Brace assembly for ceiling fans and fixtures

• US 20050045793A1
• Filed: 08/29/2003
• Published: 03/03/2005
• Est. Priority Date: 08/29/2003
• Status: Active Grant

• Current Assignee: Hubbell, Inc.
• Original Assignee: Hubbell, Inc.
• Inventors: Johnson, Steven J., Korcz, Krzysztof W.
• Granted Patent: US 7,191,994 B2
• Time in Patent Office: Days
• US Class Current: 248/343
• CPC Class Codes: F04D 29/601 specially adapted for elastic fluid pumps
• CPC Class Codes: Y10S 248/906 Electrical outlet box support
• CPC Class Codes: Y10S 248/909 Frangible component, e.g. having a score line or groove

Abstract

A brace assembly supports an outlet box that receives an electrical fixture. A first brace member has a first base. A second brace member has a second base and is adjustably received by the first brace member. A first mounting surface extends from the base of the first brace member. The first mounting surface forms a first angle greater than 90 degrees with the first base. A second mounting surface extends from the second base of the second brace member. The second mounting surface forms a second angle greater than 90 degrees with the second base. The angled mounting surfaces provide a compression fit between the brace assembly and supports to which the first and second brace members are secured.

Claims

1. A brace assembly to support an outlet box, comprising:

a brace member adapted to be installed between first and second support members, said brace member having a base; and

a first mounting surface extending from said base at a first end of said brace member, said first mounting surface forming a first angle greater than 90 degrees with said base and being adapted to create a compression fit by contacting the first support member when installed.

2. A brace assembly according to claim 1, wherein

said first angle is approximately 94 degrees.

3. A brace assembly according to claim 1, wherein

said first mounting surface has a first fastener hole to receive a first fastener to secure said brace member to the first support member.

4. A brace assembly according to claim 1, wherein

a first prong extends outwardly from said first mounting surface to secure said brace member to the first support member.

5. A brace assembly according to claim 1, wherein

a first flange extends perpendicularly outwardly from said first mounting surface and is adapted to be received on a lower surface of the first support member.

6. A brace assembly according to claim 1, wherein

said first mounting surface has a first score line to remove a first portion of said first mounting surface to accommodate various wall thicknesses.

7. A brace assembly according to claim 1, wherein

a second mounting surface extends from a second end of said brace member, said second mounting surface forming a second angle greater than 90 degrees with said base and being adapted to create a compression fit by contacting the second support member when installed.

8. An adjustable brace assembly to support an outlet box, comprising:

a first brace member having a first base;

a second brace member having a second base, said second brace member being adjustably received by said first brace member;

a first mounting surface extending from said first base of said first brace member, said first mounting surface forming a first angle greater than 90 degrees with said first base and being adapted to create a compression fit by contacting a first support member when installed; and

a second mounting surface extending from said second base of said second brace member, said second mounting surface forming a second angle greater than 90 degrees with said second base and being adapted to create a compression fit by contacting a second support member when installed.

9. A brace assembly according to claim 8, wherein

a first fastener hole in said first mounting surface receives a first fastener to secure said first brace member to the first support member.

10. A brace assembly according to claim 9, wherein

a second fastener hole in said second mounting surface receives a second fastener to secure said second brace member to the second support member.

11. A brace assembly according to claim 8, wherein

a first prong extends outwardly from said first mounting surface to secure said first brace member to the first support member.

12. A brace assembly according to claim 11, wherein

a second prong extends outwardly from said second mounting surface to secure said second brace member to the second support member.

13. A brace assembly according to claim 8, wherein

a first flange extends perpendicularly outwardly from said first mounting surface and is adapted to be received on a lower surface of the first support member.

14. A brace assembly according to claim 13, wherein

a second flange extends perpendicularly outwardly from said second mounting surface and is adapted to be received on a lower surface of the second support member.

15. A brace assembly according to claim 8, wherein

said first angle is approximately 94 degrees.

16. A brace assembly according to claim 15, wherein

said second angle is approximately 94 degrees.

17. A brace assembly according to claim 8, wherein

a tab extends outwardly from an outer surface of said second base of said second brace member, said tab contacting an inner surface of said first base of said first brace member to create an interference fit between said first and second brace members.

18. A brace assembly according to claim 8, wherein

said first mounting surface has a first score line to remove a first portion of said first mounting surface to accommodate various wall thicknesses.

19. A brace assembly according to claim 18, wherein

said second mounting surface has a second score line to remove a second portion of said second mounting surface to accommodate various wall thicknesses.

20. A brace assembly according to claim 12, wherein

a first flange extends perpendicularly outwardly from said first mounting surface and is adapted to be received on a lower surface of the first support member.

21. A brace assembly according to claim 20, wherein

a second flange extends perpendicularly outwardly from said second mounting surface and is adapted to be received on a lower surface of the second support member.

22. A brace assembly according to claim 21, wherein

a tab extends outwardly from an outer surface of said second base of said second brace member, said tab contacting an inner surface of said first base of said first brace member to create an interference fit between said first and second brace members.

23. An adjustable brace assembly to support an outlet box, comprising:

a first brace member having a first base;

a second brace member having a second base, said second brace member being adjustably received by said first brace member;

a first mounting surface extending from said first base of said first brace member, said first mounting surface forming a first angle greater than 90 degrees with said first base;

a second mounting surface extending from said second base of said second brace member, said second mounting surface forming a second angle greater than 90 degrees with said second base;

a first fastener hole in said first mounting surface to receive a first fastener to secure said first brace member to a first support member;

a second fastener hole in said second mounting surface to receive a second fastener to secure said second brace member to a second support member;

a first flange extending perpendicularly outwardly from said first mounting surface and adapted to be received on a lower surface of the first support member;

a second flange extending perpendicularly outwardly from said second mounting surface and adapted to be received on a lower surface of the second support member; and

a tab extending outwardly from an outer surface of said second base of said second brace member, said tab contacting an inner surface of said first base of said first brace member to create an interference fit between said first and second brace members.

24. A brace assembly according to claim 23, wherein

said first angle is approximately 94 degrees.

25. A brace assembly according to claim 24, wherein

said second angle is approximately 94 degrees.

26. A method of installing a brace assembly between first and second supports, comprising the steps of:

positioning the brace assembly between the first and second supports;

extending the brace assembly between the first and second supports;

raising the brace assembly between the first and second supports to flex inwardly first and second mounting surfaces of the brace assembly to create a compression fit between the brace assembly and the first and second supports;

raising the brace assembly until each of said first and second mounting flanges on the first and second mounting surfaces contact an underside of each of the first and second supports;

releasing the brace assembly; and

inserting fasteners through the first and second mounting surfaces to secure the brace assembly to the first and second supports.

27. A method of installing a brace assembly according to claim 26, further comprising

inserting prongs on the first and second mounting surfaces into the first and second supports to secure the brace assembly to the first and second supports.

28. A method of installing a brace assembly according to claim 26, further comprising

breaking each of the first and second mounting surfaces at a score line to accommodate various wall thicknesses.

29. An adjustable brace assembly to support an outlet box, comprising:

first and second substantially parallel support members;

a first brace member having a first base;

a second brace member having a second base, said second brace member being adjustably received by said first brace member; and

a first mounting surface extending from said first base of said first brace member, said first mounting surface forming a first angle greater than 90 degrees with said first base prior to installation, and substantially engaging said first support member when installed to create a compression fit therebetween.

30. An adjustable brace assembly to support an outlet box according to claim 29, wherein

a second mounting surface extends from said second base of said second brace member, said second mounting surface forming a second angle greater than 90 degrees with said second base prior to installation, and substantially engaging said second support when installed to create a compression fit therebetween.