AU2010241518A1

AU2010241518A1 - Mounting assembly and bracket for an electrical power outlet or alike

Info

Publication number: AU2010241518A1
Application number: AU2010241518A
Authority: AU
Inventors: John Fitzgerald; Peter Fitzgerald
Original assignee: Individual
Current assignee: Individual
Priority date: 2005-10-13
Filing date: 2010-11-18
Publication date: 2010-12-09
Anticipated expiration: 2026-10-13
Also published as: AU2010241518B2; AU2006228079A1; AU2006228079B2

Description

AUSTRALIA Patents Act 1990 COMPLETE SPECIFICATION Standard Patent Applicant(s) John Fitzgerald and Peter Fitzgerald Invention Title: MOUNTING ASSEMBLY AND BRACKET FOR AN ELECTRICAL POWER OUTLET OR ALIKE The following statement is a full description of this invention, including the best method for performing it known to me/us: - 2 MOUNTING ASSEMBLY AND BRACKET FOR AN ELECTRICAL POWER OUTLET OR ALIKE FIELD AND BACKGROUND TO THE PRESENT INVENTION 5 The present invention relates to an assembly for mounting an electrical power outlet, television cable outlet, television antenna outlet or alike to the wall of a building. 10 At present it is common practice for electrical power outlets to be mounted directly onto the outer face of a wall. The outer face of the wall is often lined with a lining material in its various forms including 15 plasterboard, tongue and groove pine boards, and other panelling material. In the situation where a power outlet is mounted directly onto the outer face of plasterboard, which is the most common material of construction, it is standard practice to mount a metal supporting bracket to a 20 stud or nogging prior to the plasterboard being laid over the wall framework. An electrical power outlet is then located in position to the outer face of the plasterboard by fastening screws which extend through the plasterboard and engage the metal bracket. 25 One of the difficulties with the conventional assembly described above is that both the power point and socket of an electrical appliance connected to the power point protrude a considerable distance out from the wall. 30 This can prevent an electrical appliance from being positioned against the section of the wall on which the power outlet is located. This is particularly problematic when the electrical appliance, such as a refrigerator, has been measured to fit inside a pre-formed cavity and the 35 size of the power socket has not been taken into account. It is also problematic for items such as plasma television screens which for aesthetic purposes are preferably mounted flat against a wall. 2466183_1 (GHMatters) 18/11/10 - 3 Another difficultly is that the bracket is fastened to a stud or logging which may on occasions prevent the power outlet from the being located in the most desirable 5 location on the wall. SUMMARY OF THE INVENTION According to the present invention there is 10 provided a bracket for installing a housing that can be used to mount an electrical power outlet outer lining material of a wall, the bracket including: a base portion having an opening through which electrical cabling and/or the junction components of 15 an electrical outlet can project; and at least 2 arms extending forward of the base portion, wherein each arm includes a hand formation for engaging the opening in the lining material of the wall. 20 According to an embodiment of the present invention there is provided an assembly suitable for mounting an electrical power outlet, television cable outlet, television antenna outlet or alike outlet to a wall including outer lining material, the assembly including: 25 a housing having a chamber defined by a base and side walls that extend from the base and form an opening to the inside of the chamber, wherein the base is adapted so that one or more than one of said outlets can be located thereon, and when an opening of appropriate size 30 is formed in the lining material of the wall, the base and side walls of the housing can be positioned in the opening of the lining material; and a mounting means that mounts the housing to the lining material of a wall by engaging the lining material 35 at the opening thereof. Preferably the housing includes a rim extending laterally outward from the side walls and the rim can act 2466183 1 (CHMatters) 18/11/10 to obscure from view spacing between the side walls of the housing and the opening in the lining material. Two preferred forms of the means for mounting the housing to the lining material will now be described in more detail. 5 According to one embodiment, it is preferred that the assembly also include a means for mounting the housing to the lining material that is adapted to engage opposite sides of the opening formed in the lining material and 10 thereby support the housing in position. The advantage provided by this preferred aspect of the invention is that the housing and, thus, the power outlet can be supported without being anchored to a stud. This can make the task of the retrofitting an power outlet to a full formed wall 15 easier as it is often difficult to fasten objects to stud members after lining material such as plasterboard has been installed. It is even more preferred that the means for 20 mounting the housing to the lining material be in the form of a bracket including a pair of arms each having a hand formation that are adapted to engage inner and outer faces of the lining material. 25 It is preferred that the arms be resiliently flexible and when the hand formations are located in position on opposite sides of the opening, whereby the arms bias the hands away from each other so to apply pressure to the edge of the opening. 30 It is preferred that one or more of the hand formations includes an elongated flange that extends laterally away from the arms and, when in use, engage an outer face of the lining material of the wall, and one or 35 more fingers that, during installation, can be manually bent laterally away from the arms and the opening formed in the lining material so that the fingers engage the inside face of the lining material of the wall. 2466183_1 (GHMatters) 18/11/10 -5 Although it possible that the arms may be integrally molded or attached to the housing, it is preferred that the arms be interconnected to a base plate 5 and the base plate includes an opening through which electrical wiring or junction pieces on the rear face of the outlet can project. It is preferred that the arms extend from the base 10 plate at a spacing that substantially corresponds to the width of the rear face of the base of the housing. In use, it is preferred that the bracket including the base plate, arms and hand formations be fitted in a 15 wall and the base plate and arms straddle the housing. In other words, the outside dimensions of the housing and the spacing between the arms of the bracket allow the housing to be nested within the bracket. 20 In particular, when the bracket has been located within an opening formed in the lining material of a wall, the housing can be nested inside the bracket such that the rear face of the base of the housing can be located against the base plate of the bracket and the arms extend 25 forward toward the rim of the housing. The length of the arms and height of side walls coincide so that the rim of the housing can contact the plaster lining and the rear face of the base of the housing can simultaneously contact the base plate of the bracket. 30 When the bracket and housing have been installed in this manner, a power point, antenna outlet or alike outlet can then be fitted to the front face of the base of the housing. This may be achieved using self taping screws or 35 other fasteners that pass through the housing and engage the base plate of the bracket. If desired, preformed screw or fastener holes may also be formed in the base of 2466183_1 (GHMatters) 18/11/10 - 6 the housing to assist in the outlet, housing and bracket being clamped together. According to an alternative embodiment, it is 5 preferred that the means for mounting the housing to the lining material be in the form of bracket that is directly or indirectly fastened to a stud of the wall and the bracket has a base portion having an opening through which cabling and junction components of an outlet can project. 10 The bracket according to this preferred form of the invention is ideally fastened to the stud prior to wall lining material being installed. In use, the bracket will be fitted to the stud at a 15 preselected spacing from the front face of the stud such that the when lining material is fitted over the stud, the rim of the housing will contact the lining material and the rear face of the housing will be adjacent to or engage the bracket. 20 It is preferred that the brackets according to either embodiment described above be made from metal. It will also be appreciated that the housing may be 25 attached directly to the lining material by way of fasteners including screws, toggles and other fastening devices adapted for use with plasterboard and other lining material. 30 It is preferred that the housing be adapted so to receive either one or two of said outlets. It is preferred that the housing be an integral structure. 35 It is even more preferred that the housing be an integrally moulded from plastic material. 2466183_1 (GHMatters) 18/11/10 - 7 The bracket according to the present invention may also include any one or more of the preferred features of 5 the bracket according to the first embodiment described above. For example, the arms may be resiliently deformable, the hand formations may be located on opposite sides of the opening formed in the lining material, and the bracket may be made of metal. 10 BRIEF DESCRIPTION OF DRAWINGS The present invention will now be described in further detail with reference to the accompanying figures, 15 of which: Figures 1 and 2 are front and rear perspective views respectively of a housing for mounting a power point into a recess in a wall according to an embodiment of the present invention; 20 Figure 3 is an exploded perspective view of an assembly including the housing shown in Figures 1 and 2, and a support bracket according to an embodiment of the invention for installing the housing into the wall; Figure 4 illustrates the assembly shown in Figure 3 25 in which the bracket is installed in the wall; Figure 5 illustrates the assembly shown in Figure 3 in which both the bracket and housing have been installed into a plasterboard lined wall; Figures 6 to 9 are a series of side views of the 30 bracket illustrating the sequence of steps that are carried out to install the bracket into a wall; Figure 10 is a side view of the assembly shown in Figure 4 with the bracket installed in position in the wall; 35 Figure 11 is a side view of the assembly shown in Figure 5 in which both the bracket and housing have been installed into the wall and an outlet shown in broken lines; 2466183_1 (GHMatters) 18/11/10 -8 Figure 12 is a side view of the assembly fitted to a wall with a power outlet installed; Figures 13 and 14 are close up views illustrating alternative rim or lip formations of the housing; 5 Figure 15 is a perspective view of a prior art bracket that can be fastened to a stud of a wall that has been used for mounting power outlets to the outside of the plasterboard lining; Figure 16 is a perspective view illustrating the 10 prior art bracket shown in Figure 15 being fitted to a stud at a spacing from the plasterboard lining; Figure 17 is a perspective view of the prior art bracket shown in Figures 14 and 15 and the housing being fitted to the bracket; 15 Figure 18 is a side view of a housing for mounting a power point into a recess in a wall according to an alternative embodiment of the present invention; Figure 19 is a perspective view of the housing shown in Figure 18; and 20 Figures 20, 21 and 22 are front, perspective and side views of a metal bracket that, when installed, is able to mount the housing showing in Figures 18 and 19 to plasterboard lining material. 25 DETAILED DESCRIPTION The preferred embodiments of the invention shown in the Figures contain a number of features that are the same or substantially same, and as a matter of convenience the same reference numerals have been used throughout the 30 Figures to identify the same or similar features. Figures 1 and 2 illustrate front and rear perspective views of a housing 20 having a base 21 and side walls 22 extending from the base 21 that define a 35 chamber 24. Extending outwardly from an upper edge of the side walls 22 is a rim or flange 25 that defines a front opening 26 into the chamber 24. The base 22 includes a rear opening 23 through which electrical cabling and the 24661831 (GHMatters) 18/11/10 - 9 connectors of an electrical power outlet 27 which is illustrated by the broken lines in Figure 12 can project. The preferred embodiment shown in the figures is a 5 housing 20 that is adapted to receive one electrical power outlet, television antenna outlet or alike. However, it will be appreciate that it is within the scope of the present invention that the housing may be adapted to receive two or even more than two outlets 27. 10 As can be seen in the Figures, the shape and configuration of the housing 20 is adapted such that when the housing 20 is mounted inside a cavity of a wall and the outlet is mounted to the base of the housing 20, a 15 socket such as a power socket of an electrical appliance can be plugged into the outlet and will be recessed below the surface of the wall as shown in Figure 12. In the situation where the power outlet is located behind an electrical appliance such as a fridge, plasma screen 20 television or alike, the housing recesses the power outlet into the wall and thus enables the electrical socket to be inserted without preventing the appliance from being positioned against or located close to the wall. The wall cavity to which the housing 20 may be 25 installed may have any structure and in the situation where the wall has wood panelling such as tongue and groove pine boards, the housing 20 may be fastened directly to the lining material using crews and other fasteners. In the situation where the lining material is 30 plasterboard, it is also possible that the housing may be fastened directly to the plasterboard using suitable crews and plaster toggle devices. However, some building codes and regulations may prohibit the housing 20 from being fastened directly to plasterboard. 35 The following is a discussion of how the housing 20 may be fastened to plasterboard without the use of screws 2466183_1 (GHMatters) 18/11/10 - 10 or toggles and is accepted practice under various building regulations. Figure 3 illustrates an exploded perspective view 5 of a hole preformed in plasterboard that is sized to receive the housing 20 and a bracket 30 for mounting the housing to plasterboard. The bracket 30 includes a base portion 31 having an opening 32 that corresponds in shape and size to the rear opening 23 of the housing 20 and a 10 pair of the arms 33 extending from opposite sides of the bracket 30. Each arm 33 has a hand formation 34 comprising at least two oppositely disposed fingers or flanges 35 that are spaced apart by a spacing that approximates the thickness of the plasterboard. As can be 15 best seen in Figure 6, the arms 33 are pre-tensioned so that the hand formations 34 are prior to installation separated by a spacing that is greater than the width of the preformed hole in the plaster. In order to install the bracket 30, the arms 33 are pushed toward each other 20 so that the base 31 and arms 33 can be past through the hole in the plasterboard, as shown in Figures 6 and 7. The hand formations 34 are then aligned with the plasterboard so that when the arms 33 are released, a finger 35 is placed on the inner and outer surfaces of the 25 plasterboard 40 as shown in Figures 8 and 9. When the arms 33 are released the arms via the hand formations 34, apply pressure to the plasterboard maintaining the bracket in position. Although not shown 30 in the Figures, it is also possible that the fingers 35 and hand formations 34 may have teeth that grip the plasterboard to securing the bracket in position. The arms 33 and hand formations 34 may extend from 35 the left and right sides of the base portion 31 or alternatively from the top and bottom edges of the base. The embodiment shown in the Figures has arms and hand formations on the left and right sides. 24661831 (GHMatters) 18/11/10 - 11 The arms 33 are of particular length such that when the housing 20 is nested inside the bracket 30, or in other words, the bracket 30 straddles the housing 20 the 5 base portion 31 of the bracket 30 engages the rear face of the base 21 of the housing 20 and the rim 25 is located against the outer face of the plasterboard 40. Preferably the arms have a length in the range of 3 to 15 centimetres, and suitably have a length in the range of 5 10 to 8 centimetres. An outlet fitting 27 which is illustrated in broken lines in Figures 11 and 12 can then be fixed against the base 21 of the housing 20 using convention fasteners. The crews preferably extend through preformed slots 27 or holes in the base 21 of the housing 15 20 and engage the base portion 31 of the bracket 30, thereby clamping the outlet 27 to the base 21 of the housing and also clamping the housing 20 to the bracket 30. The fasteners may be any suitable screw including self taping screws and the base portion 31 of the bracket 20 may or may not have preformed holes for the crews. In addition, as can be seen from the embodiment shown in Figures 18 and 19, the housing 20 may also include two fins or ridges 36 located on the outer face of 25 the side walls 22 of the housing 20 from the rim 25 toward the base 21 of the housing 20. The extent to which the fins or ridges 36 protrude from side walls 22 tapers when moving in direction from the rim 25 toward the base 25. The fins or ridges 36 are designed to wedge the housing 20 30 in a vertical plane when placed in a cavity or hole in the plasterboard 40. Depending on the size of the cavity or hole, it is also possible for the fins or ridges 36 to cut, indent or form grooves in the plasterboard 40. 35 Figures 13 and 14 illustrate a close up view of the hand formations 34 and the outer rim of flange 25 of the housing 20. In particular, Figure 13 illustrates the rim 25 having a tapering cross section. Figure 14 illustrates 2466183_1 (GHMatters) 18/11/10 - 12 the rim 25 having a lip 28 that is designed to cover a gap between the rim 25 and plasterboard 40 that accommodates the finger 35 located on the outer face of the plasterboard 40. As can be seen, the bracket 30 and 5 housing 20 are fitted in position against the lining material, lip formation 28 provides a cavity between the rim 25 and the lining material that accommodates the hand the outer fingers or flange 35 of the hand formation 34. 10 An advantage of the bracket shown in Figures 3 to 12 is that the housing 20 and, thus, an outlet fitting 27 is able to be mounted to a wall intermediate or between two studs of the wall and without attaching the housing 20 or bracket 30 to a stud. This enables outlet fittings 27 15 such as power outlets to be readily installed to an existing wall. Figure 15 illustrates a convention bracket 50 for mounting a power outlet 27 or alike to the outside of the 20 plasterboard 40. The bracket 50 includes a base portion 51 having an opening 52 through which electrical cabling and power point connectors of the outlet 27 can project. The bracket 50 includes two guiding sleeves 52 25 containing nails 53 that are angularly disposed to one another and offset to the base portion 51. Under normal circumstances in which the bracket 50 is used to mount a power outlet flush to the outside of the plasterboard, the nails 53 are driven into the studs with the base flush to 30 the front face of the studs or immediately beneath the plasterboard. However, in the situation where the bracket 50 is being used to mount a power outlet using the housing 20 described above to recess the power outlet from the front face of the plasterboard, the bracket 50 will need 35 to be set back from the front face of the stud 60 or the plasterboard by a spacing that is approximately equal to the height of the walls of the housing as shown in Figure 16. 2466183_1 (GHMatters) 18/11/10 - 13 Figure 17 illustrates the alternative bracket 50 and housing 20 installed in the position. The stud 60 and plasterboard 40 have to be partially cut away to assist in 5 illustrating the components assembled together. Figures 20 to 22 illustrating an alternative metal bracket 30 in accordance with an embodiment of the present invention comprising a base portion 31 having an opening 10 32 through which electrical cabling can-pass. Extending laterally of the base portion 31 is a pair of arms 33, each arm 33 having a hand formation 34 at the ends thereof. The hand formations 34 comprise an elongated flange 35 which when installed are located on the outside 15 of the plasterboard lining material and two fingers 35a, that are located on opposite sides of the arm 33. Figures 20, 21 and 22 show the fingers 35a in a straight configuration that facilitates the initial stages of installation of the bracket. When the bracket has been 20 installed, and the flange 35 is located in position on an outside face of the plasterboard, the finger 35a can be manually bent inwardly so as to engage the inside face of the plasterboard 40 and thereby secure the bracket in position (not shown in the Figures). 25 Those skilled in the art of the present invention will appreciate that many modifications and variations may be made to the preferred embodiment described above without departing from the spirit and scope of the present 30 invention. For example, it is possible that the bracket shown in Figures 3 through to 12 may be substituted with two arms that are connected to an outer face of the side walls 35 of the housing. Each arm may include hand formations, ridges, teeth or alike that secure the arms to the plasterboard lining. 2466183_1 (GHMatters) 18/11/10 - 14 According to another example in which the housing is directly connected to plasterboard or other lining material is fasteners, toggles and alike, the fasteners may be directly past through the front face of the rim. 5 In order to obscure the fasteners from view once installed it is envisaged that the housing may also include a removable piece that can be snap-locked into position to cover the fasteners. 2466183_1 (GHMatters) 18/11/10

Claims

1. A bracket for installing a housing that can be used to mount an electrical power outlet in an opening formed 5 in outer lining material of a wall, the bracket including: a base portion having an aperture through which electrical cabling and/or the junction components of an electrical outlet can project; and at least 2 arms extending forward of the base 10 portion, wherein each arm includes a hand formation for engaging the opening in the lining material of the wall.

2. The bracket according to claim 1, wherein the hand 15 formations are adapted to engage inner and outer faces of the lining material.

3. The bracket according to claim 1 or 2, wherein the arms are resiliently flexible and pre-tensioned so as that 20 the hand formations are, prior to installation, separated by a spacing so as to extend outside of the base portion of the bracket.

4. The bracket according to any one of the preceding 25 claims, wherein the arms are resiliently flexible and pre tensioned so as that the hand formations are, prior to installation, separated by a spacing that is greater than the width of a preformed opening in the lining material for accommodating the bracket and to which the bracket is 30 to be fitted.

5. The bracket according to any one of the preceding claims, whereby during installation, the arms are drawn inwardly to allow the hand formations to be located to 35 engage the opening in the lining material, and once the arms have been released the arms bias the hand formations outwardly to maintain engagement with the opening of the lining material. 2466183_1 (GHMatters) 18/11/10 - 16

6. The bracket according to any one of the preceding claims, wherein two of the arms and hand formations are positioned on opposite sides of the bracket, and when 5 installed, the arms are biased away from each other to cause the hand formations to apply pressure to opposite edges of the opening of the lining material.

7. The bracket according to any one of claims 1 to 6, 10 wherein the arms extend from the left and right sides of the base portion.

8. The bracket according to any one of the preceding claims, wherein one or more of the hand formations include 15 a flange that extends laterally to the arms and, when in use, engage an outer face of the lining material of the wall, and one or more fingers that, during installation, can be manually bent laterally away from the arms so as to engage an inside face of the lining material of the wall. 20

9. The bracket according to any one of claims 1 to 7, wherein one or more of the hand formations have at least two oppositely disposed flanges that are spaced apart by a spacing that approximates the thickness of the lining 25 material.

10. The bracket according to any one of the preceding claims, wherein the arms of the bracket have a length in the range of 3 to 15 centimetres so that when installed, 30 the base portion is able to be located 3 to 15 centimetres from an outer face of the lining material.

11. The bracket according to any one of the preceding claims, wherein the arms of the bracket have a length in 35 the range of 5 to 8 centimetres so that when installed, the base portion is able to be located 5 to 8 centimetres from an outer face of the lining material. 2466183_1 (GHMatters) 18/11/10 - 17

12. The bracket according to any one of the preceding claims, wherein the bracket is made of metal.

13. The bracket according to any on of the preceding 5 claims, wherein base portion includes preformed holes for receiving fasteners, and wherein the preformed holes are located to receive fasteners passing through an electrical outlet and the housing such that the fasteners can be used to clamp the electrical power outlet, housing and bracket 10 together.

14. The bracket according to any one of the preceding claims, wherein the hand formations have teeth or ribs for gripping the lining material. 15

15. A bracket substantially as hereinbefore described with reference to Figures 3 to 9.

16. A bracket substantially as herein described with 20 reference to Figures 20 to 22. 2466183_1 (GHMatters) 18/11/10