor, thereby to position the plate portion of the mounting bracket
alongside a
rear face of the front wall in the interior space;
a mounting flange extending from the plate portion toward the rear wall, for
mounting thereupon an electrical box, the mounting flange defxning at least
one
electrical box anchor position;
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CA 02606647 2007-10-12
whereby by in use the first and second mounting brackets are secured to a
floor or stud so as to bring the mounting flanges into opposition, for
securing
therebetween an electrical box.
In another aspect of the present invention there is provided a method of
securing an electrical box within an interior space of a partition including a
front
wall and a rear wall to define the interior space, the method comprising the
steps of:
providing the kit of the present invention;
mounting each of the first and second mounting brackets to a stud or floor to
bring the mounting flange portions of each mounting bracket into opposition;
and
mounting the electrical box between the opposed mounting flange portions
of the mounting brackets.
The present invention further encompasses any embodiment described
herein, or any embodiment related to such embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure la illustrates a preferred installation bracket and electrical box of
the present
invention (exploded view).
Figure 1 b illustrates a preferred electrical box assembly of the present
invention
comprising an installation bracket and electrical box in accordance with
Figure 1 a.
Figure 2a illustrates a preferred installation bracket and electrical box of
the present
invention (exploded view).
Figure 2b illustrates a preferred electrical box assembly of the present
invention
comprising an installation bracket and electrical box in accordance with
Figure 2a.
Figure 3a illustrates a preferred installation bracket and electrical box of
the present
invention (exploded view).
Figure 3b illustrates a preferred electrical box assembly of the present
invention
comprising an installation bracket and electrical box in accordance with
Figure 3a.
Figure 4 illustrates a cross-sectional view of an electrical box assembly of
the
present invention positioned adjacent and through dry wall.
Figure 5 illustrates a preferred method of the invention for securing an
electrical box
on a wall or within an interior space of a partition.
Figure 6 illustrates a preferred method of the invention for securing an
electrical box
on a wall or within an interior space of a partition.
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CA 02606647 2007-10-12
Figure 7 illustrates a preferred method of the invention for securing an
electrical box
on a wall or within an interior space of a partition.
Figure 8 illustrates a preferred method of the invention for securing an
electrical box
on a wall or within an interior space of a partition.
DEFINITIONS:
Electrical box: refers to any box for retaining an electrical device therein,
to be
mounted on a rear side of a wall or in a cavity of a partition, such that the
electrical
device may be accessed and / or utilized from a front side of the wall, or
external
front side of the partition, or alternatively on another side of the
electrical box as
required. Preferably, an electrical box is made of a metal or metal alloy.
Most
preferably, the electrical box is cuboidal, and includes a substantially open
side
intended to face the aperture or opening in the installation bracket, with
smaller
orifices or openings on other sides for optional passage therethrough of
electrical
wires for connecting the electrical device(s) retained in the electrical box.
In a
preferred embodiment of the present invention, the electrical box has
sufficient
depth to accommodate the electrical device and to pass through the aperture in
the
installation bracket and extend through the hole in the adjacent wall. In
certain
embodiments this forward portion of the electrical box may be a separate
annular
ring, mechanically fixed to the box prior during assembly. The separate
annular ring
may have a different shape, for example, it may be the shape form of a box
ring such
as described in United States patent application 60/829,602 filed on October
16,
2006. In most preferred embodiments the electrical box combination may be
sized
so that it can easy slide back and forth through the aperture in the
installation bracket
until a desired depth of the electrical box is achieved in the wall or
partition. The
electrical box typically, but not necessarily, includes an open side adjacent
or near
the installation bracket to which it is affixed so that access may be gained
to an
interior space of the electrical box via an opening in the installation
bracket.
Alternatively, or additionally, the electrical box may include an optionally
removable back plate forming a side of an electrical box generally opposite
the side
adjacent an installation bracket, so that access to the interior space may be
achieved
from a rear side of the electrical box relative to a front wall and
installation bracket
of the invention. In such embodiments, the electrical box may include both a
back
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CA 02606647 2007-10-12
plate portion as well as an annular extender to provide depth to the
electrical box.
The depth of the annular extender may be selected according to the desired
application, the electrical device to be retained in the electrical box, and /
or the
depth of a cavity in a partition.
Electrical box assembly: refers to any assembly at least comprising an
installation
bracket of the present invention in combination with an electrical. Further
optional
components of the assembly may include one or more electrical devices,
fasteners
etc.
Electrical device: typically refers to any electrical device to be at least
partially
retained within an electrical box in accordance with the teachings of the
present
invention. Moreover, such a device may be reachable from the electrical box by
occupants of a building in which the electrical device is located. For
example, such
as electrical device may be selected from the following non-limiting group: a
switch,
a socket, an electrical motor, a speaker, a horn etc. In any embodiment of the
present invention, the electrical box or electrical box assembly may be
suitable for
the incorporation of multiple gangs of electrical devices.
Fastener: refers to any means of fixing or binding one component to another
such as
for example components of an electrical box assembly in accordance with the
teachings herein. A fastener typically includes a nail, or a threaded fastener
such as
a bolt and nut, or a threaded screw such as a self-tapping screw. Other
fasteners
may include a curable or settable material suitable to adhere one surface to
another,
such as a glue.
Installation bracket: refers to any device that is able to mount thereupon and
retain in
a desired position an electrical box on a wall or within a cavity of a
partition. The
installation bracket, in a basic form, may include some means upon which the
electrical box may be mounted to the bracket, as well as some means to mount
the
bracket to a secure or fixed object forming part of or adjacent the wall or
partition,
such as a wall stud or floor member. In accordance with the teachings of the
present
invention, a prefened installation bracket may further include one or more
mounting
flanges to assist in mounting of an electrical box thereto.
Mounting bracket: refers to a component of a kit of the present invention,
wherein
two mounting brackets function together to secure an electrical box in a
desired
position.
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CA 02606647 2007-10-12
Mounting flange: refers to any flange or portion of material attached to,
integral
with, or extending from selected installation brackets of the present
invention, or at
least extending adjacent mounting plates thereof. Preferably, each mounting
flange
assists in holding, retaining or securing en electrical box to an installation
bracket in
accordance with the teachings of the present invention. A mounting flange may
preferably include one or more anchor positions for affixing, mounting or
securing
thereto an electrical box or a component thereof. For example, a mounting
flange
may contact and support an electrical box, and fiuther may include means to
permit
fasteners to help fasten the electrical box to each mounting flange, thereby
to help
secure or mount the electrical box to the installation bracket. In most
preferred
embodiments, a mounting flange may be integral to a mounting plate of an
installation bracket, wherein the bracket is formed by stamping or cutting
sheet
metal, and bending a portion of the stamped or cut section of sheet metal at
an angle,
preferably about a 90 angle, relative to a plane of the mounting plate.
Further, the
bending of the aforementioned portion may result in the generation of an
aperture or
opening in the installation bracket suitable to allow access to an internal
recess of an
electrical box mounted thereto, and in a preferred embodiment of the present
invention to allow passage therethough of an electrical box prior to final
assembly of
the electrical box assembly.
Mounting plate: refers to a portion of an installation bracket of the present
invention,
which may be positioned alongside or near an internal surface front wall of a
partition, so that an electrical box may be affixed thereto or therethrough,
for
example via adjacent mounting flanges. Typically, a mounting plate may form a
main structural feature of an instaliation bracket of the present invention,
such that
floor stud or wall member attachment brackets, as well as mounting flanges,
may
extend therefrom. Typically, but not necessarily, a mounting plate may include
a
substantially planar or plate like member, that takes any shape or form, and
includes
an aperture located therein to allow access to an internal recess of an
electrical box
mounted thereto, and in a preferred embodiment of the present invention to
allow
passage therethrough of an electrical prior to fmal assembly of the electrical
box
assembly. In many embodiments, the mounting plate may be a single section of
material for example stamped or molded from a metal sheet. However, in still
further embodiments the mounting plate may have more than one part, such as
two
distinct mounting plates either separate but coordinating to define
therebetween a
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CA 02606647 2007-10-12
space equivalent to an aperture of a regular mounting plate, or alternatively,
the two
mounting plates may be slidably connected to permit a distance between the
plates,
or at least mounting flanges on the plates or portions thereof, and a size of
an
aperture defined between the plates, to vary. In this way, electrical boxes of
various
widths may be accommodated by preferred installation brackets of the
invention.
Partition: refers to any wall upon which or adjacent which an electrical box
is to be
mounted. In preferred embodiments the partition includes two walls (e.g. a
front
wall and a rear wall) defming therebetween a cavity, wherein an electrical box
may
be mounted within the cavity in accordance with the teachings of the present
invention. Most preferably, the electrical box may be mounted on or adjacent a
rear
surface (i.e. a surface internal to the cavity) of the front wall of the
partition. The
partition, including the front wall and the rear wall where present, may
comprise any
material suitable for forming the partition. More commonly, the partition may
comprise drywall, wood, expanded polystyrene, insulative foam, or any other
materials commonly used in the building industry.
Preferred / preferably: unless otherwise stated refers to features that limit
only the
broadest embodiments of the invention.
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CA 02606647 2007-10-12
DETAILED DESCRIPTION OF THE INVENTION
Installation brackets according to the present invention can accommodate
electrical boxes of various sizes. Mountiing of an electrical box to an
installation
bracket of the invention simply involves adjusting the installation bracket
(or
components thereof) in a manner to suite the size (e.g. width) or depth of the
electrical box, and then securing the electrical box to the installation
bracket for
example by way of suitable fasteners. The adaptability of the installation
brackets
facilitates electrical box placement during building construction, making such
placement more secure as well as saving valuable time of skilled electricians.
Depending upon the application, the installation brackets of the present
invention in various embodiments may allow for mounting of electrical boxes of
variable width, variable height, variable depth, or variable width and / or
height and /
or depth. In this way, an electrician working at a building construction side
can
readily and without difficulty adapt the installation brackets of the
invention to suit
the electrical devices to be installed, and the electrical boxes required to
accommodate the electrical devices.
Preferred embodiments of the installation brackets and corresponding
electrical box assemblies will now be described with specific reference to the
drawings. The embodiments are illustrated for exemplary purposes only, and in
no
way limit the scope of the invention disclosed herein.
Turning first to Figure 1 a, there is shown a preferred installation bracket
of
the present invention shown generally at 10. The bracket includes a mounting
plate
11 defining an aperture or opening 12 to allow for access to an internal space
of an
electrical box 20 to be mourited to the bracket. The opening 12 may be smaller
than
the dimensions of an electrical box such that the box is affixed to the
mounting
plate, but unable to pass through the opening 12. However, in more preferred
embodiments the opening 12 has a size sufficient for passage therethrough of
electrical box 20. For example, opening 12 may have a size just sufficient for
the
electrical box 20 to be mounted in a sliding relationship through the
installation
bracket. In this way, the electrical box may be positioned for example though
an
installation bracket from a front side of a wall, or loosely secured to the
installation
bracket, adjusted until a desired depth is achieved relative to the mounting
plate and
the front wall, and then secured in position for example by tightening
suitable
fasteners in a manner that will become further apparent from the foregoing.
CA 02606647 2007-10-12
The bracket 10 further includes stud or floor attachment means 13
comprising orifices 14a, 14b for passage therethrough of fasteners (not shown)
to
secure the bracket to a stud or floor member for example using self-tapping
wood-
screws. Although not shown, orifices 14a and 14b could alternatively be
located on
additional flange 17. Once the bracket 10 is secured to a stud or floor
member,
mounting plate 11 is typically positioned alongside or near to a rear face of
a wall of
a partition, for example within a cavity between two walls of the partition.
An important feature of the bracket 10 includes mounting flanges 15a, 15b
that are affixed to or generally integral with mounting plate 11. Although two
mounting flanges are illustrated in Figure 1, disposed on each side of opening
12,
one or more mounting flanges may be present as required. Each mounting flange
includes orifices 16a, 16b therethough intended for aligmnent with one or more
of
orifices 21 a, 21 b of side wal122 of electrical box 20. Electrical box 20 can
be
positioned between (or slid over if dimensions allow) mounting flanges 15a,
15b
until either or both of orifices 21 a and 21 b of the electrical box align
with either or
both of orifices 16a and 16b of the mounting flanges. In this way, an
electrician
may select a required depth for electrical box 20 relative to mounting plate
11
according to whether orifices 16a and 16b both align with orifices 21a and
21b, or
alternatively whether (if more depth is required) only orifice 16a aligns with
orifice
21 b. In any event, once the required orifices are aligned to achieve the
required
depth of the electrical box, fasteners may be passed through the orifices to
secure the
electrical box to the mounting flanges.
Figure 1 a further illustrates two preferred features of the electrical box
20.
Firstly, the electrical box has a forward portion 23 (differentiated from the
main
portion of the electrical box by a dotted line) such that when the electrical
box may
be positioned as shown for example in Figure lb, with the electrical box 20
extending though opening 12 in installation bracket 10, with the forward
portion of
the electrical box extends beyond or in front of a front face of the mounting
plate 11.
The double arrow shown in Figure lb illustrates how the electrica.l box 20 may
be
slid backwards and forwards through opening 12 as required to achieve a
desired
depth in a wall (not shown) so that the forward portion is also positioned as
required. The forward portion 23 of the electrical box may in certain
embodiments
(not shown) be made as separate piece, mechanically fixed to the box during
assembly so it slides back and forth with the box. This allows flexibility in
altering
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CA 02606647 2007-10-12
, ' = '
the geometry and even the size of opening of the forward portion of the box. A
typical separate piece may take the form of a box ring design as would be
known to
those skilled in the art. Also shown in Figure 1 a and 1 b are mounting tabs
16a and
16b on electrical box 20. These mounting tabs may have several uses, such as
for
example the addition or mounting of another component such as a cover plate to
the
box.
Another embodiment of the invention, similar to that shown in Figures 1 a
and 1 b, is shown in Figure 2a. In this embodiment, the mechanism of
attachment of
the electrical box 20 to the mounting flanges 15a, 15b is slightly different
to that
shown in Figure 1, in that orifices 16a, 16b are replaced by at least one slot
extending in each mounting flange generally away from a plane of the mounting
plate, towards a rear wall of a partition (not shown). In Figure 2, two
substantially
parallel slots 40a, 40b are illustrated in each mounting flange, which allow
electrical
box 20 to be affixed thereto via fasteners (not shown) extending through
orifices
41 a, 41 b in side wa1122 of the electrical box. It will be appreciated that
the slots
40a, 40b permit greater freedom of choice regarding the exact depth of the
electrical
box relative to the mounting plate. An electrician installing the electrical
box may,
for example, first loosely attach the electrical box via fasteners passing
thought
orifices 41 a, 41 b, and slots 40a, 40b, and slide the electrical box in and
out, the
fasteners sliding in slots 40a, 40b, until the desired depth for the
electrical box is
attained. Then, the electrical box may be more tightly secured in position on
the
installation bracket by tightening the aforementioned fasteners. A skilled
artisan
will further appreciate that slots corresponding to slots 40a, 40b may instead
be
disposed in side wal122 of electrical box 20, with mounting flanges 15a, 15b
including orifices for the fasteners.
Mounting flanges 15a, 15b may be affixed or integral with mounting plate 11
in any way or form. In most preferred embodiments, the mounting plate and the
mounting flanges may comprise the same material, and may be stamped, cut from
a
single sheet of material, or molded from a material, such as a metal or metal
alloy.
In this scenario, mounting flanges 15a, 15b may each be formed by bending or
folding a portion of the formed material as required, optionally assisted by
scoring
the material. The same applies for stud or floor attachment means 13.
Also illustrated in Figure 2a are two floor or stud attachment means 13a and
13b extending on opposite sides of opening 12 in installation bracket 10.
Flange 17
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CA 02606647 2007-10-12
on each floor or stud attachment means may assist in positioning and / or
securing of
the bracket relative to a stud or floor member. This is in particular useful
for floor
mounting and may be omitted for stud mounting.
Figure 2b illustrates how electrical box 20 may be positioned though opening
12 in installation bracket 10 prior to securing of the electrical box thereto.
The
double-ended arrow illustrates how the position of the electrical box may be
adjusted prior to securing of the electrical box to the installation bracket
via
mounting flanges 15a and 15b. Note how orifice 41a aligns with slot 40a in the
mounting flange 15b so that a fastener may be passed through both the mounting
flange 15b as well as wa1122'of electrical box 20.
A further preferred embodiment of the installation bracket of the invention is
illustrated in Figure 3a. This embodiment is similar to those embodiments
illustrated in Figures 1 and 2, with an important additional feature. In
Figure 3,
mounting plate 11 is formed of two distinct mounting plate sections 50a, 50b
that
are moveable relative to one another (see double-ended arrows) thereby to vary
the
distance d across a width of opening 12. In this way, installation bracket 10
is able
to accommodate not only electrical boxes of varying depth (as discussed in
relation
to Figures 1 and 2) but also electrical boxes of varying width or height.
Preferably,
mounting plate sections 50a, 50b are fixed to one another in a sliding
relationship, so
that the distance d can be altered without risk of otherwise disrupting the
relative
orientation or positions of the sections. As shown in Figure 3a, mounting
plate
sections 50a and 50b may each be separately attached to a stud or to a floor
for
example via stud or floor attachment means 13a, 13b (although only one of 13a
and
13b may be required if plate sections 50a and 50b are suitably attached to one
another in sliding relationship). However, mounting plate sections 50a, 50b
need
not necessarily be connected in any way. The invention further encompasses
embodiments virtually identical to that shown in Figure 3a, with the exception
that
the mounting plate is formed from two distinct and separate mounting plate
sections,
which can also be moved relative to one another to vary distance d. The
formation
of the mounting plate from such two distinct mounting plate sections does not
depart
from the scope of the present invention, since the sections still co-operate
to achieve
a desired function of the installation bracket to secure an electrical box in
a desired
position. However, in preferred embodiments each mounting plate section may be
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CA 02606647 2007-10-12
required to be independently secured to a wall stud or floor member via stud
or floor
attachment means.
It should also be noted that the relative orientation of the mounting flanges
shown in Figure 3a may be altered. In Figure 3a, interface 52 between mounting
plate sections 50a and 50b bisects each of mounting flanges 15a and 15b. In
still
further embodiments, the mounting flanges may be located on left and right
sides of
opening 12 such that each of mounting plate sections 50a and 50b includes an
entire
mounting flange. Still further embodiments of the invention may comprise
mounting flanges integral with the mounting brackets on all sides of opening
12.
Alternatively, if opening 12 has a shape other, than square or rectangular,
multiple
mounting flanges may be present as required, or in the case of a circular or
oval
opening 12 a tubular mounting flange may be used.
Corresponding Figure 3b illustrates an electrical box assembly in which the
electrical box 20 has been positioned through opening 12 located between
mounting
plate sections 50a and 50b. The additional double-ended arrow (compared with
Figure 3a) illustrates how the electrical box can be moved backwards and
forwards
to a desired position relative to the installation bracket 10 and wall (not
shown).
The present invention further includes, at least in selected embodiments, a
kit
for mounting an electrical box to a partition comprising a front wall and a
rear wall
defining therebetween an interior space, the kit comprising a first and second
mounting bracket, each mounting bracket comprising: (1) a plate portion; (2) a
stud
or floor attachment means for securing the mounting bracket to a stud or a
floor,
thereby to position the plate porbion of the mounting bracket alongside a rear
face of
the front wall in the interior space; (3) a mounting flange extending from the
plate
portion toward the rear wall, for mounting thereupon an electrical box, the
mounting
flange defining at least one electrical box anchor position, or more
preferably at least
two electrical box anchor positions, located at different distances toward the
rear
wall from a plane of the front wall, the mounting bracket thereby
accommodating
electrical boxes of varying depths within the interior space of the partition;
whereby
in use the first and second mounting brackets are secured to a floor or stud
so as to
bring the mounting flanges into opposition, for securing therebetween an
electrical
box. Preferably, the kit may further comprise any one or more of the following
additional components:
an electrical box;
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CA 02606647 2007-10-12
a plurality of fasteners to fasten each mounting bracket to a stud or floor;
and
a plurality of fasteners to fasten each mounting bracket to a box ring, or any
electrical box, or to fasten the mounting brackets to one another.
The embodiments of the invention shown in Figure 3 may include mounting
flanges 15a, 15b to affix an electrical box to the installation bracket.
However, the
invention further encompasses embodiments of the invention in which mounting
flanges 15a, 15b are absent, so that electrical box 20 is affixed to the
mounting plate
via more traditional means, for example employing direct securing via
fasteners
though orifices in the mounting plate. Such embodiments of the installation
bracket
are expected to accommodate electrical boxes of varying widths (by virtue of
the
moveability of the mounting plate sections 50a, 50b relative to one another),
but
exhibit less flexibility with regard to the accommodation of electrical boxes
of
varying depths (as shown in Figure 1 and 2).
It will also be appreciated that several embodiments of the invention
illustrated in the Figures include mounting flanges extending upwards and
downwards relative to the mounting plate of the installation bracket. The
invention
further encompasses installation brackets and corresponding electrical box
assemblies, in which the brackets or assemblies are effectively rotated though
90
relative to the embodiments illustrated, thereby to dispose the mounting
flanges of
the installation brackets at left and right sides of the opening in the
mounting plate.
Further, in any of the illustrated embodiments of the invention, the
orientation of the stud or floor attachment means 13a and 13b may be changed
according to the application. For example for stud attachment the stud or
floor
attachment means may be better oriented at 90 compared to the embodiments
illustrated so that stud attachment to two different studs may be effected
without
difficultly. This type of configuration is illustrated by reference to Figure
4, which
provides a cross-sectional view of an electrical box assembly of the invention
mounted between two studs. A section of dry wal180 is shown with a hole or
opening 82 therein. The installation bracket is shown generally at 10, with a
mounting plate and 1 or stud attachment means running generally flush with a
rear
side of the dry wall 80. End portions of the installation bracket are secured
via
fasteners (not shown) to studs 81 a, 81 b. Electrical box 20, comprising a
forward
portion 23 extending through opening 82 in the dry wall 80 is secured to
mounting
flanges 15a, 15b of the installation bracket 10 via fasteners (not shown). The
double
CA 02606647 2007-10-12
arrow illustrates how the electrical box 20 may be moved backwards and
forwards
relative to the installation bracket and dry wall until a desired depth of the
electrical
is achieved.
The present invention fwrther encompasses an electrical box assembly
comprising:
(1) any installation bracket of the present invention;
(2) an electrical box for mounting to the mounting flange(s) of the
installation bracket; and
(3) a plurality of fasteners or an adhesive material to fasten components
(1) and (2) together.
Such an electrical box assembly may take any form, and may comprise a kit
of separate parts for assembly into an electrical box assembly, as well as an
assembled electrical box assembly either independent to or integral with a
wall or
partition.
It should be noted that in the embodiments of the invention shown in Figures
1 to 4, or indeed any other embodiment of the installation bracket, electrical
box
assembly, or kit of the present invention, the opening 12 may be smaller than
the
d'unetisions of the electrical box 20 such that an electrical box may be
affixed to the
mounting plate, but unable to pass through the opening. However, in the
preferred
embodiments (generally illustrated in the Figures) the opening 12 has a size
sufficient for passage therethrough of electrical box 20. For example, opening
12
may have a size just sufficient for the electrical box 20 to be mounted in a
sliding
relationship with the installation bracket. In this way, the electrical box
may be
positioned or loosely secured through or adjacent the installation bracket,
positioned
at a desired depth relative to the mounting plate and the front wall, and then
secured
in position for example by tightening suitable fasteners. Such embodiments are
particularly preferred, since the resulting electrical box assembly may
include little
or no gap between the electrical box and the insta.llation bracket.
Furthermore, the
electrical box, and optionally an integral box ring if present, may be
inserted through
the opening in an installation bracket that has been pre-installed in a wall.
The
electrical box may be further provided with a detachable back plate, so that
access to
an interior volume of the electrical box may be gained from a rear side
thereof,
opposite the side adjacent the mounting plate. In this way, the electrical box
may
include a back plate portion and an annular extender to provide depth to the
16
CA 02606647 2007-10-12
electrical box, wherein the annular extender may have any suitable depth
according
to the electrical device to be contained in the electrical box, and / or the
depth of a
cavity in the dry wall.
A preferred method of the invention is illustrated with reference to Figure 5.
This method provides for the securing of an electrical box within an interior
space of
a partition including a front wall and a rear wall to defme the interior
space, the
method comprising:
in step 101 mounting an installation bracket of the present invention
comprising mounting flange(s) to a stud or floor; and
in step 102 mounting the electrical box to the mounting flange(s) of the
installation bracket.
A preferred method of the invention, corresponding to the method of Figure
5, is shown in Figure 6. In this method, step 102 of mounting the electrical
box to
the mounting flanges of the installation bracket shown in Figure 5, is broken
into
three distinct steps 102a, 102b, and 102c.
in step 102a, the electrical box is slidably mounted to the mounting flange(s)
using threaded fasteners;
in step 102b the electrical box is positioned at a desired position relative
to a
plane of the mounting plate; and
in step 102c the electrical box is secured at the desired position by
tightening
the threaded fasteners.
Another preferred method of the invention is shown in Figure 7, for securing
an electrical box within an interior space of a partition including a front
wall and a
rear wall to defme the interior space, the method comprising the steps of:
in step 201 providing a kit of the present invention, as previously described;
in step 202 mounting each of the first and second mounting brackets to a stud
or floor to bring the mounting flange portions of each mounting bracket into
opposition; and
in step 203 mounting the electrical box between the opposed mounting
flange portions of the mounting brackets.
A preferred method of the invention, corresponding to that shown in Figure
7, is illustrated with reference to Figure 8. In this method, step 203 of
mounting the
electrical box discussed with reference to Figure 7 is broken out into steps
203a,
203b, and 203c, wherein:
17
CA 02606647 2007-10-12
step 203a involves slidably mounting the electrical box to the mounting
flange portions of the mounting brackets using threaded fasteners;
step 203b involves positioning the electrical box at a desired position
relative
to a plane of the front wall; and
step 203c involves securing the electrical box at the desired position by
tightening the threaded fasteners.
Whilst the invention has been described with reference to specific
embodiments of the installation brackets, corresponding electrical box
assemblies,
and their methods of construction and use, such embodiments are merely
intended to
be illustrative of the invention and are in no way intended to be limiting.
Other
embodiments exist that have not been specifically described which nonetheless
lie
within the spirit and scope of the invention. It is the intention to include
all such
embodiments within the scope of the appended claims.
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