Note: Descriptions are shown in the official language in which they were submitted.
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BRACKET AND ASSEMBLY FOR ELECTRICAL DEVICES
FIELD OF THE DISCLOSURE
[0001] The present disclosure generally relates to a bracket for
securing an electrical assembly to a concrete wall.
BACKGROUND
[0002] In standard wood or metal frame building construction, electrical
receptacle boxes can simply be mounted on upright wood or metal wall studs, in
order to mount an electrical device, such as a convenience outlet or an
electrical
switch, and associated electrical conduit and the like. Building construction
using concrete masonry units (CMUs) (also known and referred to herein as
concrete blocks, cinder blocks, or masonry blocks), however, provides a unique
challenge in that at least some wiring of electrical receptacles needs to be
completed as the wall is being built, thus requiring cooperation between
electricians and masons.
[0003] Before installation of an electrical device in a concrete block
wall, an electrician must typically first build an electrical assembly which
includes
an electrical box, a cover or frame (sometimes referred to as a plaster ring),
conduit fitting, and a section of conduit. Once the mason builds the concrete
block wall to the desired level of electrical installation, the electrician
must hold
the assembly in place while the mason notches the block to accommodate the
assembly, applies the mortar, and sets the block. The electrician must then
secure the assembly within the block, which typically involves filling the
hollow
core of the block with broken pieces of block and mortar. This process can be
time-consuming and must be completed before the mason arrives at the next
desired location for electrical installation.
SUMMARY OF THE DISCLOSURE
[0004] Among the various aspects of the present disclosure is the
provision of a bracket and an electrical assembly including such a bracket for
mounting or otherwise securing a standard electrical assembly (e.g.,
electrical
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box, cover, and electrical device) within (that is, the bracket and/or
electrical
assembly including such bracket is disposed at least partially or completely
within) a concrete masonry unit (CMU) (particularly, for example, the inner
core
region of one or more CM Us).
[0005] Briefly, therefore, the present disclosure is directed to a bracket
for securing within an inner core region of a concrete masonry unit (CMU). In
general, the bracket comprises a face portion having a front side, a back
side,
and a bracket opening. In one embodiment, the face portion is substantially
planar. The bracket also comprises one or more support members extending
rearwardly away from the back side. In certain embodiments, the support
member(s) include one or more holes configured to receive one or more
fasteners for mounting the bracket to the inner core surface of the CMU. In
other
embodiments, the support member(s) are configured to apply a force to one or
more surfaces of the inner core region of the CMU, thus securing the bracket
within the CMU.
[0006] Another aspect of the disclosure is directed to an electrical
assembly including the bracket for securing the assembly within an inner core
region of a CMU. The bracket comprises a face portion having a front side, a
back side, and a bracket opening. In one embodiment, the face portion is
substantially planar. The bracket also comprises one or more support members
extending rearwardly away from the back side for securing the bracket within
the
inner core region of the CMU. In certain embodiments, the support member(s)
include one or more holes configured to receive one or more fasteners for
mounting the bracket to the inner core surface of the CMU. In other
embodiments, the support member(s) are configured to apply a force to one or
more surfaces of the inner core region of the CMU, thus securing the bracket
within the CMU. In addition to the bracket, the electrical assembly comprises
an
electrical box having side walls defining a front opening. The bracket opening
is
configured to cooperate with the front opening of the electrical box when the
electrical box is positioned on the back side of the face portion. The
electrical
assembly also comprises a cover plate for positioning on the front side of the
face portion and mounting on the electrical box in a covering relationship to
the
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front opening and the bracket opening and capable of mounting an electrical
device. The electrical device can be included as part of the electrical
assembly
and can be, for example, a convenience outlet, an electrical switch, an
electrical
terminal, or combinations thereof. Other suitable electrical devices are also
contemplated.
[0007] The shape of the bracket opening will generally depend upon
the shape of the front opening of the electrical box to be used in conjunction
therewith. The bracket opening can be, for example, substantially rectangular-
shaped, substantially square-shaped, or substantially circular-shaped. Thus,
for
example, the electrical box shape and/or the front opening thereof can
likewise
be substantially rectangular-shaped (e.g., for single-gang electrical boxes),
substantially square-shaped (e.g., for dual-gang electrical boxes), or
substantially round or circular-shaped (e.g., for electrical fixtures), or any
other
shape that cooperates with the bracket opening.
[Own] As noted above, the bracket comprises one or more support
members which facilitate securing the bracket within the inner core region of
the
CMU. In one embodiment, the bracket comprises one support member. In
another embodiment, the bracket comprises two support members. In another
embodiment, the bracket comprises one or two support members. In another
embodiment, the bracket comprises two or more (e.g., 2, 3, 4, 5, or more)
support members.
[0009] In certain embodiments, the support member(s) generally
include at least one bracket arm portion that is connected to the face portion
(e.g., on or near that back side of the face portion) and extends rearwardly
away
from the face portion (particularly, a back side or region thereof). In these
embodiments, the bracket arm can be used as a mounting portion for mounting
the support member to a surface of the inner core region of the CMU, or can be
connected to another mounting portion for mounting the support member to a
surface of the inner core region of the CMU. In one particular embodiment, the
support member includes at least one bracket arm. In another embodiment, the
support member includes at least two bracket arms. In another embodiment, the
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support member includes at least three bracket arms. For example, the support
member can include 1, 2, 3, 4, 5, or more, bracket arms.
[ono] In other embodiments, the support member(s) may be
configured to apply a force to an inner surface(s) of the inner core region of
the
CMU. For example, the support member(s) may be spring-loaded or provided
with a tension bend, whereby the bracket is pressed against, or wedged
between, substantially or partially opposing surfaces of the inner core region
of
the CMU.
[0011] In various embodiments, the support member (including, in
certain embodiments, bracket arms and/or other mounting portions thereof)
extend rearwardly from the face portion at various angles. In one embodiment,
for example, the support member(s) may extend rearwardly from the face portion
at an angle that substantially corresponds with the shape of the inner core of
the
CMU to facilitate mounting of the bracket to a surface of the inner core (via
the
support member). In another embodiment, for example, the support member(s)
may extend rearwardly from the face portion at an angle(s) that facilitate the
application of a force to an inner surface(s) of the inner core region of the
CMU.
By way of example, in CMUs having a substantially cuboid- or rectangular
cuboid-shaped inner core, the support members can extend substantially
perpendicularly away from the back side (i.e., at substantially a 90 degree
angle). For differently-shaped CMU inner cores, the support members can
extend at other angles that generally correspond to the shape of such inner
cores, to facilitate securing of the bracket within the inner core (via the
support
member, e.g., the bracket arm or other suitable portion). In one particular
embodiment, the support member(s) comprises two bracket arms and a
mounting portion connecting the two bracket arms. Holes for mounting the
support member(s) to the inner core of the CMU can be provided in the bracket
arms, for example, and/or in the mounting portion. In certain of these
embodiments, the bracket arms extend substantially perpendicularly away from
the back side of the face portion and the mounting portion is connected to the
bracket arms such that the mounting portion is substantially parallel to the
back
side of the face portion. In other embodiments, the bracket arms and mounting
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portion (if present) extend at angle(s) that generally correspond to the shape
of
the inner core of the CMU.
[0012] Another aspect of the present disclosure is directed to a method
of securing an electrical assembly including the bracket within an inner core
region of a CMU. The method comprises combining the bracket, electrical box,
and cover plate to form the assembly and securing the bracket within the inner
core region of the CMU. It will be understood that the assembly may be formed
either before or after securing the bracket.
[0013] According to additional aspects of the present disclosure, kits
are provided that may be used to construct the brackets and/or electrical
assemblies and/or carry out the methods described herein. For example, a kit
may comprise one or more face portions and one or more support members,
whether already assembled to form the bracket or in separate pieces for
assembly by the end user. By way of another example, the kit may comprise a
bracket (again, whether assembled or unassembled), an electrical box, and a
cover plate, optionally assembled to form the electrical assembly. The kits
may
further include fasteners (e.g., for assembling the bracket and/or the
electrical
assembly, and/or for securing the bracket and/or the electrical assembly
within
the CMU), an electrical device, conduit, conduit fittings, electrical wire,
and the
like. The kit may also include instructions, for example, for assembling the
bracket and/or the electrical assembly, and/or for securing the bracket and/or
the
assembly within the CMU.
[0014] For purposes of the present disclosure, CMUs that can receive
the bracket and electrical assembly described herein comprise a concrete block
having one or more (e.g., two or three) vertically extending cavities or cores
extending therethrough. CMUs typically have a nominal width of about 16
inches (-410 millimeters) long and are available in nominal widths of about 4,
6,
8, 10, and 12 inches (-100, -150, -200, -254, and -300 millimeters,
respectively). For example, one particularly common CMU has a nominal size of
16 x 8 x 8 inches (410 x 200 x 200 millimeters).
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[0015] Although CMUs commonly have a substantially rectangular
shape, it will be understood that the bracket and assembly described herein
can
be utilized in connection with any shape or style block having a hollow core.
For
instance, a range of specialized shapes or block portions exist in order to
accommodate particular construction features, such as score lines, grooves, or
flutes on various sides of the CMU, bullnose (i.e., rounded) corners, cut
headers,
lintels, stretchers on one or both ends of the block, and the like. A variety
of
decorative blocks also exist and can accommodate the bracket and electrical
assembly disclosed herein in a hollow inner core region thereof
[0016] Therefore, it will be understood that the bracket and electrical
assembly (and components thereof) can have a range of shapes and angles for
use, for example, in CMUs having non-rectangular cores (e.g., pear core CMUs)
and/or with electrical boxes of varying shapes and sizes.
[0017] Other objects and features will be in part apparent and in part
pointed out hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The details of the present disclosure, both as to its construction
and operation can best be understood with reference to the accompanying
drawings, in which like numerals refer to like parts, and in which:
[0019] FIG. 1 is a perspective view of a bracket in accordance with an
exemplary embodiment of the present disclosure.
[0020] FIG. 2 is a top side view of a bracket in accordance with an
exemplary embodiment of the present disclosure.
[0021] FIG. 3 is a front side view of a bracket in accordance with an
exemplary embodiment of the present disclosure.
[0022] FIG. 4 is a right side view of a bracket in accordance with an
exemplary embodiment of the present disclosure.
[0023] FIG. 5 is an exploded view of an electrical assembly in
accordance with an exemplary embodiment of the present disclosure.
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[0024] FIG. 6 is a perspective view of an electrical assembly in
accordance with an exemplary embodiment of the present disclosure and further
including an exemplary electrical receptacle.
[0025] FIGS. 7-9 depict the securing of an electrical assembly within a
CMU in accordance with an exemplary embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE
DISCLOSURE
[0026] The accompanying Figures and this description depict and
describe embodiments of a bracket and electrical assembly in accordance with
the present disclosure, and features and components thereof. It should also be
noted that any references herein to front and back, right and left, top and
bottom
and upper and lower are intended for convenience of description, not to limit
an
invention disclosed herein or its components to any one positional or spatial
orientation.
[0027] Referring to FIGS. 1-4, an exemplary bracket 100 is illustrated.
Bracket 100 may be fabricated from any suitably rigid material. In exemplary
embodiments, suitable rigid materials include, but are not limited to, sheet
metal
and plastic. In certain embodiments, bracket 100 may be generally rectangular
with a top edge 102, an opposite bottom edge 104, and opposing side edges
106, 108. The portion of the bracket 100 between the top edge 102, bottom
edge 104, and side edges 106, 108 is defined as a face portion 110.
[0028] Bracket 100 further comprises an opening 112 disposed in the
face portion 110 for cooperating with an opening in an electrical receptacle
box
and a corresponding cover plate or frame, to be discussed more fully
hereinafter.
In certain embodiments, opening 112 is disposed closer to the top edge 102
than
the bottom edge 104. Although the Figures illustrate that opening 112 is
substantially square-shaped, it will be understood that opening 112 can have a
variety of shapes to cooperate with differently-shaped electrical boxes and/or
cover plates (e.g., for one-gang, two-gang, and other electrical fixtures or
installations). In one embodiment, for example, opening 112 can be
substantially rectangular-shaped, substantially square-shaped, or
substantially
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circular-shaped. Oval, triangular, or any other polygonal shapes for opening
112
are also contemplated.
(0029] The bracket 100 also includes at least one support member
114. In connection with the illustrated embodiment, the support member
includes at least one, at preferably at least two (e.g., two, three, four,
etc.), holes
116. Fasteners 118 are disposed in holes 116 in the support member(s) 114 for
securing the bracket 100 to an inner surface of the hollow core of a CMU, to
be
described more fully hereinafter. In one preferred embodiment shown in FIGS. 1
and 2, for example, the holes 116 and corresponding fasteners 118 are
positioned in a mounting portion 114a connecting two bracket arm(s) 114b
oriented substantially perpendicularly to the back side of the face portion.
It will
be appreciated that holes 116 may additionally or alternatively be positioned
in
the bracket arm portion(s) 114b of the support member(s), for example, for
securing the bracket to a different inner core surface of the CMU. As such,
the
mounting portion 114a of the support member(s) disposed substantially parallel
to the back side of the face portion may or may not be present on the support
member(s) 114 if holes are provided in the bracket arm portions 114b.
Exemplary fasteners 118 include, but are not limited to, threaded screws
(e.g.,
those suitable for concrete applications), nuts and bolts, screw or nail
anchor
systems, and other suitable fastening devices.
[0030] In other embodiments (not shown), the support members can
be configured to apply a force to a surface(s) of the inner core region of the
CMU, as described above. For example, the support member(s) may comprise
spring-loaded components and/or a torsion bend for securing the bracket within
the inner core of the CMU by pressing or wedging the bracket against
substantially or partially opposing surfaces of the inner core of the CMU.
[0031] As noted previously, the overall shape of the bracket 100 will
generally depend upon the shape of the inner core of the CMU in which the
bracket and assembly is to be used. For instance, brackets having convex or
concave face portions 110 (as opposed to the substantially planar face
portions
as shown in the Figures) and/or support member(s) 114 having various shapes
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and angles (e.g., rounded, triangular, etc.) (as opposed to the substantially
rectangular face portions as shown in the Figures) are contemplated.
[0032] In some embodiments, the bracket 100 is formed as a single
unitary member. In other embodiments, the support member(s) 114 can be
permanently or removably attached to optional side flanges 120 of the face
portion of the bracket (as shown, for example, in FIGS. 1, 2, and 4) or
attached
to the back side of the face portion (not shown) by welding, gluing, or using
fasteners (e.g., rivets, screws, nuts and bolts, etc.).
[0033] The thickness of the rigid material forming the bracket 100 can
range from about 0.02 inches to about 0.1 inches (about 0.5 millimeters to
about
2.5 millimeters), e.g., from about 0.04 inches to about 0.08 inches (about
=
1 millimeter to about 2 millimeters). In various embodiments, the thickness of
the different regions of the bracket 100 may or may not be uniform (e.g., the
support member(s) 114 may be thicker than the face portion 110 and thus more
rigid to provide additional mounting strength).
[0034] The bracket 100 may also include additional structures and/or
components to assist in securing the bracket within the inner core region of
the
CMU. For example, a tab 122 may be optionally provided in the side flanges
120. In use, the tab 122 can be bend outward to form a stop that rests against
the CMU and further prevents the bracket from disengaging from the inner core
region of the CMU. The face portion 110 and/or the side flanges 120 may also
include one or more projections 124 for gripping a surface of the inner core
region. As the bracket is tightened, for example, projections 124 can dig into
the
surface of the block and these additional points of contact further secure the
bracket to the inner core region of the CMU.
[0035] Referring to FIG. 5, an exploded view of an electrical assembly
200 in accordance with one embodiment of the present disclosure is
illustrated.
In preferred embodiments, the assembly 200 includes an electrical box 202, a
cover plate or frame 204, and the bracket 100 as described herein. The
electrical box 202 is attached to the cover 204, via the opening 112 so as to
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sandwich or otherwise secure the planar portion surrounding the opening 112
substantially between the box 202 and the cover 204, forming the assembly 200.
[0036] The electrical box 202 can be any of a number of conventional
electrical boxes formed of a rigid material, such as sheet metal or plastic.
As
shown, the box 202 has an open front for cooperating with the opening 112 and
to allow electrician access for the installation of electrical receptacles,
wiring
conduit, and the like. Knock-out panels 206 can be provided in the box 202 to
facilitate such installation. Although a substantially square box and box
opening
is illustrated in the Figures, it will be understood that the box 202 and/or
the
opening thereof could be rectangular, circular, or any other desirable
configuration. The choice of the box shape and/or opening may depend, for
example, upon the shape of the bracket opening 112, as discussed above. In
one embodiment, for example, box 202 and/or the opening thereof can be
substantially rectangular-shaped, substantially square-shaped, or
substantially
circular-shaped. Oval, triangular, or any other polygonal shapes for box 202
and/or the opening thereof are also contemplated.
[0037] As noted above, the assembly 200 also includes cover 204,
which covers the opening 112 and the open front of the box 202. The cover 204
is connected to the box 202 by multiple fasteners 208, received by one or more
openings 210a, 210b in the cover and corresponding holes 212a, 212b in the
box 202. Exemplary fasteners 208 include, but are not limited to, threaded
screws, nuts and bolts, and other suitable fastening devices. The cover 204
may
be adjusted on the assembly 200 by moving the cover 204 and/or box 202 with
respect to optionally elongated openings 210a, 210b.
[0038] The cover 202 at least partially covers the opening 114 and the
box opening and carries openings 214a, 214b for mounting one or more
electrical devices 218 with fasteners 216 received by openings 214a, 214b.
Exemplary fasteners 216 include, but are not limited to, threaded screws, nuts
and bolts, and other suitable fastening devices. Exemplary electrical devices
218 include convenience outlets (shown in FIG. 6, for example), electrical
switches, electrical terminals, or any other suitable device. As shown in the
Figures, the cover 202 may also include a frame portion 220 for offset
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of an electrical device with respect to opening 114 and the box opening, such
that the electrical device is substantially flush with the front surface of
the CMU
wall.
[0039] Referring to FIGS. 7-9, in use the bracket (alone or in
combination with a receptacle box and cover plate to form an electrical
assembly) is used in connection with a CMU 300 and, in particular, is inserted
into the hollow inner cavity or core 302 of the CMU and mounted or otherwise
secured to a surface 304 thereof. In a particular embodiment, the support
member (s) 114 are fastened to the CMU 300 by fasteners (e.g., screws, nails,
and the like) extending through the holes 116 in the back and/or side walls of
the
support member (s) 114, as noted above. When installed, the position of the
cover plate 202 may be flush with the front face of the CMU wall (see, e.g.,
FIG.
9), or may be recessed or projecting, as desired.
[0040] In general, methods of the present disclosure include methods
of securing an electrical assembly including the bracket described herein
within
the inner core of a CMU. The methods involve combining the bracket, electrical
box, and cover plate to form the assembly and securing the assembly (via the
bracket) within the CMU. One of skill in the art will recognize that the user
can
complete these steps in any particular order. Although FIG. 7 depicts the
assembly (or bracket) being mounted to the CMU using a hand screwdriver, it
will be understood that electrical or battery-operated power tools may also be
employed. It will be understood that it may not be necessary to completely
drive
the fasteners into the CMU; a few turns of the fastener with a hand tool or
power
tool may be sufficient to secure the bracket and/or assembly within the inner
core region of the CMU. Further, it will be understood that where the support
members are configured to apply a force to the surface(s) of the inner core
region of the CMU, hand tools or power tools may not be necessary to secure
the bracket and/or assembly within the inner core region of the CMU.
[0041] The present disclosure is well adapted to attain the ends and
advantages mentioned as well as those that are inherent therein. The various
embodiments disclosed above are for illustrative purposes only, as the present
disclosure may be modified and practiced in different but equivalent manners
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apparent to those of ordinary skill in the art having the benefit of the
teachings
herein. Having described some exemplary embodiments of the present
invention, it will be understood that the brackets and assemblies and
components thereof may be formed and/or used in a variety of sizes. For
example, any desired size of open portion to permit the use of more than one
electrical device within the electrical box is contemplated. The use of ganged
devices also is possible. While numerous changes may be made by those
having ordinary skill in the art, such changes are encompassed within the
spirit
and scope of this disclosure as defined by the appended claims. Furthermore,
no limitations are intended to the details of construction or design herein
shown,
other than as described in the claims below. It is therefore evident that the
various illustrative embodiments disclosed above may be altered or modified
and
all such variations are considered within the scope and spirit of the present
invention as defined by the claims below. The terms in the claims shall have
their plain, ordinary meaning unless otherwise explicitly and clearly defined
by
the patentee.
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