WO2005055370A2 - Ceiling box safety mounting bracket - Google Patents
Ceiling box safety mounting bracket Download PDFInfo
- Publication number
- WO2005055370A2 WO2005055370A2 PCT/US2004/039587 US2004039587W WO2005055370A2 WO 2005055370 A2 WO2005055370 A2 WO 2005055370A2 US 2004039587 W US2004039587 W US 2004039587W WO 2005055370 A2 WO2005055370 A2 WO 2005055370A2
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- bracket
- electrical box
- fastener
- mating
- interior
- Prior art date
Links
Classifications
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02G—INSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES
- H02G3/00—Installations of electric cables or lines or protective tubing therefor in or on buildings, equivalent structures or vehicles
- H02G3/02—Details
- H02G3/08—Distribution boxes; Connection or junction boxes
- H02G3/18—Distribution boxes; Connection or junction boxes providing line outlets
- H02G3/20—Ceiling roses or other lighting sets
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02G—INSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES
- H02G3/00—Installations of electric cables or lines or protective tubing therefor in or on buildings, equivalent structures or vehicles
- H02G3/02—Details
- H02G3/08—Distribution boxes; Connection or junction boxes
- H02G3/12—Distribution boxes; Connection or junction boxes for flush mounting
- H02G3/123—Distribution boxes; Connection or junction boxes for flush mounting in thin walls
- H02G3/126—Distribution boxes; Connection or junction boxes for flush mounting in thin walls with supporting means for mounting on a single wall stud
Definitions
- a ceiling fan through normal operation, may create oscillatory stresses on the electrical box it is attached to. If attached to a light-duty box, these forces may carry through the fan support to the electrical box, which may cause the box to twist slightly on each oscillation. Over time this motion may cause the nails, or other fasteners, used to secure the electrical box to move and/or loosen, which may lead to failure of the electrical box supporting structure. Additionally, if the box structure is not sufficiently rigid, forces may be transferred to the drywall, or other material, of the ceiling. Now drywall, plaster, paneling and most other ceiling materials are not designed to carry loads. These materials may carry a load briefly, but over time cracks may develop leading to an unpredictable failure of the material. If both the electrical box supporting structure and the ceiling material fail, the result is a fixture falling at an unpredictable time, which can lead to property damage, personal injury and litigation against the makers of the ceiling fan, lighting fixture, electrical box manufacturer as well as other involved parties.
- a non-moving ceiling fixture mounted to a light-weight box may carry a load sufficiently well under static conditions for many years. Earthquakes are unpredictable events that may occur at any time, and in some locations with such severity as to cause large thrust and oscillatory motions on the lighting fixture and electrical box. A homeowner may be completely unaware of a dangerously supported fixture until a tremor causes it to fall. The dangers of inadequately supported lighting fixtures therefore encompasses more fixtures than ceiling fans.
- This type of box is typically constructed of steel or other metal, as the needed plastic supports would be very thick in comparison. These boxes tend are more complex and require more materials and building steps to fabricate. The cost of this type of box also tends to be much higher to the end user.
- a final type represented in U.S. Patent Nos. RE 34,603 and 6,100,469, utilizes fasteners through a metal electrical box sidewall into the adjacent structural member. This type relies on the strength of the sidewall to avoid the fastener head pulling through the sidewall material under load, and is therefore unsuitable for plastic materials. Furthermore, this type relies on the box structure to resist a downward force, which may place strain on welds and joints.
- the claimed inventions relate generally to electrical boxes that may be installed to a ceiling, and more particularly to electrical box ancillaiy devices, such as brackets and struts, that permit the carrying of heavy ceiling appliances such as ceiling fans and lighting fixtures.
- brackets and other devices for reinforcing DChng electrical boxes to structural members, such as trusses and joists, against the load of fixtures including ceiling fans and lighting fixtures.
- ceiling electrical boxes having built-in reinforcement. Additionally disclosed herein, explicitly or implicitly, methods of using and installing those brackets, devices and boxes. Detailed information on various example embodiments of the inventions are provided in the Detailed Description below, and the inventions are defined by the appended claims.
- Figures la, lb and lc (herein after referred to as figure 1) show an exemplary reinforcement bracket.
- Figures 2a, 2b and 2c show a four inch plastic electrical box with the bracket of figure 1 installed.
- Figures 3 a, 3b and 3 c show a three inch plastic electrical box with the bracket of figure 1 installed.
- Figures 4a, 4b and 4c show a three inch metallic electrical box with the bracket of figure 1 installed.
- Figures 5 a, 5b and 5 c show an installation of two identical brackets into two types of electrical boxes.
- Figures 6a, 6b, 6c and 6d show an exemplary electrical box with built-in reinforcement.
- Figure 7 shows an alternate bracing electrical box with three flanges.
- Figures 8a, 8b, 8c and 8d show an exemplary electrical box having flanges and an integrated bracket.
- Figures 9a and 9b show an alternate electrical box having reinforcement.
- Figures 10a, 10b, 10c, lOd and lOe show another exemplary electrical box with flanges and an insert molded reinforcement.
- Figures 11a and 1 lb show another exemplary reinforced electrical box.
- Figures 12a, 12b and 12c show an alternate reinforcing bracket.
- FIGS 13a, 13b and 13c show an additional alternate reinforcing bracket.
- Bracket 11a includes two largely planar portions, 12a and 15 a, connected by bend 17a.
- Planar portion 12a in this example, forms an interface providing a mating to the top of an electrical box at the inside.
- the ends of planar portions 12a and 15a are shaped to form an interface to the side of an electrical box at the inside, that interface being shown at 13a and 14a.
- ends 13a and 14a provide two interfaces for two specific electrical box types, as will be discussed presently, one interface provided at 13aa and 14aa for a substantially flat electrical box sidewall and another interface at 13ab and 14ab for a screw boss, which are integral in many plastic electrical ceiling boxes.
- Planar portion 15a provides a strut-like portion providing resistance to a compressive force applied between the top and side interfaces. That strut-like portion functions to at least partially convert a downward force on the electrical box to a horizontal force in the direction of the structural member.
- two fastener features, in this example recesses, 16aa and 16ab (shown 16a in fig. lb) provide attachment points for screws.
- Recesses 16aa and 16ab are oriented so that fasteners inserted therein may fasten the bracket 11a through the electrical box sidewall and into an adjacent structural member.
- recesses 16aa and 16ab are configured to align fasteners at approximately 60 degrees from the vertical for an electrical box mounted to a vertical structural member surface. This permits the fasteners to be driven into the structural member with a single tool, such as an ordinary screwdriver or hammer, through many electrical box openings. It is preferred that this angle and the position of any fastener features be set so as to permit ease of access to the fasteners using ordinary tools, although other angles or positions may be chosen without departing from the larger scope of the invention.
- the driving force may be directly applied by a tool external to the electrical box, for example a screwdriver or hammer.
- Recesses 16aa and 16ab may include a substantially cylindrical portion, not shown, for guiding the fastener at a desired angle relative to the bracket.
- recesses 16aa and 16ab provide seats for screws, which recesses are not threaded to provide free movement so that bracket 11a may be brought tightly into a supportive position.
- a bend 18a is provided near end 14a to orient that end perpendicular to the electrical box sidewall providing for transverse motion by which bracket 11a may be brought more snugly into a supportive position during installation of the bracket.
- the bracket 11a of figure 1 may be fashioned utilizing ordinary sheet-metal die- processing procedures to make the various bends and and shapes of the bracket, as well as other reinforcing brackets.
- Preferred materials for reinforcing brackets, such as 1 la include zinc-plated mild steel, due to that material's strength, durability, widespread availability and applicable manufacturing facilities.
- Other metals may be used, such as aluminum, brass or "pot” metals, keeping in mind that different thicknesses may be required to achieve necessary strength and bracing characteristics. Processes other than die processes may be used as desired, for example extrusion processes, particularly where a bracket is to be made from aluminum or its alloys.
- FIG. 2a Shown in figures 2a, 2b and 2c (herein after figure 2) is a four inch plastic electrical box 20a with bracket 11a installed; figure 2a showing a perspective view through the electrical box opening, figure 2b showing a bottom view, and figure 2c showing a sectional view through axis 1.
- Electrical box 20a includes an aperture through which access is permitted to manipulate wires inserted into the electrical box and to make connections thereto.
- Electrical box 20a includes flanges 22a for holding nails 23 in a relative position whereby nails 23 may be driven into a support member to secure the box 20a into position.
- top mating interface 12a (not shown) rests against the electrical box top inside surface 26a, while side interface 14aa resting against a flat portion 21a of electrical box sidewall. Screws 24 are driven through bracket 11a and sidewall 21a into the structural member to secure the bracket 11a into installed position.
- Bracket 1 la is designed to reinforce two particular box types.
- Figures 3a, 3b and 3c show a three inch plastic electrical box 20b with bracket 11a intalled therein, with figure 3 a showing a perspective view through the electrical box opening; figure 3b showing a view looking at the bottom, and figure 3 c showing a sectional view through axis 3.
- Electrical box 20b also includes flanges 22b for fastening the box 20b to a structural member by way of nails 23. For this box, the installation position of bracket 11a also brings top mating surface 12a (not shown) against electrical box top inside surface 26b.
- This electrical box 20b includes a boss 25b for insertion of a mounting screw, whereby a fixture may be attached to electrical box 20b.
- Bracket 11a rests against boss 20b at the side interfaces 14ab and optionally 13ab (not shown). Screws 24 are likewise driven through bracket 1 la and sidewall 21b into the structural member to secure the bracket 11a into installed position.
- bracket 1 la permits use in metallic electrical boxes as well.
- a bracket 1 la is shown installed into a 3 inch metal-type electrical box 20c, with figure 4a showing a view from the box bottom, figure 4b showing a sectional view through axis 2, and figure 4c showing a perspective view.
- This electrical box 20c includes alignment wings 22c with holes pre-formed to permit fastening to a structural member with nails, screws, or other fasteners.
- bracket 11a mates top mating surface 12a against the top of the electrical box 26c, and also mates side interface 14aa against electrical box sidewall 21c.
- screws 24 are driven through bracket 11a and sidewall 21c into the structural member, although pre- drilling of holes through sidewall 21c may be necessary if holes are not formed therein prior to installation.
- Figures 5a, 5b and 5c further illustrate the installation of two brackets of the type shown in figure 1 using two electrical box types; figure 5 a showing a view looking up through the bottom of the electrical boxes and at the ceiling, figure 5b showing a sectional view about the axis labeled 4, and figure 5c showing an inverted perspective view (turned upside down for ease of viewing).
- Ordinary and modern construction utilizes wood structural members, of which one member 30 is shown. Member 30 might be the lower portion of a truss, a joist, or other structural member upon which a hng is to be fashioned.
- Ordinary construction utilizes drywall 31 fastened by nails or screws to structural members, one screw 32 being shown.
- Both boxes 26a and 26b are normally installed prior to drywall application to structural member 30 through flanges, one 22b being shown, and nails 23.
- Drywall 31 is applied afterward, and holes cut therein to provide access to the interior of the electrical boxes.
- access to structural member 30 may be restricted, particularly if there is little or no access space surrounding structural member 30. In other situations access may be inconvenient, for example where structural member 30 is the lower part of a truss accessible through an attic or other space.
- a bracket 11a may be installed without direct access to structural member 30 through the interior of the box.
- Bracket 1 la is inserted into the box and placed in proper mounting position, next to the electrical box sidewall adjacent to the structural member. Screws 24, or other fasteners, are then driven through the bracket 11a, the electrical box sidewall 21a or 21b and into the structural member 30.
- Figure 5b includes a cutout 33 area to show screw 24 clearly.
- An electrical box may optionally have a reinforcing bracket built in.
- Figures 6a, 6b, 6c and 6d show conceptually how this might be done in a metal-type box.
- an electrical box 40a is made in an intermediate stage, the box having a top 45, sides, and an unbent flap 41.
- Electrical box 40a may be fashioned from usual processes for electrical box manufacture, including stamping, pressing, punching, spot welding and other techniques.
- fastener features 42 have been stamped prior to the next step.
- Those fastener features might be, for example, screw guides, nail guides, or conical or countersunk structures for securing a screw head.
- flap 41 is bent as shown in figure 6b, to form a brace 43 and a top interface portion 44 meeting with top 45.
- this step may actually include several successive steps in which bends are progressively made to flap 41.
- Figure 6c also shows the completed configuration as seen through the bottom of the box.
- Figure 6d shows a sectional view through the axis labeled 5.
- sidewall 46 is preferably pre-punched or drilled with holes for fasteners to pass through when inserted in 42, by which the installer may avoid drilling operations.
- This electrical box does not include wings or other extra-box support structures, but rather relies on the bracing structure formed by brace 43 and top interface portion 44 to stabilize the attachment of the electrical box 40b to a structural member.
- At least three fastener features are included, as shown, in at least two axes to form a tri-point securement geometry.
- Electrical box 40b may be considered to be an "old work” or “rework” type box, as it may be conveniently installed to a finished ceiling. To do so, an installer would (1) find an attachable structural member, (2) cut a matching hole in the drywall, paneling, or other wall structure so the electrical box may be positioned next to the structural member, (3) insert the box and (4) fasten the box to the structural member through fastener features 42.
- FIG. 7 shows an alternate bracing electrical box 50 having three flanges.
- Those flanges include two horizontal flanges 51, which are included in conventional electrical boxes.
- An additional flange 52 is added substantially outside the plane formed by flanges 51, in this example attached to and above the electrical box top 54.
- Nails 53 are driven into a structural member during installation. Without the use of flange 52 and corresponding nail 53a, a weighted box has a tendency to rotate about an axis passing through the points where the nails 53b enter the structural member, where the most stress occurs in the nail material.
- Flange 52 and nail 53b when used, prevent this rotation and keep the box in a more stable position. Now this box is more useful for new construction, as the task of driving the nails would be most difficult without tearing out a large section of wall necessary to swing a hammer or insert a power tool.
- Figures 8a, 8b, 8c and 8d show another bracing electrical box 60a having conventional flanges 61 and an integrated bracket 62a, figure 8a showing a perspective view of the box internal space, figure 8b shows a view of the outside of the box looking at the sidewall in adjacency to the bracket, figure 8c shows a bottom view of the box and figure 8d shows a sectional view in the axis marked 6.
- bracket 62a is molded out of plastic and integral to the structure of the electrical box. Ribbing 63 may be provided to resist the force applied by fasteners 64 when attached, while niinimizing the amount of plastic material needed. This particular electrical box is useful for new installations where access to the structural member is not restricted.
- FIG. 9a and 9b Shown in figures 9a and 9b is an alternate electrical box 60b showing two different perspective views to the interior of the box.
- Electrical box 60b has the same integrated bracket 62a and ribbing 63 as box 60a of figure 8, but omits flanges 61.
- This box may be installed in a similar manner to the box 40a of figure 6, and is considered to be an "old work" type box.
- Figures 10a, 10b, 10c, lOd and lOe show another bracing electrical box 60c having conventional flanges 61 and an insert molded bracket 62b, figure 10a showing a perspective view of the box internal space, figure 10b showing a view of the outside of the box looking at the sidewall in adjacency to the bracket, figure 10c shows a bottom view of the box, figure lOd showing a sectional view in the axis marked 7, and figure lOe showing the detail in the area marked 8.
- bracket 62b is molded in place during the molding process.
- Bracket 62b might be made of any stiff, strong and temperature insensitive material, for example steel, aluminum, brass, wood, carbon fiber, or other metal alloy or composite material, that withstands the temperatures of the plastic molding process and provides the desired reinforcement. Bracket 62b is placed in appropriate position inside the electrical box mold at the time the plastic part of the box is fabricated, the plastic generally encompassing or surrounding the bracket sufficiently to hold the bracket in place so that it does not become dislodged through .ordinary use. Additional thicknesses of plastic material may be fashioned at the points of stress, for example 66 where bracket 62b meets the sidewall of the box and more particularly 65 where bracket meets the top of the box. Electrical box 60c is considered to be a "new work" type box.
- Figures 11a and 1 lb show an alternate electrical box 60d similar to the box 60c of figure 10, with figures 11a and 1 lb showing two different perspective views to the interior of the box.
- Electrical box 60d has the same insert molded bracket 62b as box 60a of figure 10, but omits flanges 61.
- This box may also be installed in a similar manner to the box 40a of figure 6, and is considered to be an "old work" type box.
- the above described boxes may include alignment features, such as tabs, to align the electrical box into proper position with respect to the ceiling surface, particularly if the boxes are intended for old-work installations.
- FIGS 12a, 12b and 12c show an alternate configuration of a reinforcing bracket lib, including figures 12a and 12c showing perspective views and figure 12b showing a side view.
- This bracket 1 lb includes a substantially flat surface 12b for mating with the top of an electrical box. Mating surfaces 13b and 14b are provided to rest against an electrical box sidewall, that sidewall preferably being flat.
- Two legs 15b extend between mating surfaces 13b and 14b connecting the bracket portion including mating surface 12b with the bracket portions containing fastener features 16b.
- a separation 19 is provided between the two legs 15b to permit mounting around an obstruction in the electrical box, for example a screw boss.
- the compressive portion of this bracket 1 lb is small, and is mainly around the bend at 13b. Because of this, this bracket is preferably constructed of stiffer and/or stronger materials than that of 1 la to maintain a similar bracing capacity.
- Figures 13a, 13b and 13c show another alternate configuration of a reinforcing bracket of the type of 11a, figures 13 a and 13c showing perspective views and 13b a side view.
- Bracket lie includes a top mating interface 12c, fastener features 16c, and a strut portion 15c.
- This bracket is intended to fit an electrical box having a substantial cylindrical sidewall, for example the 3 inch ceiling electrical box shown in figures 3a-c, and thus curved regions 13ca and 14ca are provided to mate thereto.
- Side interface areas 13cb and 14cb may be used to mate to a fastener boss, as in the bracket of 1 la.
- Bends 17c and 18c are included to orient strut portion 15c, top mating surface 12c, and side interface areas 13ca, 13cb, 14ca and 14cb in positions that will mate well with the intended electrical boxes, provide reinforcement and orient fastener features in a direction that assists the insertion of fasteners therein into a structural member.
- Bracket lie may be made using similar methods and materials as to that of bracket 11a.
- reinforcement brackets, devices or features be designed to consume a minimal amount of the interior volume, so as to maximize the number of wires and electrical connections that can be made within the electrical box.
- a kit containing a reinforcement device and necessary fasteners may be advantageously assembled for the convenience of the installer.
- a kit might be included, for example, in the product packaging of an electrical applicance, for example a ceiling fan or lighting fixture, providing added convenience to the installer of the product in situations where the use of the bracket is desirable.
- a fastener bit suitable for insertion into a drill may also add to the convenience of the installer at a reasonable expense.
- a preferred fastener type for use with reinforcement devices and brackets is the pilotless screw, as commonly used in decking, fencing and drywall applications. That type of screw can be driven into woods used for construction as well as many plastics with minimal splitting and/or stretching of the material.
- the use of that type of screw simplifies the installation of the bracket by reducing the need for drilling pilot holes, which under many circumstances will be awkward given the overhead working position and the restrictions of available access to the interior of the particular electrical box, and further require the use of long drill bits or adapters which may not be in the equipment inventory of typical installers.
- the use of screws is also preferred to mitigate the effects of thermal and humidity cycles, which is a known problem with nails.
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- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Connection Or Junction Boxes (AREA)
Abstract
Description
Claims
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP04812163A EP1700322A4 (en) | 2003-11-26 | 2004-11-24 | Ceiling box safety mounting bracket |
AU2004296062A AU2004296062A1 (en) | 2003-11-26 | 2004-11-24 | Ceiling box safety mounting bracket |
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/723,501 US6881900B2 (en) | 2003-07-03 | 2003-11-26 | Ceiling box safety mounting bracket |
US10/723,501 | 2003-11-26 | ||
US10/722,955 US6909045B2 (en) | 2003-07-03 | 2003-11-26 | Article of manufacture for reinforcing a ceiling electrical box |
US10/722,955 | 2003-11-26 |
Publications (2)
Publication Number | Publication Date |
---|---|
WO2005055370A2 true WO2005055370A2 (en) | 2005-06-16 |
WO2005055370A3 WO2005055370A3 (en) | 2005-11-17 |
Family
ID=34657399
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US2004/039587 WO2005055370A2 (en) | 2003-11-26 | 2004-11-24 | Ceiling box safety mounting bracket |
Country Status (3)
Country | Link |
---|---|
EP (1) | EP1700322A4 (en) |
AU (1) | AU2004296062A1 (en) |
WO (1) | WO2005055370A2 (en) |
Family Cites Families (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4403708A (en) * | 1982-07-19 | 1983-09-13 | Smolik Robert A | Electrical receptacle box assembly |
US6734356B1 (en) * | 1999-08-13 | 2004-05-11 | Arlington Industries, Inc. | Prepackaged mounting assembly and bracket combination |
US6595479B2 (en) * | 2001-05-15 | 2003-07-22 | Hubbell Incorporated | Electrical fixture mounting assembly |
US6756541B1 (en) * | 2001-10-19 | 2004-06-29 | Mark Mollick | Electrical outlet box with mounting means |
US6722621B2 (en) * | 2002-07-03 | 2004-04-20 | Hubbell Incorporated | Electrical box assembly with removable protective cover |
-
2004
- 2004-11-24 WO PCT/US2004/039587 patent/WO2005055370A2/en active Application Filing
- 2004-11-24 EP EP04812163A patent/EP1700322A4/en not_active Withdrawn
- 2004-11-24 AU AU2004296062A patent/AU2004296062A1/en not_active Abandoned
Non-Patent Citations (1)
Title |
---|
See references of EP1700322A4 * |
Also Published As
Publication number | Publication date |
---|---|
AU2004296062A1 (en) | 2005-06-16 |
WO2005055370A3 (en) | 2005-11-17 |
EP1700322A4 (en) | 2009-01-21 |
EP1700322A2 (en) | 2006-09-13 |
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