Plastic box for ceiling fan support

• US 5,234,119 A
• Filed: 04/30/1991
• Issued: 08/10/1993
• Est. Priority Date: 06/29/1990
• Status: Expired due to Term

• Current Assignee: Hubbell, Inc.
• Original Assignee: Hubbell, Inc.
• Inventors: Jorgensen, Robert W., Slater, William E.
• Primary Examiner(s): Pollard, Steven M.
• Application Number:
  US07/696,258
• Time in Patent Office: 833 Days
• Field of Search: 220/3.2, 220/3.3, 220/3.9, 248/906
• US Class Current: 220/3.9
• CPC Class Codes: H02G 3/20 Ceiling roses or other lighting sets

Abstract

A plastic ceiling box adapted to support a ceiling fan thereon and adapted to be mounted on a structural member, such as a ceiling joist. The ceiling box comprises a body member having a lower wall and a pair of side walls defining a recess for snugly receiving the ceiling joist therein. Box mounting holes for receiving box mounting fasteners are located at opposite sides and ends of the lower wall for attaching the ceiling box to the joist. Openings for receiving fan supporting fasteners are formed in the body member adjacent the box mounting holes. Brackets at opposite ends of the body member aid in attaching the body member to the joist. This overall arrangement provides sufficient support and strength to resist dynamic loads of a ceiling fan even though the ceiling box is formed of plastic.

Claims

1. A ceiling box adapted to support a ceiling fan thereon and adapted to be mounted on a structural member, the combination comprising:

a body member having a lower wall and first and second opposed side walls defining a recess for receiving the structural member therein;

first means, formed in said lower wall, for receiving a first box mounting fastener therein;

second means, formed in said lower wall, for receiving a second box mounting fastener therein, said first and second means being located at opposite sides and ends of said lower wall;

third means, formed in said body member adjacent said first means, for receiving a first fan supporting fastener therein; and

fourth means, formed in said body member adjacent said second means, for receiving a second fan supporting fastener therein,

said ceiling box being integrally formed of substantially rigid plastic.

2. The ceiling box according to claim 1, wherein

said third means includes a first opening located adjacent said first means to receive a first fan supporting fastener therein and said fourth means includes a second opening located adjacent said second means to receive a second fan supporting fastener therein.

3. The ceiling box according to claim 1, wherein

said lower wall and first and second side walls are substantially planar.

4. The ceiling box according to claim 3, wherein

said lower wall is substantially perpendicular to said first and second side walls and said recess is substantially rectangular in cross-section.

5. The ceiling box according to claim 3, wherein

said recess is sized to snugly receive the structural member and to allow intimate contact of said lower wall and said first and second side walls with the structural member to prevent rocking and rotation movements of said body member when a structural member is received in said recess.

6. The ceiling box according to claim 3, wherein

said first and second means include first and second screw holes, respectively, in said lower wall for receiving the first and second box mounting fasteners therethrough into said recess.

7. The ceiling box according to claim 3, wherein

said third and fourth means include first and second openings, respectively, for receiving first and second fan supporting fasteners therein.

8. The ceiling box according to claim 3, wherein said body member further comprises

first and second top walls coupled to said first and second side walls, respectively;

first and second outer walls coupled to said first and second side walls and first and second top walls; and

first and second end walls coupled to said first and second outer walls and said lower wall;

said first and second outer walls and said first and second end walls having a continuous bottom edge defining an open bottom end; and

said lower wall, first and second top walls, first and second side walls, first and second end walls and first and second outer walls define a substantially U-shaped inner cavity in said body member.

9. The ceiling box according to claim 8, wherein

said body member includes at least one break-out window adapted to receive electrical wires after a portion is broken away.

10. The ceiling box according to claim 9, wherein

said at least one break-out window is located in at least one of said first and second outer walls.

11. The ceiling box according to claim 8, wherein

said bottom edge lies in a plane substantially parallel to said lower wall, and said lower wall is spaced approximately 0.5 inch from said bottom edge.

12. The ceiling box according to claim 1, wherein said body member further comprises:

first and second brackets;

said first bracket being coupled to said body member adjacent said first means and said third means and to form a first substantially planar surface with said first side wall for contacting the structural member; and

said second bracket being coupled to said body member adjacent said second means and said fourth means and to form a second substantially planar surface with said second side wall for contacting the structural member.

13. The ceiling box according to claim 12, and further comprising

fifth means formed in said first bracket for receiving at least one first bracket fastener and sixth means formed in said second bracket for receiving at least one second bracket fastener.

14. A plastic ceiling box adapted to support a ceiling fan thereon and adapted to be mounted on a ceiling joist, the combination comprising:

a substantially planar lower wall having means for mounting said ceiling box to the ceiling joist;

first and second substantially planar opposed side walls coupled to and substantially perpendicular to said lower wall for defining a joist receiving recess sized to snugly receive a ceiling joist therein;

an outer wall structure coupled to said first and second side walls and said lower wall for defining a substantially U-shaped inner cavity with a continuous bottom edge defining an open bottom;

a first bracket being coupled to said outer wall structure to form a first substantially planar surface with said first side wall for contacting one side of the ceiling joist;

a second bracket being coupled to said outer wall structure to form a second substantially planar surface with said second side wall for contacting the other side of the ceiling joist; and

fastening means, coupled to said outer wall structure at said bottom edge, for coupling the ceiling fan thereto.

15. The plastic ceiling box according to claim 14, wherein

said ceiling box is formed as a one-piece, unitary, integrally molded member.

16. The plastic ceiling box according to claim 14, wherein

said means for mounting includes a pair of mounting holes extending through said lower wall for receiving a mounting fastener in each of said mounting holes.

17. The plastic ceiling box according to claim 16, wherein

said lower wall is substantially rectangular with one of said mounting holes located adjacent a first corner of said lower wall, and the other of said mounting holes located in a second corner of said lower wall opposite to said first corner.

18. The plastic ceiling box according to claim 17, wherein

said fastening means includes a pair of openings for threadedly receiving a pair of fan supporting fasteners therein.

19. The plastic ceiling box according to claim 18, wherein

one of said openings is located adjacent one of said mounting holes, and the other of said openings is located adjacent the other of said mounting holes.

20. The plastic ceiling box according to claim 18, wherein

said fastening means is directly coupled to said outer wall structure.